MACK MP7, MP8, MP10 Service Manual

Mack
MAINTENANCE AND LUBRICATION
®
MAINTENANCE AND LUBRICATION
MP7, MP8, and MP10 Engines
MAINTENANCE AND LUBRICATION
MP7, MP8, and MP10 Engines
21394653
© Mack Trucks, Inc. 2010 Printed in U.S.A.
21394653
21394653
Contents
Operator’sManualVehicleMaintenanceCXU,CHU,GU,TD,MRUandLEU...1
Foreword..............................................................................................1
WarningLabelInformation........................................................................1
GeneralInformation................................................................................3
InformationFortheOwner........................................................................3
FederalEmissionRequirements..................................................................5
LabelInformation..................................................................................12
SafetyInformation.................................................................................19
ProperMaintenanceProcedure..................................................................19
InjuryPrevention...................................................................................22
EngineDamagePrevention.......................................................................30
ElectricSystemDamagePrevention............................................................32
ReportingSafetyDefects.........................................................................34
GeneralEngineInformation......................................................................35
EngineOverview,MP7andMP8LeftSideView...........................................35
EngineOverview,MP7andMP8RightSideView..........................................36
EngineOverview,MP10LeftSideView......................................................37
EngineOverview,MP10RightSideView....................................................38
ElectricalSystem...................................................................................39
Batteries..............................................................................................39
BatteryW armer.....................................................................................41
BatteryCondition...................................................................................41
Charging..............................................................................................42
LoadTest.............................................................................................44
ElectricalConnectionProtection................................................................44
PrecautionsWhenInstallingElectricalEquipment..........................................47
EngineStorage......................................................................................50
EngineStorage......................................................................................50
MaintenanceandService.........................................................................51
MaintenanceHazards..............................................................................51
EngineComponents,ServiceSchedules.......................................................51
CoolingSystem.....................................................................................54
FuelSystem..........................................................................................63
EngineOil............................................................................................75
EngineAirFilter....................................................................................82
ExhaustAfter-TreatmentSystem................................................................85
DriveBeltReplacementIntervals...............................................................94
AutomaticBeltTensionerMaintenance......................................................102
TurbochargerandChargeAirCooler.........................................................106
PreventiveMaintenanceAirSuspensions...................................................109
SteeringandBrakesMaintenance.............................................................110
Tires,WheelsandHubMaintenance.........................................................114
ChassisMaintenance.............................................................................128
CabMaintenance.................................................................................130
Lubrication.........................................................................................136
OilCapacityTablesandViscosityCharts...................................................142
ServiceCheckList...............................................................................146
PreventiveMaintenance.........................................................................146
ServiceCharts.....................................................................................150
ScheduledServices...............................................................................150
TireRecord........................................................................................154
FuelandOilRecord..............................................................................155
EngineData........................................................................................156
Literature...........................................................................................157
ServiceAssistanceandManuals..............................................................157
CUSTOMERSER VICE........................................................................158
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU1
Foreword
DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperational andsafetyinformationthatisneededbyalldriversandownersofthisvehicle.
Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis operated.Thismanualalsocontainsaconsiderableamountofinformationconcerning thevehicle,suchasvehicleidentication,PreventiveMaintenancerecommendations andalogforyourservicerecords.Pleasekeepthisinthevehicleatalltimes. Informationfromothercomponentmanufacturersissuppliedinseparatemanuals intheOwnersPackage.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKInc. shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefectthatcould causeacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto NHTSA,U.S.DepartmentofTransportation,W ashington,DC20590,byTTYat1 (800)424-9153,orvisittheirwebsiteatwww.nhtsa.dot.gov.
MACKTrucks,Inc.
Greensboro,NCUSA
Ordernumber:PV776-21394653
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedin retrievalsystem,ortransmittedinanyformsbyanymeans,electronic,mechanical, photocopying,recordingorotherwise,withoutthepriorwrittenpermissionofMACK Inc.
WarningLabelInformation
IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadandthat youfullyunderstandeachandeverystepofthedrivingandhandlinginformation inthisOperatorsManual.Becertainthatyoufullyunderstandandfollowall safetywarnings.Itisextremelyimportantthatthisinformationisreadand understoodbeforethevehicleisoperated.
ITISIMPOR TANTTHA TTHEFOLLOWINGINFORMA TIONCONCERNING LABELSBEREAD,UNDERSTOODANDALW AYSFOLLOWED.
2Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Thefollowingtypesoflabelsareusedthroughoutthismanual:
Note:Anotedenesanoperatingprocedure,practice,condition,etc.,whichis essentialtoproperoperationofthevehicle.
DANGER
Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresult inseriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablack backgroundwithablackborder.
WARNING
Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcould resultinpersonalinjuryorseveredamagetothevehicle.Thewarninglabelisin
blacktypeonagraybackgroundwithablackborder.
CAUTION
Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonal injuryisnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblack typeonawhitebackgroundwithablackborder.
WarningandAdvisoryLabels
Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsof thevehicletoalertdriversandservicetechniciansaboutsituationsthatmaylead topersonalinjuryorequipmentdamage.Intheeventthatalabelisdamagedor missingthelabelmustbereplaced.ContactyourauthorizedMACKTruckdealer forassistanceregardingWarningandAdvisorylabels.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU3
GeneralInformation
InformationFortheOwner
Iftherearequestionsonthemaintenanceandperformanceofyourvehicle,please discussthemwithyourMACKTruckdealer.Y ourauthorizeddealerisrequiredto havetrainedmechanics,specialtoolsandsparepartstofullyserviceyourvehicle. Ifnecessary,yourdealerwillcontactMACKInc.orothermanufacturersforany assistance.
InadditiontothisMaintenanceManual,theremaybeadditionalinstruction/operators manualssuppliedbycomponentmanufacturers.Thesemanualsareplacedinthe OwnersPackageandplacedinthecab.Besuretoreadallthemanualsthoroughly beforeoperatingthevehicle.
Also,varioussafetylabelsmaybeplacedoncomponentsbythecomponent manufacturer.Besuretoreadandfollowtheselabelstopreventdamagetothe vehicle,personalinjuryorevendeath.
InformationinthismanualreferstoMACKcomponentsandMACKdrivetrain.
EstablishaPreventiveMaintenanceProgramwiththehelpofyourlocalMACK Truckdealer.APreventiveMaintenanceProgrammakesitpossibletomaximize theamountoftimeyourvehicleisupandrunning,resultinginlongercomponent life.Thismakesforasafervehiclebyreducinganymechanicalfailuresduetopoor maintenancepractices.
Note:Federallawrequiresmanufacturerstonotifyownersofitsproductsintheevent ofaFederalMotorV ehicleSafetyStandardorifasafetyrelateddefectisdiscovered. Ifyouarenottheoriginalownerofthisvehicle,pleasenotifyusaboutthechangein ownershipattheaddressbeloworthroughanauthorizedMACKTruckdealer.Thisis theonlywaywewillbeabletocontactyouifnecessary.
MACKInc.
NortheastRegion
7900NationalServiceRoad,Mail:P .O.Box26259
Greensboro,NC27402
TEL:(336)291-9001
UnitedStatesofAmerica
ThisMaintenanceManualcoversallMACKvehiclesmanufacturedbyMACKInc., includingthewholechassisandallMACKmanufacturedcomponents.Forspecic maintenanceinformationonvendorcomponents,seetherespectivemanufacturers serviceandmaintenanceliterature.
Thismanual,togetherwithmanualsforspeciccomponentscontainimportant informationtobeabletooperatethisvehiclesafely.Theycontainadviceand
4Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
instructionswhichwillenableyoutogettheoperatingeconomyandperformance thatyouexpectfromthisqualityvehicle.
Allinformation,illustrationsandspecicationscontainedinthismanualarebased uponthelatestproductinformationavailableatthetimeofpublication.Ifany questionsariseconcerningthecurrentstatusofFederalorstatelaws,theappropriate Federalorstateagencyshouldbecontacted.
Note:Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactual vehicle,however,keycomponentsaddressedinthismanualarerepresentedas accuratelyaspossible.
MACKInc.reservestherighttomakechangesatanytimeortochangespecications ordesignwithoutnoticeandwithoutincurringobligation.
General
USA
TheFederalCleanAirAct,Section203(a)(3),statesthefollowingconcerningthe removalofairpollutioncontroldevicesormodicationofacertiedenginetoa non-certiedconguration: CAA,Section(a)(3)(A)prohibitsanypersonfromremovingorrenderinginoperative anyemissioncontroldeviceorelementofdesigninstalledonorinamotorvehicle ormotorvehicleengineincompliancewithfederalregulationsundertheCleanAir Actpriortothesaleanddeliveryofthevehicletotheultimatepurchaser.Thestatute alsoprohibitsanypersonfromknowinglyremovingorrenderinginoperativeany emissioncontroldeviceorelementofdesignaftersaleanddeliveryofavehicleor enginetotheultimatepurchaser.Anypersonwhoviolatestheseprovisionseither byremovingorrenderinginoperativeemissionscontroldevicespriortothesaleor deliveryofanengineorvehicletoanultimatepurchaser,orbyknowinglyremoving orrendinginoperativesuchdevicesafterthesaleanddeliveryofanengineorvehicle toanultimatepurchaser,canbesubjecttopenaltiesofupto$3,750perincident. Anydealerormanufacturerwhoviolatestheseprovisionscanbesubjecttopenalties ofupto$37,500perincident.
Canada
ThesameconditionsthatapplyintheUSAapplytoCanada,withoneexception. Afterthevehicleissoldtoaretailcustomer,thatis,theenduser,thejurisdiction controllingtheemissioncontroldevicesbecomestheprovinceinwhichthevehicleis licensed.Nochangesshouldbemadethatrenderanyorallofthedevicesinoperative.
Shouldtheowner/operatorwishtomakeanychangestotheemissioncontroldevices, checkwiththeprovincialauthoritybeforemakinganysuchchanges.
Operator’sManualVehicleMaintenanceCXU,
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Mexico
ThesameconditionsthatapplyintheUSAapplytoMexico.RefertotheMexican FederalLawforEmissionControlwhichadherestoEPAregulations.Nochanges shouldbemadethatrenderanyoralloftheemissionscontroldevicesinoperative.
Shouldtheowner/operatorwishtomakeanychangestotheemissioncontroldevices, checkwiththestateauthoritybeforemakinganysuchchanges.
FederalEmissionRequirements
ThissectioncoverstherequirementoftheUnitedStatesCleanAirActwhichstates:
Themanufacturershallfurnishwitheachnewmotorvehicleormotorvehicleengine suchwritteninstructionsforthemaintenanceanduseofthevehicleorengineby theultimatepurchaserasmaybereasonableandnecessarytoassuretheproper functioningofemissioncontroldevicesandsystems.
Thissectionalsocoverstherequirementsoftheemissionsregulationspromulgated undertheMotorV ehicleSafetyActinCanada.
6Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
TamperingwithGaseousEmissionControl SystemsProhibited
TheFederalCleanAirActprohibitstheremovalorrenderinginoperativeofany deviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengine incompliancewithFederalEmissionRegulationsby:
1Anypersonpriortoitssaleanddeliverytotheultimatepurchaser,or
2Anymanufacturerordistributorafteritssaleanddeliverytotheultimatepurchaser,
or
3Anypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or
tradingmotorvehiclesormotorvehicleenginesfollowingitssaleanddelivery totheultimatepurchaser,or
4Anypersonwhooperatesaeetofmotorvehiclesfollowingitssaleanddelivery
totheultimatepurchaser.
Note:Forspecicsoftheprohibitedvehicle/enginemodicationsrefertotheMACK Bodybuilderdocumentation.
EnginesOtherthanMACK
ForspecicinformationonenginesotherthanMACK,refertotheengine vendorspublications.
NoiseEmissions
MACKInc.warrantstotherstpersonwhopurchasesthisvehicleforpurposesother thanresaleandtoeachsubsequentpurchaser,thatthisvehicleasmanufacturedby MACKInc.wasdesigned,builtandequippedtoconform,atthetimeitleftthecontrol ofMACKInc.,withallapplicableU.S.EP ANoiseControlRegulations.
Thiswarrantycoversthisvehicleasdesigned,builtandequippedbyMACKInc.,and isnotlimitedtoanyparticularpart,componentorsystemofthevehiclemanufactured byMACKInc.Defectsindesign,assemblyorinanypart,componentorsystemof thevehicleasmanufacturedbyMACKInc.,which,atthetimeitleftthecontrolof MACKInc.causednoiseemissionstoexceedFederalstandards,arecoveredby thiswarrantyforthelifeofthevehicle.
Operator’sManualVehicleMaintenanceCXU,
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NoiseControlSystem,OperatorInspectionandMaintenance Requirements
ANoiseControlSystemMaintenanceLogislocatedinthismanual.Thislogshould beusedtodocumentallNoiseControlSystemrelatedmaintenance,whetherthe maintenanceresultsfromaspecicnoisecontrolsysteminspection,oradeciency identiedduringanothergeneralmaintenanceevent.
Ifadditionallogspaceisneeded,furtherentriesmaybeaddedonaseparatesheetof paper.Storetheseadditionswiththemainlogtopreserveacomprehensiverecord.It isrecommendedthatcopiesofallnoiseemissionsrelatedmaintenanceinvoicesbe retained.
ThefollowingNoiseControlSysteminspectionandmaintenanceinstructionscontain suggestedmaintenanceintervals.Theseintervalsmayneedadjustmentinorderto bestaccommodatethespecicvehicleusage.Thefollowinginstructionsonlyconcern NoiseEmissionsrelateditemsanddonotaddressormodifyanygeneralvehicle maintenancerequirements.
ThefollowingelementsmakeuptheNoiseControlSystem:
NoiseShieldingandInsulationDevices
CoolingSystem
ExhaustSystem/DPFSystem
AirIntake/AirInductionSystem
EngineControl,EGRandFuelSystems
SelectiveCatalyticReduction(SCR)
TamperingwithNoiseControlSystem
Federallawprohibitsthefollowingactsorthecausingthereof:
(1)Theremovalorrenderinginoperativebyanyperson,otherthanforpurposesof maintenance,repair,orreplacement,ofanydeviceorelementofdesignincorporated intoanynewvehicleforthepurposeofnoisecontrolpriortoitssaleordeliverytothe ultimatepurchaserorwhileitisinuse;
or
(2)theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremoved orrenderedinoperativebyanyperson.
Amongtheactsthatconstitutetamperingaretheactslistedbelow:
Removal,orrenderinginoperative,ofanyexhaustcomponents,includingmufers,
heavyordouble-wallexhausttubing,exibletubingorexhaustpipeclamping.
8Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Removal,orrenderinginoperative,ofthetemperature-modulatedcoolingfan
system.
Removalofthecoolingfanshroud.
Removal,orrenderinginoperative,oftheaircleanerorairintakein-linesilencer.
Removalofthesounddeadeningmaterialfromthehoodorcabtunnel.
Removal,orrenderinginoperative,oftheenginespeedgovernorsoastoallow
enginespeedtoexceedthemanufacturersspecications.
Removalofsplashshieldslocatedinsidethewheelhousings.
Removalofengineblockshields.
Removalofenginecrankcaseshieldsorinsulation.
Removalofinsulatedrockerarmcovers.
Removaloftransmissionnoiseshields.
NoiseShieldingandInsulationDevices
Maintenance
Ensuresoundshieldingandinsulatingdevicesareintact.Inspectcomponentsfor damage.Primarysystemcomponentsrequiringnoiserelatedinspectionincludethe hood,enginecompartmentinsulatingmaterials(includinghoodinsulation,bulkhead insulation,doghouseinsulation,etc.)splashshields,cabskirts,fendershields,and bodypanels.Inspectallrelatedfasteners,brackets,andclampsfordamageand tightness.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeNoiseShieldingandInsulationDevices:
Removingorrenderinginoperativetheengineand/ortransmissionnoisedeadening panels,shieldsorinsulatingmaterials.
Removingorrenderinginoperativethecab-tunnelorhoodnoiseinsulatingmaterials.
Removingorrenderinginoperativeanyvehiclebodymountedsoundinsulation componentsand/orshields(caborfendershields,skirts,wheelhousingsplashshields, etc.).
Operator’sManualVehicleMaintenanceCXU,
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CoolingSystem
WARNING
DONOTworknearthefanwiththeenginerunningortheignitionintheON position.Theenginefancanengageatanytimewithoutwarning.Anyonenear thefanwhenitturnsoncouldbeseriouslyinjured.
Maintenance
Visuallyinspectcoolingsystemcomponentsfordamage,and/ormisalignment.
Primarysystemcomponentsrequiringnoiserelatedinspectionincludefanblades,fan clutch,fanshroud,fanring,andrecirculationshields.Checkfanblades,fanring,fan shroud,belttensionerandrecirculationshieldsforanydamage.Verifythatfanblades clearthefanring.Inspectallrelatedfasteners,brackets,andclampsfordamageand tightness.Conrmoperationoftemperaturemodulatedfanclutch.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeCoolingSystem:
Removingorrenderinginoperativecoolingsystemcomponents(suchasthe temperaturemodulatedfanclutch,fanshroud,fanring,recirculationshields,etc.).
ExhaustSystem
WARNING
Hotengine!Avoidallmovablepartsorhotengineparts,exhaustgases,and/or uids.Ahotengine,exhaust,and/oruidscancauseburns.
10Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Maintenance
Makesuretheexhaustsystemisintact.Inspectfordamage,misalignmentand/or leakage.Primarysystemcomponentsrequiringnoiserelatedinspectioninclude exhaustmanifold,turbocharger,andallexhaustsystem(rigidandexible)piping. Closelycheckthesystemforexhaustleaks.Specialattentionshouldbegiventoall welds,seams,gaskets,supportpoints,clamps,couplingsandconnections.
Inspectallexhaustsystemfasteners,brackets,andclampsfordamageandtightness.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeExhaustSystem:
Removingorrenderinginoperativeexhaustsystemcomponents(suchasthepipes, clamps,etc.).
AirIntake/AirInductionSystem
Maintenance
Makesuretheairintakesystemisintact.Inspectcomponentsfordamage, misalignmentand/orleakage.Primarysystemcomponentsrequiringnoiserelated inspectionincludetheaircleanerhousing,aircleanerelement,turbocharger,charge aircoolerandintakemanifold.
Alsoinspectallducts,pipes,hoses,tubingandelbowsusedtointerconnectthe system.Specialattentionshouldbegiventoallwelds,seams,gaskets,supportpoints, clamps,couplingsandconnections.
Inspectallintakesystemfasteners,brackets,andclampsfordamageandtightness.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeAirIntake/AirInductionSystem:
Removingorrenderinginoperativeairintake/inductionsystemcomponents(lter, lterhousings,ducts,etc.).
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU11
EngineControl,EGRandFuelSystems
ActsthatconstitutetamperingwithEngineControl,EGRandFuelSystems:
Removingrenderinginoperative,ormodifyingtheenginecontrolsystemsuchas theECU,EGRsystemcomponents,orfuelsystemcomponents,inordertoallow theenginetooperateoutsideofthemanufacturersspecicationsisnotallowedand violatesbothwarrantyandlegislation.
12Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
LabelInformation
VehicleIdenticationNumberLabel
Allmotorvehiclesarerequiredtobeidentiedbya17-digitVehicleIdentication Number(VIN).U.S.andCanadianregulationsdictatetheformatofthenumber. TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK, suchastypeofvehicle,model,typeofbrakesystem,grossvehicleweightrange andmodelyear.
TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations includeastampingontheverticalfaceoftheright-handframerail(somewhere betweenthefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge, thedooropeningareaortheseatriser)andonthevehiclesafetycerticationlabels andotherlabelsonthedooredgeordooropeningarea.Whenthevehicleisreceived, checktheVINateachlocationonthevehicleandverifythattheyareidentical.The vehicleidenticationnumbermustnotbechanged,coveredorobliterated.
VINFrameStamping
W0031972
Operator’sManualVehicleMaintenanceCXU,
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W0031973
VINLabelonDriversSeatRiser
14Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
RegulatoryLabels
Inadditionto,orinplaceofthepreviouslymentionedlabels,MACKTrucks,Inc. mayafxoneormoreofthefollowinglabelstothecab.
Heater/DefrosterOmissionLabel
Awindshielddefroster,asrequiredbyFMVSS103,WindshieldDefrostingand Defogging,isnotrequiredforvehiclesdestinedforsaleintheStateofHawaii,
PuertoRico,theNorthernMarianaIslands,Guam,theVirginIslandsandAmerican Samoa.V ehiclesdestinedforsaleintheseareasmust,however,conformtoallother applicableFMVSSregulations.Ifavehicledestinedforsaleinoneoftheseareas doesnothaveafactory-installeddefroster,alabelisafxedtothecabnearthevehicle certicationlabel(seeillustrationbelow).
OmissionofHeater/DefrosterLabel
W0031974
Operator’sManualVehicleMaintenanceCXU,
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ExportLabel
InordertocomplywithU.S.regulations,allMACKvehiclesintendedforexportfrom theUnitedStates(includingexporttoCanada)willhaveanExportLabel,similarto thelabelshownbelow,afxedtotheinsideofthewindshield.
TypicalExportLabel(IncludingExport
toCanada)
W0031975
16Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Export/SpecialApplicationLabel
Export(excludingexporttoCanada)orspecialapplicationvehiclessuppliedfrom theassemblyplantarenotnecessarilydesignedtoconformtoapplicableFederal andCanadianmotorvehiclesafetystandards.Onthesevehicles,anExport/Special ApplicationLabel,similartothelabelshownintheillustrationbelow ,isafxedto thecab.
Export/SpecialApplicationLabel
W0031976
Operator’sManualVehicleMaintenanceCXU,
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Exportvehicles(otherthanthoseintendedforsaleinCanada)alsohaveanExport Label,similartothelabelshownbelow,afxedtothedoorarea.
W0031977
TypicalExportLabel(OtherThanExport
toCanada)
18Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Off-HighwayIdenticationLabel
InadditiontotheExport/SpecialApplicationLabel,vehiclesdesignedstrictlyfor off-highwayoperationswillhaveanOff-HighwayIdenticationLabel,similartothe labelshownintheillustrationbelow,afxedtothecab.
W0031978
Off-HighwayIdenticationLabel
Operator’sManualVehicleMaintenanceCXU,
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SafetyInformation
ProperMaintenanceProcedure
DANGER
Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin neutral,andchockthewheels.Failuretodosocanresultinunexpectedvehicle movementandcancauseseriouspersonalinjuryordeath.
DANGER
Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruse aproperlyventedexhausthose.Prolongedorexcessiveexposuremaycause seriousillnessordeath.
DANGER
Neveroperatetheengineinanareawherehydrocarbonvapors(gasoline,for example)arepresentoraresuspectedtobepresent.Hydrocarbonvaporscanenter theairintakeandoverspeedtheengine,causingsevereenginedamageand/oran explosionandre.Seriouspersonalinjuryordeathcouldoccur.
DANGER
Nevertrytooperateorworkonthisvehiclewhileundertheinuenceofalcohol. Yourreexescanbeaffectedbyevenasmallamountofalcohol.Drinkingand operatingthisvehiclecanleadtoanaccident,causingseriouspersonalinjuryor death.
20Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
WARNING
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining, correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto personalinjuryormakingyourvehicleunsafe.
WARNING
Dieselengineexhaustandsomeofitsconstituentsareknowntothestateof Californiatocausecancer,birthdefectsandotherreproductiveharm.
DuringMaintenance
Removekeyfromignitionwhileworkingonvehicleorengine.
DONOTallowunauthorizedpersonnelon,aroundorinthevehiclewhen maintenanceorrepairisbeingperformed.
Whenoperatingtheengineinanenclosedarea,venttheexhausttotheoutside.
Beforeservicingyourvehicle,applytheparkingbrakesandadequatelychockthe
wheelsinordertopreventunintendedvehiclemovement.Iftheserviceprocedure requirestheparkingbrakestobereleasedrechecktoensurethatthewheelsare adequatelychockedtopreventanyforwardand/orrearwardmovement.
DONOTusecombustiblesubstancesinoraroundtheengineeitherduringrepair
ormaintenanceorwhenrunningtheengine.
DONOTwearlooseclothingorjewelrythatcancatchorgetsnaggedbypartsor
movingcomponentsontheengine.Alsowearallprotectiveequipmentrequiredby thejobconditions,suchasprotectiveglasses,hearingprotection,etc.
Makecertainthatallprotectivecoversandguardsareinplaceandproperlysecured.
Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.
Reportallproblemsinatimelymannerbeforetheythreatenthesafetyofoperating
thevehicle.
DONOTworkontheenginewhileitisrunning.
Makesureprotectivelocksandcoversareintheirproperplace.
DONOTusehighamperageelectronicstartingdevicesforjump-startingthe
engine.Relyonconventionalbatterychargingforchargingthebatteriesor jump-startwiththehelpofastartbattery.
Operator’sManualVehicleMaintenanceCXU,
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DONOTattemptrepairsyoudonotunderstand.Ifyoudonothavetheproper
tools/knowledgetoperformtherepairscorrectly,MACKrecommendscontacting yournearestMACKTruckdealerforallnecessaryrepairs.
Whenstartinganengineafterrepairshavebeenmadetothefuelorinjection
system,prepareequipmentforshuttingofftheengineintakeairand/orfuelsupply (tostoptheengine),incasethereisanoverspeedonstart-up.
Starttheengineonlyfromthedriverseat.Neveroperatethestartermotoracross
thestarterterminalsorthebatteriesasthiscouldbypasstheengineneutral-start systemaswellascausingdamagetotheelectricalorelectronicsystems.
CompressedAirandWater
DANGER
Compressedaircancauseseriouspersonalinjury.Whenusingcompressedairfor cleaning,wearaprotectivefaceshield,protectiveclothingandprotectiveshoes. Pressurizedwatercouldcauseparticlesand/orhotwatertobesprayedinyour directionandcausepersonalinjury.Themaximumairpressuremustbebelow 30psi(200kPa)forcleaningpurposes.
AsbestosInformation
Note:TheMACKengineandreplacementpartsforitshippedfromthefactoryare asbestosfree.MACKrecommendstheuseofonlygenuineMACKspareparts. Neveruseanypartsthatcontainorarethoughttocontainasbestos.Exposureto asbestosberscancreateserioushealthrisks,includingdeath.
FluidPenetration
DANGER
Alwaysuseapieceofpaperorcardboardwhencheckingforaleak.Escapinguid underhighpressure,evenapin-holesizedleak,canpenetratebodytissue,causing seriousinjuryordeath.Ifuidisinjectedintoyourskin,immediatetreatmentmust beadministeredbyadoctorfamiliarwiththistypeofinjury.
22Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
InjuryPrevention
BurnPrevention
EngineParts
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine and/oruidcancauseseriousburns.
WARNING
DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardany longerbeforeraisingthehood. DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling. Also,donotremovethecapwhiletheengineandradiatorarestillhot.Scalding uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon, whichcancausepersonalinjuryanddamagetoenginecomponents.
W0001525
DONOTtouchanypartoftheenginewhileitishot.Allowtheenginetocoolbefore anyrepairormaintenanceisperformedontheengine.
Relieveallpressureinair,oil,fuelorcoolingsystemsbeforeanylines,ttingsor relateditemsaredisconnectedorremoved.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU23
Coolant
WARNING
Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.
W0001527
Topreventpersonalinjury,donotclimbupontheenginetoremovethellercap. Useasuitable,properlypositionedladdertoreachthecap.Atnormaloperating temperature,theenginecoolantisveryhotandunderpressure.Ifpressureisrelieved rapidlyinahotcoolingsystem,thehotcoolantcanturnintosteam.Anycontactwith hotcoolantorsteamcancausesevereburns.Theradiatorandallheatingsystemand radiatorlinesandhosescontainhotcoolant.
Verifycoolantlevelonlybythemarkingsontheexpansiontank.Opentheller caponlyaftertheengineisstoppedandcooleddown.Removethellercapslowly torelievepressure.
Oils
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine and/oruidcancauseseriousburns.
Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When changingoil,wearprotectivegloves.
24Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Batteries
WARNING
Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskof injuryduetocontactwithsulfuricacidoranexplosion.
WARNING
Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds, chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm. Washhandsafterhandling.
Batteryelectrolytecontainsacidandcancauseinjury.Avoidcontactwiththeskin andeyes.W ashhandsaftertouchingbatteriesandconnectors.Useofglovesis recommended.Alwayswearprotectiveglasseswhenworkingwithbatteries.
SpeedRestrictiveTires
DANGER
Operatingavehicleequippedwithspeedrestrictivetiresinexcessoftheirstated ratingmayresultintreadseparationand/orblowoutresultinginthelossofsteering controlandpossiblecollision.Seriouspersonalinjuryordeathcouldoccur.Always maintainproperairpressureandneverexceedthetireratings.
Whenavehicleisequippedwithspeedrestrictivetires,DONOToperatethevehicle inexcessoftheindicatedspeeds.Ifyourvehicleisequippedwithsuchtires,thespeed restrictionswillbestatedonthesidewallofthetires.Theoperatorofthisvehicleis urgedtocheckthetiresofthevehicletodetermineifthereareanylimitations.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU25
FireorExplosionPrevention
DANGER
Thedieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritis fromtheinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedto ushouttheaircleanerelement,theenginemayoverspeedduringstart-up.Engine damageandsevereinjuryand/ordeathfromburnsorexplosioncanoccur.
DANGER
Excessiveheatmaycausethepressurizedcomponentsoftheairconditionedsystem toexplode.SomemixturesofR134arefrigerantcanbecomecombustibleat elevatedpressures.Neverweld,solder,steamcleanoruseagastorchnearanypart oftheairconditioningsystem.Severeinjuryordeathmayoccurfromanexplosion.
W0001526
DANGER
DONOTserviceanypartofthefuelsystemwhilesmokingorinthepresenceof ames,sparksorhotsurfaces.Failuretofollowtheseprecautionscanresultinre, whichcancauseseriousinjuryordeath.
WARNING
DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe eventofare.
26Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
W0001527
Theengineshouldnotbeoperatedinanareawherecombustiblegasesaresuspected tobeintheair.Thesecouldbedrawnintotheenginethroughtheengineairintake systemandcouldcausetheenginetooverspeedwithpossibleseriousdamagetothe engineandbodilyinjuryorpropertydamage.
Makeprovisionsforshuttingofftheengineintakeairorfuelsupplytostoptheengine ifthereisanoverspeedonstart-upafterperformingrepairormaintenanceonit.
ContactyournearestMACKTruckdealerforanynecessaryairconditioningtesting orrepairs.
Allfuels,mostlubricantsandsomecoolantmixturesareammable.Dieselfuel isammable.Gasolineisammable.Themixtureofdieselandgasolinefumesis extremelyexplosive.DONOTsmokewhilerefuelingorwheninarefuelingarea.
Keepallfuelsandlubricantsstoredinproperlymarkedcontainersandawayfromall unauthorizedpersonnel.Storeoilyragsorotherammablematerialinaprotective container,inasafeplace.
Removeallammablematerialsuchasfuel,oilandothersubstancesbeforethey accumulateontheengine.
DONOTexposetheenginetoames,drivingoverburningground.
DONOTweldoramecutonoraroundpipesortubesthatcontainammableuids.
Exhaustheatshieldsmaybeinstalledtoprotectoilorfuelcarryinglinesandpipes fromhotexhaustparts.Toprotectfrompipeorsealfailure,installheatshields correctly.
Provideadequateandproperwasteoildisposal.Alwaysdisposeofwasteliquids accordingtoFederalandlocalregulations.Oilandfuelltersshouldbeproperly installedandhousingcoverstightenedtothepropertorquewhenbeingchanged.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU27
StartingAids
DANGER
DONOTuseetherorothercombustiblestartingaidsonanyengineequipped withapreheater .Iftheengineisequippedwithapreheater,introductionofether orsimilarstartingaidscouldcauseareorexplosionresultinginsevereproperty damage,seriouspersonalinjuryordeath.
DONOTuseetherorothercombustiblestartingaidsonenginesthathavea heaterelementorotherheatingdevicesinstalledintheintakemanifoldfor heatingtheintakeairduringcold-starts.
W0001484
FireExtinguisher
Anytimeworkisbeingdonetothefuelsystemoranyotherareawhereammable substancesarebeingused,haveareextinguisheravailableandknowhowtouseit. Inspectandhaveitservicedasrecommendedonitsinstructionlabel.
28Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
RespiratoryHazardPrevention
DANGER
Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruse aproperlyventedexhausthose.Prolongedorexcessiveexposuremaycause seriousillnessordeath.
WARNING
Dieselengineexhaustandsomeofitsconstituentsareknowntothestateof Californiatocausecancer,birthdefectsandotherreproductiveharm.
W0001523
Alwaysworkinawellventilatedspaceiftheengineneedstoberunningandusea hosetoroutetheexhausttotheoutside.
PoisonousSubstances
DANGER
Coolantistoxic;riskofpoisoning. DONOTdrinkcoolant.Useproperhandprotectionwhenhandling.Keepcoolant outofreachofchildrenandanimals.Failuretofollowtheseprecautionscancause seriousillnessordeath.
Coolingsystemsupplementaladditivecontainsalkali.Topreventpersonalinjury , avoidcontactwiththeskinandeyes.
DONOTdrinkcoolantofanyconcentration.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU29
CrushingorCuttingPrevention
DANGER
Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin neutralandchockthewheels.Failuretodosocanresultinunexpectedvehicle movementandcancauseseriouspersonalinjuryordeath.
WARNING
DONOTworknearthefanwiththeenginerunningortheignitionintheON position.Theenginefancanengageatanytimewithoutwarning.Anyonenear thefanwhenitturnsoncouldbeseriouslyinjured.
W0001524
Neverattemptadjustmentsorrepairswhiletheengineisrunning,seeyourauthorized MACKTruckdealer.
Inspectthefanbladeassemblybeforeserviceforcracksorloosemountingbefore startingtheengine.Neverstandalongsidearotatingfanassembly ,particularlyat highfanspeeds.
Wearprotectiveglasseswhenstrikingobjectstoavoidinjurytoyoureyes.Chipsor otherdebriscanyoffobjectsthatarestruck.Makesurenoonecanbeinjuredby yingdebrisbeforestrikinganyobject.
W0001528
30Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
ClimbingUpandDown
DANGER
Alwayshavethreelimbs(onefootandtwohandsortwofeetandonehand)in contactwiththevehicleatalltimeswhenenteringorexitingthecaborthearea behindthecab.Failuretofollowthiswarningcanresultinseriouspersonalinjury ordeath.
DONOTclimbuponorjumpofffromtheengineorstandoncomponentsthatcannot supportyourweight.Useanadequateladderorscaffolding,suitablysituated.
DONOTusetopofengineorcowlingledgeasfootholdwhenreachingontopofcab. Cleansteps,handholdsandareasofthevehicleonwhichyouwillbeworkingorare around.RefertotheOperatorsManualforproperentryandexitprocedures.
Alwaysuseathree-pointstance(twohandsandonefootoronehandandtwo feet)wheneverclimbingupordown.
EngineDamagePrevention
BeforeStartingtheEngine
DANGER
Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin neutralandchockthewheels.Failuretodosocanresultinunexpectedvehicle movementandcancauseseriouspersonalinjuryordeath.
Inspectengineforpotentialhazards.Makesureallprotectiveguardsandcoversare properlyinstalledifanengineneedstobestartedtomakeadjustmentsorchecks.To helppreventanaccidentbymovingparts,workcarefullyaroundthem.
DONOTdisableorbypassautomaticalarm/shutoffcircuits.Theyareprovidedto preventpersonalinjuryandenginedamage.
OnlyproperlytrainedandauthorizedMACKServiceTechniciansmayattemptrepairs onthisvehicle.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU31
EngineStarting
DONOTstarttheengineormoveanyofthecontrolsordisengagetheparkingbrake ifthewarningtagDONOTOPERATEisattachedtotheignitionkeyorlocatedon thedash.Checkwiththepersonwhoattachedthetagbeforestarting.
Makesurenooneisworkingonorclosetotheengineorcomponentsdrivenbythe enginebeforestartingit.Alwaysmakeaninspectionoftheenginebeforeandafter starting.
Dieselengineexhaustcontainsproductsofcombustionwhichmaybeharmfultoyour health.Alwaysstartandoperatetheengineinawell-ventilatedarea,andifinan enclosedarea,venttheexhausttotheoutside.
Starttheengineonlyfromthedriverseatinthecab.Neverstarttheengineby shortingacrossthestartermotorterminalsorbatteriestostarttheengineasthiscould bypasstheengineneutral-startsystemaswellasdamagetheelectricalandelectronic system.Alwaysstarttheengineaccordingtotherequiredenginestartingprocedure describedinthisoperatorsmanualtopreventmajorenginecomponentdamageand personalinjury.
32Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
ElectricSystemDamagePrevention
ElectricandElectronicSystems
WARNING
Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskof injuryduetocontactwithsulfuricacidoranexplosion.
W0001526
Neverdisconnectanychargingunitcircuitorbatterycircuitcablefromthebattery whenthechargingunitisoperating.Asparkcancausetheammablevapormixture ofhydrogenandoxygentoexplode.
Topreventpotentialsparksfromignitingcombustiblegasesproducedbysome batteries,attachthenegative(-)terminallastwhenhookingupandremovethe negativeterminalrstaftertheenginehasstarted.Checkregularlyaroundtheengine andenginecompartmentforlooseorfrayedwires.Havealllooseorfrayedelectrical wirestightened,repairedorreplacedbeforeoperatingthevehicle.
GroundingPractices
Propergroundingforvehicleandengineelectricalandelectronicsystemsisnecessary forpropervehicleandengineperformanceandreliability.Impropergroundingwill resultinuncontrolledandunreliableelectricalpaths.
Uncontrolledengineelectricalcircuitpathscanresultindamagetomainbearings, crankshaftjournalssurfacesandaluminumcomponents.Uncontrolledelectrical circuitpathscanalsocauseelectricalnoisewhichmaydegradevehicleandradio performance.
Operatingengineswithouttheengine-to-framegroundstrapinstalledcancause damagetotheengine.Topreventelectricaldischargedamage,checktomakesure theengineselectricalsystemhasanengine-to-framegroundstrap.Allground connectionsshouldbetightandfreeofcorrosion.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU33
ElectronicEngineControlSystem
DANGER
Theengineuseshighvoltagetotheelectronicunitinjectors. DONOTcomeincontactwiththeunitinjectorterminalswhiletheengineis running.Anelectricshockcancauseaninvoluntarymusclespasmandcauseloss ofbalanceandfallsleadingtoseverepersonalinjuryordeath.
W0001522
Tamperingwiththeelectronicsysteminstallationcanbedangerousandcouldresultin personalinjuryordeathand/orenginedamage.Itisveryimportanttotaketheproper precautionswiththeelectricalandelectronicsystemwhenchargingthebatteries, jump-startingorperformingelectricweldingonthevehicle.SeethevehicleOperators Manualforcorrectprocedures.
Thisengineisequippedwithmonitoringfeaturesthatmaycausereducedpoweror shutdownundercertainconditions.Thepoweroutput,monitoringandidlingfeatures canonlybeprogrammedand/orchangedwithelectronicservicetoolsandpasswords.
Certainfeatures,suchaslowoilpressure,highcoolanttemperatureorlowcoolant levelcouldcausetheenginepowerand/orvehiclespeedtobelimitedandtheengine mayalsoshutdown.Theshutdownwilltakeapproximately30secondsfromthe timethewarningfeatureisactivated.SeethevehicleOperatorsManualformore information.
34Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
ReportingSafetyDefects
USA
TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKInc. shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefectthatcould causeavehicleaccident,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto NHTSA,U.S.DepartmentofTransportation,W ashington,DC20590,byTTYat1 (800)424-9153,orvisittheirwebsiteatwww.nhtsa.dot.gov.
Canada
RefercustomercomplaintstoMACKTrucksCanada,Inc.ortoTransportCanada, DefectInvestigationsandRecalls.
Canadiancustomerswhowishtoreportasafety-relateddefecttoTransportCanada, DefectInvestigationsandRecalls,maytelephonethetollfreehotline1(800) 333-0510(withinCanadaonly)orcall1(613)993-9851(fromOttawaregionor outsideCanada).ContactTransportCanadabymailat:TransportCanada,ASFAD, PlacedeV illeTowerC,330SparksStreet,OttawaONK1A0N5.
Foradditionalroadsafetyinformation,pleasevisittheRoadSafetywebsiteat: http://www.tc.gc.ca/roadsafety/menu.htm
Mexico
MACKTrucksdeMexico,S.A.deC.V .shouldbeinformedimmediatelyifyou believethevehiclehasadefectthatcouldcauseavehicleaccident,injuryordeath. ContactMACKTrucksdeMexicobycalling:01(800)9094900(withinMexico only)or011-52-55-50-81-68-50,orbywritingto:MACKTrucksdeMexico,S.A. deC.V .,Prol.PaseodelaReforma600,1er .Piso121,Col.SantaFePeaBlanca, C.P.01210,Mexico,D.F.
Note:ForRoadsideassistanceinformationsee“CUSTOMERSERVICE”,page158.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU35
GeneralEngineInformation
EngineOverview,MP7andMP8LeftSideView
MP8EngineShown,MP7EngineSimilar
1.BreatherTube9.FuelFilter
2.IntakeManifold10.Hand-PrimingPump
3.AirCompressor11.CrankcaseVentilator
4.PowerSteeringPump12.Alternator
5.FuelPump
6.EngineControlModule(ECM)14.Alternator/ACCompressorBelt
7.FuelFilter15.Fan/CoolantPumpBelt
8.Fuel/WaterSeparator16.EGRMixingChamber
13.ACCompressor
W2006034
36Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
EngineOverview,MP7andMP8RightSideView
MP8EngineShown,MP7EngineSimilar
17.ExhaustManifold24.V enturiPipe
18.V alveCover25.OilFilters
19.IntakeAirHeater(IAH)optional26.OilPan
20.Thermostat27.EGRCooler
21.BeltTensioner28.Turbocharger
22.CoolantPump
23.CoolantFilter30.EGRV alve
29.StarterMotor
W2006035
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU37
EngineOverview,MP10LeftSideView
1.BreatherTube9.Fuel/WaterSeparator
2.IntakeManifold10.FuelFilter
3.AirCompressor11.Hand-PrimingPump
4.PowerSteeringPump12.Alternator
5.FuelPump
6.CrankcaseV entilator14.Alternator/ACCompressorBelt
7.EngineControlModule(ECM)15.Fan/CoolantPumpBelt
8.FuelFilter16.V enturiPipe
13.ACCompressor
17.EGRMixingChamber
W2006037
38Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
EngineOverview,MP10RightSideView
18.ExhaustManifold24.CoolantFilter
19.V alveCover25.OilFilters
20.IntakeAirHeater(IAH)26.EGRCooler
21.Thermostat27.OilPan
22.BeltTensioner
23.CoolantPump29.Turbocharger
28.StarterMotor
30.EGRV alve
W2006036
ElectricalSystem
Batteries
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU39
WARNING
Batteryposts,terminalsandrelated accessoriescontainleadandlead compounds,chemicalsknowntothe StateofCaliforniatocausecancerand reproductiveharm.Washhandsafter handling.
CAUTION
Disconnectingbatterycableswhen vehicleisequippedwithpowerdoor lockswillresultinautomaticlocking ofdoors.
CAUTION
WARNING
Alwaysweareyeprotectionwhen workingaroundbatteriestoprevent theriskofinjuryduetocontactwith sulfuricacidoranexplosion.
Amaintenance-freebatterydoesnotrequiretheadditionofwaterforitsnormal expectedlife.Typicalfeaturesincludeheavy-dutyconstructionandawrought lead-calciumgridtoresistvibration,shock,overcharge,heatandthermalrunaway. Nevertheless,thesebatteriesarevulnerabletotheravagesofcoldweatheroperation iftotallyignored.
Whenusingapressurewashertoclean thevehicle,donotdirectthesprayat electricalcomponentsintheengine compartmentsuchasthealternator, starterandcompressors.Waterspray frompressurewasherscandamage electricalcomponents.
W0054087
Battery
40Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Besurethatthebatteriesusedinaparticularvehicleareratedforthespecied ColdCrankingAmperes(CCAs)necessarytoensurereliablecoldweatherstarts. Thisisimportant,sinceevenwell-maintainedbatterieschilledto18°C(0°F)may temporarilybecapableofprovidingonly40%oftheirratedcapacityat27°C(80°F).
Keeptheterminalscleantopreventformationofpower-robbingcorrosion.
Inwinter,toavoidfreezingtheelectrolyte,thebatterymustbefullycharged.Afully dischargedbatterywillfreezesolidat5°C(23°F)andpossiblysustainpermanent damage.
Beforetheonsetofcoldweather,besuretoprotectthisvitalcomponentbymonitoring itsconditionaswellasinspectingthechargingandstartingsystems.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU41
BatteryWarmer
Abatterywarmercanbeaddedtoraisethetemperatureofthebatterycoreand facilitatequickstartingincoldweather.
BatteryCondition
Therstprocedurewhentestingabatteryistocheckforexternaldamagesuch asacrackedcase,looseorcorrodedterminals,orsignsofexcessivegassingor overcharging.
Abatterymustbefullychargedbeforealoadtestisperformed.Testthebatterywitha hydrometertodeterminethelevelofcharge.
Onmaintenance-freebatteriesequippedwithabuilt-inhydrometer(eye),thebattery conditionisinterpretedasfollows:
W0054088
BatteryCondition
42Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
GreendotvisibleAnygreenappearanceshouldbeinterpretedasagreendotand
meansthatthebatteryisatorabovea65%stateofchargeandisreadyforuseor testing.Thisdoesnotautomaticallymeanthatthebatteryisingoodcondition.
Darkgreendotnotvisible(blackdot)Thisindicatesthatthebatteryisbelowa
65%stateofchargeandmustbechargedbeforetesting.Ablackdotdoesnotmean thatthebatteryisautomaticallybad.
ClearorlightyellowThismeansthattheelectrolytelevelisbelowthelevelof
thebuilt-inhydrometer,whichmayhavebeencausedbytippingofthebattery,a crackedcase,orovercharging.Thisbatteryshouldbereplaced.
Charging
Chargingshouldbeconductedcarefullyundercontrolledconditions.Nevercharge afrozenbattery .Ifafrozenbatteryissuspected,thawitinawarmareaforseveral hoursbeforecharging.
Thefollowingchartshowsthenormalchargingtimesnecessarytoreachafullcharge at26°C(80°F).Incoldertemperatures,thenecessarychargingtimemayincrease.
Open
Circuit
V oltage
12.61.265100%FullCharge
12.41.22575%15
12.21.19050%35
12.01.15525%50
11.81.1200%65
Battery
Spe­cic
Grav-
ity*
Stateof
Charge
*Correctfortemperature.
**Ifcolder,itwilltakelonger.
ChargingTimetoFullChargeat80°F**
at60 amps
min.
min.
min.
min.
at50 amps
at40 amps
20
min.
45
min.
65
min.
85
min.
at30 amps
27
min.
min.
min.
min.
min.
55
min.
85
min.
110
min.
at20 amps
35
min.
75
min.
115
min.
150
min.
at10 amps
48
95
145
195
90
min.
180
min.
280
min.
370
min.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU43
CompletelyDischargedBatteries
Extremelycoldorcompletelydischargedbatteriesmaynotinitiallyshowacharge sincetheelectrolyteisnearlypurewaterand,therefore,apoorconductor.Asthe acidlevelintheelectrolyteincreasesduringcharging,thechargingcurrentwillalso increase.Usethefollowingprocedurewhenchargingacompletelydischargedbattery:
1Measurethevoltageatthebatteryterminals.Ifitisbelow10volts,currentwillbe
verylowandmaynotshowuponmanybatterychargerammeters.
2Setthechargeronthehighsetting.
3Somechargershaveapolarityprotectionfeaturewhichpreventsaccidentalreversal
ofthechargerleads.Acompletelydischargedbatterywillnothaveenoughvoltage tooverridethisfeature,makingitappearthatthebatterywillnotacceptacharge. Checkthechargermanufacturersinstructionsonhowtobypassthisfeature.
4Oncethebatterystartstoacceptacharge,thechargingratewillriseveryrapidly.
Carefullymonitortheammetertopreventtoo-highachargingrate.
5Proceedtochargebatteryatone-tenthofitsratedcapacityforone-halfhour.
Example:Forbatteryratedat64(amps-hour),chargeat6.4ampsetting.
Note:Batterieswithverylowvoltage(below11.6volts)orthosethatdonot initiallyacceptachargearenotnecessarilydefective.Batteriesthathavebeen dischargedforlongperiodsoftimemaybeheavilysulfatedorhydrated(containing leadshortsthatcausethebatterytoself-discharge).T oacceptacharge,batteries witheitheroftheseconditionsmayrequirealongerchargingtimeoraveryhigh initialcharge.
Usethefollowingcharttodeterminethetimerequiredforthebatterytobegin acceptingameasurablecharge.(Ifthebatteryhasnotstartedtoacceptachargeafter thespeciedtime,itshouldbereplaced.)
ChargerV oltage
16.0ormoreUpto4
14.0to15.9Upto8
13.9orless
Hours
Upto16
44Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
LoadTest
Abatterymustbefullychargedbeforeperformingaloadtest.Toload-testabattery thatisfullycharged,proceedasfollows:
1Connectaloadtesterandvoltmeteracrossthebatteryterminals.
2Applyaloadsothatagureof300ampsisobtainedfor15secondstoremovethe
batterysurfacecharge.
3Wait60secondstoletthebatteryrecoverandthenapplythepropertestload
tothebatterytodetermineitscondition.Togettheproperload,usehalfthe crankingperformancerating.Readthevoltageafter15seconds.Rememberthat theminimumvoltagevariesaccordingtotemperature.Consultthefollowingchart fortheproperspecication.Ifthebatteryvoltagedoesnotfallbelowtheminimum testvoltageafter15seconds,thebatteryisacceptableforuse.
LoadTestT emperatureCorrection
MinimumV oltage
C
9.62170
9.51660
9.41050
9.3440
9.1130
8.9
8.71210
8.5180
7
Temperature
F
20
ElectricalConnectionProtection
Ifcorrosionisseenatanyexternalring-typeterminalconnections,suchasthoseused atthestarter,alternator,chassisand/orenginegrounds,etc.,LPSHardCoatCorrosion Protectantmustbeappliedtotheconnectionafterdisconnecting,cleaningand reconnectingtheringterminal.Additionally ,LPSHardCoatshouldbeappliedtoany ring-typeterminalconnectorfollowinganytypeofserviceprocedurewhichinvolved disconnecting/reconnectingtheringterminals(suchascomponentreplacement, troubleshooting,serviceandrepair,etc.).
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU45
WiringHarness/CableandConnectorProtection
Tohelpprotectyourvehicle’sexternalhighamperageelectricalcablesand connectionsfromcorrosionduetotheeffectsofnewersalts(calciumchlorideand magnesiumchloride)ontheroadways,MACKisofferingacorrosioninhibitorpart 20916273forpurchasethroughthePDC. MACKrecommendscoatingallhighamperage(positiveandground)exposed electricalconnectionsataminimumofevery6monthsor,whenevertheconnector hasbeendisassembled.Thefollowinglistcontainstherecommendedconnectionsthat shouldbeliberallycoatedwiththecorrosioninhibitor;
Batteryconnections
Batterymainshutoffswitchconnections
Maxiand/orMegafuseconnections
Allgroundstudconnections
Electricalpneumaticpass-thruconnections
Allalternatorconnections
Allstarterconnections
Intakepreheaterandpreheaterrelayconnections
Electricalpowerinverterconnections
Allconnectionsshouldbecleanedandfreeofpreviouslyappliedinhibitors,oil,dirt, dustorothercontaminantspriortoapplication.Allowtimefortheproducttodry beforeuse(dryingtimemayvarydependingtemperature,humidity,etc.).
FormoreinformationregardingthiscorrosioninhibitorproducedbyLPSWorldwide, visittheirwebsiteatwww.lpslabs.com.
46Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Lighting
WARNING
Usingincorrectbulbsorlampsmayresultinfailuresthatcouldleadtoareora vehicleaccidentcausedbyimproperlighting.
Checkalllightsonthevehicledailyforproperfunction.Replaceburnedoutinserts andbulbs.Replaceanybrokenorcrackedsideorrearreectors.Headlightsshouldbe checkedforaimatleastonceperyear.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU47
PrecautionsWhenInstallingElectricalEquipment
Connectingelectricallypoweredorelectricallycontrolledequipmenttoavehicle maycauseinterferencewithothervehicleelectricalorelectronicequipment(suchas ABSsystems,RolloverStabilitySystems,etc.).Theamountofinterferencedepends upontheoperatingfrequencyofanynewsignalsandthedegreetowhichtransient signalsarecoupledtothevehiclesystem.
Note:Whenevernewelectricalequipmentisinstalled,itistheobligationofthe installertoensurethatthenewequipmentdoesnotinterferewiththeproperoperation ofallotherelectricalsystemsonthevehicle.
Ifnewelectricalequipmentisinstalled,avehiclecheckoutprocedureshouldbe performed.
1Performthecheckoutprocedureunderthefollowingconditions:
Enginerunning
Brakesystemairpressureinoperatingrange
Vehiclestationary
Brakepedalfullydepressed
2Operatethenewequipmentunderallstarting,runningandsutdownconditions.
3ListenforsignsofairexhaustingfromtheABSmodulatorvalves(whichisan
indicationofaninterferencecondition).
4Correctallinterferenceconditionsbeforeoperatingthevehicle.
Note:Thecenterpinofthestandardseven-pintrailerelectricalconnectorhasbeen standardizedasthededicatedconnectionforuninterruptedpowerfortrailerABS.This pinisalwayshotwhenthetractorignitionisturnedon.
DANGER
Sometrailersmanufacturedpriorto thetrailerABSregulationsmayuse thecenterpintopowercertaintrailer auxiliaryequipment.Thepossibility existsthatthisauxiliaryequipmentmay beunexpectedlyactivatedbythetruck ortractorelectricalsystem,resultingin personalinjuryordamagetoequipment. Cautionmustbeusedwhenconnecting thetrailerelectricalconnectortoensure thatpowertothecenterpinwillnot unintentionallyactivateanytrailer auxiliaryequipment.
48Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
MACKRoadStabilityAdvantage
TheMACKRoadStabilityAdvantage(RSA)isanavailableoptiononcertain MACKhighwaytractorsandstraighttrucks.TheRSAsystem,whichisbasedonthe BendixABS-6AdvancedwithESP(ElectronicStabilityProgram)System,aidsthe operatorinmaintainingcontrolofthevehicleduringjackknifeorrollovereventsby applyingselectbrakesandreducingenginepowerasrequiredbythespecicsituation. Thissystemisintegralwiththeanti-lockbrakesystemandusesthestandardABS components(suchaswheelspeedsensorsandmodulatorvalves).Additionally ,a steeringanglesensorandayawrate/lateralaccelerationsensorpackageprovides informationconcerningvehiclemovementtotheelectroniccontrolunit.
Beforedeliverytotheenduser,aparametersettunedforthespecicvehicleandthe VINforthechassisareloadedintotheABSelectroniccontrolunit.Thisensures optimalperformanceoftheMACKRSAsystemforthespecicvehicle.
AlterationsandmodicationstoanRSA-equippedvehicle,suchaswheelbase changes(eitherlengtheningorshortening),theadditionofanauxiliaryliftaxleorthe removalofafactory-installedliftaxle,ormajorbodychanges,suchasconversionofa tractortoatruckoranaxle,suspensionorsteeringsystemcomponentmodication, areNOTallowed,asthesechangeswilladverselyaffectperformanceoftheroad stabilitysystem.Shouldsuchchangesbeunavoidable,thesystemmustbedisabledby havingaqualiedtechnicianreplacetheBendixAdvancedEC-60(ABScontrolunit withESP)withaBendixPremiumEC-60ECU(ABScontrolunitwithoutESP).
DANGER
FailuretodisabletheRSAsystemona vehiclethathasbeenmodiedoraltered willresultinseriousvehiclebraking andperformanceissues,including unnecessarysysteminterventions. Theseinterventionscouldleadtoaloss ofvehiclecontrol. Inadditiontodisablingthesystem,any cablabels,suchaswarningandcaution labelsrelatingtotheBendixABS-6 AdvancedwithESPsystemlocatedon thesunvisormustberemoved,and notationsmustbemadeintheoperators manualssothatthevehicleoperatorhas aclearunderstandingastowhichABS optionsareinstalledonthevehicle.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU49
Thelocationoftheyawrate/lateralaccelerationsensormustnotbealtered.
Aftermarketsteeringwheelsmustnotbeused.OnlyOEM-suppliedreplacement steeringwheelsshouldbeused.Duringanyprocedurethatinvolvesremovaland reinstallationorreplacementoftheOEMsteeringwheel,caremustbeusednotto crushordamagethesteeringanglesensorwhichismountedonthesteeringcolumn.
IncreasingsteeringanglebeyondmaximumisNOTpermitted.However,steering anglesmaybeincreasedtothemaximumfactorysettingsifrequired.Refertothe applicablesteeringsystemservicemanualfordetailedinformation.
Thesteeringanglesensormustberecalibratedfollowinganyadjustmentsorchanges tothesteeringsystem.
Changingsteeraxleand/ordriveaxletrackwidthispermissible.
Changingfrontorrearaxlebrakedrumstodrumshavingadifferentangethickness ispermissible.
TheABSwithESPECUrequiresapreciserollingcircumferenceratiobetweenthe frontsteeraxleandthereardriveaxlesforoptimumperformanceofthesystem. Forthisreason,thesystemcontinuouslycalculatesthepreciseratioandstoresthe informationintheECUmemory .
CAUTION
EffectivenessoftheRSAsystemrelies ontheaccuracyofthereportedvehicle speed.Ifmajorchangestotiresizesare made,suchthatchangestothevehicle speedometer/odometersettingsare required,theABSwithESPECUmust bereprogrammedwiththenewvalues byaqualiedtechnician.
50Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
EngineStorage
EngineStorage
Ifthevehiclemustbeparkedforaperiod(morethan30days),protectitasfollows:
1Draintheengineoil.
2Filluptotheproperlevelwithoiloftherecommendedqualityandviscosity.
3Fillupthefueltankswiththerecommendedgradeoffuel.
4Runtheenginefortwominutesaround1000rpm.Shuttheenginedown.DO
NOTdraintheoilafterthisrun.
5Checkthecoolantforproperlevelsofantifreezeandinhibitor(SCA)protection.
Serviceasnecessary.
6Sealallengineopeningsusingprotectivecovers.
Toreturntoserviceanenginepreservedinthismanner,removepreviouslyinstalled protectivecovers.Checkalluidlevelsandifnecessaryreplaceengineoil contaminatedbycondensation.
Operator’sManualVehicleMaintenanceCXU,
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MaintenanceandService
MaintenanceHazards
DANGER
Beforeworkingonorinspectingavehicle,settheparkingbrakes,placethe transmissioninneutralandchockthewheels.Failuretodosocanresultin unexpectedvehiclemovementandcancauseseriouspersonalinjuryordeath.
DANGER
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining, correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto personalinjuryordeath,ormakingyourvehicleunsafe.
Note:Readallsafetyinformationbeforeworkingonthevehicle.
EngineComponents,ServiceSchedules
Component
FuelFilter (MP7,MP8and MP10)
WaterSeparator (MP7,MP8and MP10)
AirFilterEP A 2010
AirFilterEuro4ChangeAtmaximumrestrictionasindicated
Coolant (MP7,MP8and MP10)
Coolant, ExtendedLife (ELC) (MP7,MP8and MP10)
OperationKm(Miles)/MaximumMonths/Hours
ChangeEachoilchange*
FilterchangeEachoilchange*
Change160000(100,000)or12months,
whichevercomesrst
ongauge,or12months
Change500000(300,000)6000or24months,
whichevercomesrst
Change1000000(600,000)or48months,
whichevercomesrst
52Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Component
CoolantFilter (MP7,MP8and MP10)
CoolantFilter, ExtendedLife (ELC) (MP7,MP8and MP10)
Coolant ConditionerEuro 4
Valves/Injectors (MP7and MP8)**
Valves/Injectors (MP7andMP8) **
Valves/Injectors (MP10)**
Valves/Injectors (MP10)**
DriveBeltsCXU, CHUandTD Euro4(Highway)
DriveBelts GU,LEUand MRUEuro4 (V ocational)
Catalyzed DPFFilter(If equipped) (MP7,MP8and MP10)
Aftertreatment Doser(If equipped) (MP7,MP8and MP10)
OperationKm(Miles)/MaximumMonths/Hours
Change80000(50,000)or6months,
whichevercomesrst
Change240000(150,000)or12months,
whichevercomesrst (MP7,MP8andMP10)
ChangeTraditionalcoolantsrequiring
SupplementalCoolantAdditive (SCA) 80000(50,000)or6months
InitialAdjust
Adjust
InitialAdjust
Adjust
Change500000(300,000)or36months,
Change240000(150,000)or12months,
Change240000(150,000)or4,500hours,
Clean240000(150,000)or4,500hours,
200000(125,000)or12months, whichevercomesrst
400000(250,000)or24months, whichevercomesrst
100000(60,000)or6months, whichevercomesrst
200000(125,000)or12months, whichevercomesrst
whichevercomesrst
whichevercomesrst
whichevercomesrst
whichevercomesrst
Operator’sManualVehicleMaintenanceCXU,
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Component
DieselExhaust Fluid(DEF) PumpFilter (MP7,MP8and MP10)
DieselExhaust Fluid(DEF)Tank FillerNeckFilter Cleaning (MP7,MP8and MP10)
*Undercertainconditions(forexample,irregularfuelquality),thefuel/water separatorltersmayrequiremorefrequentreplacement.
**Valvesmustbeadjustedwhenevertherockershafthasbeenremovedand reinstalledforanyreason.
OperationKm(Miles)/MaximumMonths/Hours
ChangeFirstChange;161000(100,000)or
3200hours,whichevercomesrst 241000(150,000)or4800hoursor three(3)years,whichevercomesrst
Clean280000(175,000)or12months,
whichevercomesrst
54Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
CoolingSystem
GeneralCoolantInformation
DANGER
Coolantistoxic;riskofpoisoning.DONOTdrinkcoolant.Useproperhand protectionwhenhandling.Keepcoolantoutofreachofchildrenandanimals. Failuretofollowtheseprecautionscancauseseriousillnessordeath.
WARNING
DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardbefore raisingthehood. DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling. Also,DONOTremovethecapwhiletheengineandradiatorarestillhot.Scalding uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon andcancausepersonalinjury.
WARNING
Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.
CAUTION
MACKInc.doesnotrecommendusingplainwaterinthecoolingsystem.W ater aloneiscorrosiveatengineoperatingtemperaturesanddoesnotprovideadequate boilingprotection.Theenginemaydevelopcorrosionandcavitationproblemsin theengineandradiator,andtheboilingpointofthecoolantisloweredcompared toaproperantifreezeandwatermixture.FailuretofollowMACKInc.cooling systemcare/maintenancerecommendationscanrenderthewarrantyinvalid.
Operator’sManualVehicleMaintenanceCXU,
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Thecoolingsystemplaysanimportantroleinoverallengineperformancebykeeping theenginewithinthenormaloperatingtemperaturerangehotenoughforefcient combustion,andcoolenoughtopreventenginedamagecausedbyoverheating. Goodpreventivemaintenancepractices,alongwithmonitoringcoolingsystem performance,goalongwayinpreventingenginedamagethatcouldresultfrom coolingsystemproblems.Themaintenanceitemsandtestsoutlinedinthissection shouldbeperformedattheintervalsspeciedtoensureoptimumperformancefrom thecoolingsystem.
SurgeTankCap
MACKconventionalmodels(CXU,CHU,GUandTD)utilizeacoolantsurgetank mountedontopoftheradiator.Thesurgetankhasallcaplocatedonthetop right-handsideofthetank,andapressurecapratedat16lb.whichincorporates anoverowtubelocatedontheleft-handsideofthetank.Checkthecoolantlevel regularly,makingsurethecoolantlevelisbetweentheCOLDMINandCOLD MAXlinesonthebackofthetank.AteachCandDinspectioninterval,inspectthe rubbergasketsoneachofthecaps.Replacethecap(s)ifthegasketsshowevidence ofdamagewhichcouldaffectsealing.
WARNING
DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystemto coolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseand waitforthepressureinthesystemtodissipate.Afterthepressurehasdissipated, completelyremovethecap.
W0054042
SurgeTankConventionalModels
1.PressureCap
2.FillCap
56Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
MACKlowcabforwardmodels(MRU,LEU)utilizeasurgetankwhichislocatedon theleft-handsideofthechassis,mountedonastanchiontotherearofthecab.This surgetankutilizesastandardradiatorpressurecap.Checkthecoolantlevelregularly, makingsurethecoolantisvisibleinthesightglasslocatedonthesideofthetank. AteachCandDinspectioninterval,removetheradiatorcapandinspectthegasket foranydefectsthatwouldaffectsealing.Also,pressure-testthecapusingasuitable coolingsystemandradiatorcaptester.Surgetankcappressurespecicationsareas follows:
MP7Engines(MRUandLEUModels)16-lb.pressurecap
MP8Engines(MRUModelsonly)16-lb.pressurecap
WARNING
DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystem tocoolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseto therststop,andthenwaitforthepressureinthesystemtodissipate.Afterthe pressurehasdissipated,completelyremovethecap.
Themainpurposeofcoolantistotransportheatfromthehotpartsoftheenginetothe radiatorandtoprotectthecoolingsystemfromcorrosion.
Inadditiontothis,thecoolantmust:
Protectagainstpittingandcavitationerosiondamageofthewaterpumpand
cylinderliners.
Protectagainstfreezingandboiling.
Preventformationofscale,sludgedepositsandclogging.
Beharmlesstopolymermaterialsandsealsinthecoolingsystem.
Maintainitsliquidpropertiesincoldclimates.
Manyenginefailurescanbetracedbacktoaprobleminthecoolingsystem.Ifthe coolantlevelisallowedtogobelowthebottomofthetank,thereistheriskofthe engineshuttingdown.Seetheoperatorsmanualformoreinformationonthewarning functions.
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Note:AlwaysdisposeofcoolantaccordingtoFederalorlocalregulations.T akeall usedcoolanttoarecyclingorwastecollectioncenter.
Coolantmixtureconsistingofanantifreezesolutioninwatershouldbeused year-roundtoprovidefreezeandboil-overprotectionaswellasprovidingastable environmentforsealsandhoses.
Note:DONOTuseantifreezeformulatedforautomobilegasolineengines.These haveaveryhighsilicatecontentthatwillclogtheradiatorandleaveunwanted depositsintheengine.
CoolantSystemCapacities
CAUTION
Capacitiesmayvaryduetohosesand sizeofradiator,aswellasaccessory coolingequipment.Afterrunning theengineuntilnormaloperating temperatureisreached,checkthe coolantlevelandaddcoolantasneeded.
UsethechartshowninconjunctionwiththeEthylene-GlycolandPropylene-Glycol ProtectionChartsinthissectiontodeterminetheamountofantifreezeneededto protectyourvehicle.
58Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Chassis
Model
CXU
CHU
TD7
GU7
GU8
MRU
LEU***MP7Automatictransmissionwithout
*Coolantcapacitieslistedareforchassisequippedwithmanualtransmissions. Forautomatictransmissions,add9.5liters(10qts). **AllisonautomatictransmissionisnotanavailableoptionforMRUmodels equippedwithanMP8engine. ***LEUmodelsarenotavailablewithamanualtransmission.
MP7* MP8*
MP7* MP8*
MP10*53(56)
MP7* MP8*
MP7* MP8*
MP7Manualtransmissionwithout auxiliarycoolingpackage MP7Manualtransmissionwithauxiliary coolingpackage MP7Automatictransmissionwithout auxiliarycoolingpackage MP7Automatictransmissionwithauxiliary coolingpackage MP8**
auxiliarycoolingpackage MP7Automatictransmissionwithauxiliary coolingpackage
EngineModelCoolantCapacityin
52(55) 54(57)
52(55) 54(57)
52(55) 54(57)
52(55) 54(57)
39(41) 48(51) 48(51) 58(61) 52(55)
48(51) 58(61)
Liters(Quarts)
Operator’sManualVehicleMaintenanceCXU,
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Usethefollowingantifreezeprotectionchartstodeterminethepercentageof antifreezeneededtoachievespecicprotectionlevelsforvariouscoolantsystems.
Ethylene-GlycolProtectionChart
EthyleneGlycolAmbientAirTemperature
40%
50%
60%
Propylene-GlycolProtectionChart
PropyleneGlycolAmbientAirTemperature
40%
50%
60%
Awellfunctioningandmaintainedcoolingsystemisasimportanttotheengineas performingregularoilchangesorusinggoodfuel.T ogetthebestresultusequality productsandservicethesystematthecorrectintervals.Pleasereadthissection carefully.
24°C(12°F)
37°C(34°F)
52°C(62°F)
21°C(6°F)
33°C(27°F)
49°C(56°F)
Keeptheradiator(includingchargeaircooler)andthefrontalareafreefrombugs, dirt,leaves,etc.(see“CleaningChargeAirCoolerandRadiatorPackage”,page 107forcleaninginformation).
Checkthecoolantlevelinthetankregularly.Fillthetankasnecessarywiththe correctcoolant.
60Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Inspectionofthewholecoolingsystemisimportant.Checkforswollenordeteriorated heaterandradiatorhoses,loosehoseclampsandconnections,andradiatorleaks.
DANGER
DONOTworknearthefanwiththeenginerunning.Theenginefancanengageat anytimewithoutwarning.Anyonenearthefanwhenitturnsoncouldbeseriously injured.Beforeturningontheignition,besurethatnooneisnearthefan.
CAUTION
Neveraddcoolanttoahotoroverheatedengine.Enginedamagecanresult.Allow theenginetocoolrst.
Additives
Additiveshelppreventrust,scaleandmineraldepositsfromforming.Additivesalso protectmetalsfromcorrosion,preventwaterpumpandcylinderlinercavitationand containanti-foamingagents.Additivesaredepletedduringnormalengineoperation andneedtobereplaced.Fornon-extendedlifecoolantmixture,thismeansthe additionofSupplementalCoolantAdditives(SCA)atanytimetheadditivegoes belowtherecommendedlevel.Forextendedlifecoolantmixture,thismeansan extenderpackageaddedhalfwaythroughthecoolantlifetime.
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RegularCoolantChangeInterval
CoolantSCAlevelmustbetestedatleasttwiceperyearorwhenevercoolantloss occurs.Formaximumcoolantsystemefciency ,testthesystemateveryengineoil changeinterval,every1,000hoursorevery6months(whichevercomesrst).For properSCAlevels,consultServiceManual.
RegularCoolantFilterChangeIntervals
WARNING
Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids cancauseseriousburns.
Thechargedcoolantltercontains8unitsofSCAthatarereleasedslowlyovertime tomaintaintherecommendedlevelduringoperation.Consultengineservicemanual forproperSCAlevelandchangeintervals.
62Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
ExtendedLifeCoolantChangeInterval
CAUTION
Extendedlifecoolantwilltestasoutofadditives(SCA),butSCAshouldnotbe added.ShortenedenginelifemaybetheresultofaddingSCA.
Note:DONOTaddsupplementcoolantadditives(SCA)toextendedlifecoolant.
Shouldtheextendedlifecoolantsystembecomecontaminatedwithregularcoolant exceeding10%ofthesystemstotalcapacityorifSCAisaddedtoextendedlife coolant,drainthesystemandrellwithnewextendedlifecoolantorregularcoolant.
ExtendedLiftCoolantFilterChangeInterval
WARNING
Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids cancauseseriousburns.
CAUTION
DONOTusealterthatcontainsSCA.Damagetocomponentscanresult.
Operator’sManualVehicleMaintenanceCXU,
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FuelSystem
FuelSafetyReminders
DANGER
Adieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritis fromtheinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedto ushouttheaircleanerelement,theenginemayoverspeedduringstart-up.Engine damage,severepersonalinjuryordeathfromburnsorexplosionmayoccur.
DANGER
DONOTmixgasolineoralcoholwithdieseloilfuel.Thismixturecancausean explosionandresultinseverepersonalinjuryordeath.
DANGER
DONOTremovethefueltankcapnearanopename.Dieselfumesare combustibleandcancauseanexplosionorreresultinginseverepersonalinjury ordeath.
WARNING
Ifafuelleakisdetected,stoptheengineimmediately.Thevaporsfromhotfuelare highlyammablewhichmayresultinare.
WARNING
DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe eventofare.
64Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
DieselFuelSpecication
Quality
CAUTION
Dieselenginesfor2007andlatermodelyearvehiclesaredesignedtooperate onlywithUltraLowSulfurDiesel(ULSD)fuel.UseoffuelotherthanULSD willreducetheefciencyanddurabilityoftheengine,permanentlydamagethe advancedemissioncontrolsystems,reducefueleconomyandpossiblypreventthe enginefromrunningatall.Manufacturerswarrantiesarelikelytoberenderedvoid byusageofimproperorincorrectfuel,andusageoffuelsotherthanULSDfuelin diesel-poweredvehiclesisillegalandpunishablewithcivilpenalties.Useoffuel additivestocompensateforthelowersulfurcontentisNOTrecommendedby MACKInc.
Theproperselectionoffuelisessentialforgoodeconomy,performanceandengine life.No.2DULSDshouldbeusedwhenclimaticconditionspermit.No.1DULSD canbeusedduringcoldweatherconditions.BlendsofNo.1DandNo.2DULSD fuelscanbeusedtosuitvariousclimaticconditions.
Note:Theuseoflighterfuels(gradeNo.1-D)canreducefueleconomy.
Note:Euro4Engines
UltraLowSulfurDiesel(ULSD)fuelwithamaximumsulfurcontentof15ppmis requiredtomeetemissioncerticationforEuro4emissionengines.Usingapproved dieselfuelwithamaximumsulfurcontentof500ppminEuro4emissionengines willmeetallreliabilitystandards.
Thefuelsusedmustbeclean,completelydistilled,stableandnon-corrosive.Always trytokeepthefueltankfull.DONOTputalcoholintothefueltank.Fillthetank aftercompletingdrivingfortheday.
FuelSulfurContent
Fuelsoldforuseindiesel-poweredenginesfor2007andlatermodelyearvehicles mayonlycontainamaximumsulfurcontentof0.0015%byweight.Thiswasdoneto reduceparticleemissionsintheexhaust.
Note:Theuseofultra-lowsulfurdieselfueldoesnotpermitextensionofengine oilchangeintervalsoroillterchanges.
Operator’sManualVehicleMaintenanceCXU,
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CetaneNumber
Directinjecteddieselenginesrequireaminimumcetanenumberof43undernormal startingconditions.Fuelwithahighercetanevaluemayberequiredforhigh-altitude orcold-weatheroperation.
Filtration
Fuelshouldbecleanandfreeofcontamination.Cleanfuelsshouldhavenomorethan
0.05%ofsedimentandwater.
FuelAdditives
Fueladditivesaregenerallynotrecommendedorneededforfuelslistedearlier. Cetaneimproverscanbeusedasnecessary.Biocidesmaybeneededtoeliminate microorganismgrowthinstoragetanks.Incoldconditions,treatmentforwaterin thevehicletanksmayalsobenecessary.
Consultyourfuelsupplierabouttheuseofadditivestopreventincompatibilityamong additivesalreadyinthefuelandtheadditivestobeused.
SupplementalFuelEnhancers
CAUTION
Supplementaladditivesarenotrecommendedbecauseofahighriskofinjection systemproblemsorenginedamage.
Therearemanyaftermarketproductsavailabletodaywhichareintendedtobeadded bythecustomer .Theygenerallyincreaseoperatingcostwithoutprovidingbenets. Includedareavarietyofindependentlymarketedproductswhichclaimtobe:
Cetaneimprovers
Emissioncontroladditives
Detergents
Combustionimprovers
Smokesuppressants
Coldweatherowimprovers
Note:Repairexpensesresultingfrommalfunctionsinthefuelsystemorwithengine componentswhenfuelenhancershavebeenusedarenotcoveredunderwarranty.
66Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Somefueladditivescanbeusedtoprovidetemporaryrelief,buttheydonotreplace goodfuelhandlingpractices.Theseproductscanbeused:
IsopropylAlcoholUse1/2literper450liters(1pintper125gallons)offuelfor
winterfreeze-upprotection.
BiocideFortreatmentofmicrobegrowthorblackslime.Followmanufacturers
instructionfortreatment.
ProhibitedAdditives
WARNING
Theadditionofgasolinetodieselfuelwillcreateaseriousrehazard.Serious personalinjurycanresult.
ThefollowingadditivesarespecicallyNOTallowedandmustNOTbemixed inwiththevehicledieselfuel:
GasolineAddinggasolinetodieselfuelwillreducethecetanenumberandincrease
combustiontemperature.Ifatankcontainsadieselfuel/gasolinemixture,itshould bedrainedandcleanedassoonaspossible.
UsedlubricatingoilMACKInc.doesnotrecommendtheuseofanytypeofused
lubricatingoilasanextenderinthedieselfuel.Usedlubricationoilcontains solidsandacidsfromthecombustionprocessthatcanseverelycorrodepartsof theinjectionsystem,resultinginreducedpowerandhighermaintenancecost overtime.
AlternativeFuels
Alternativefuelscanbeofseveraldifferenttypes.Therearevegetablebasedfuels, aviationfuelandrecycledpetroleumbasedfuelsthatareusedincombustionengines. Theseareingeneralnotcompatiblewithmodernheavy-dutyover-the-roaddiesel engines.
Theuseofunauthorizedfuelsmaycompromisethelevelsofpollutantsintheexhaust tothepointwheretheenginedoesnotmeettheemissionrequirements.Thiswould makethevehicleillegaltodriveonpublicroads.DONOTuseanykindofalternative fuelunlessspecicallyauthorizedbyMACKInc.
Operator’sManualVehicleMaintenanceCXU,
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BioDiesel
TheonlyBioDieselFuelapprovedbyMACKInc.foruseinEPA2010MACK EnginesisSoyMethylEster(SMEorSOME)inblendsuptoB5Concentration (5%blend).
Note:Althoughhigherconcentrationsareavailable,concentrationuptoB5 (maximum)aretheonlyblendscurrentlyapprovedbyMACKInc.
FuelStorage
Iffuelisstoredonsite:
Keepstoragetankcoveredtopreventwaterentry.
DONOTuseatankmadeofgalvanizedmetaloranygalvanizedpipingfordiesel
oilstorage.Dieselwillreactwiththezinc,formingsolidsthatcanclogfuellters andcauseenginedamage.
Fuelstoredforalongtimemayoxidizeandformsolids,causinglteringproblems.
Keeptheareaaroundthellcapclean.Tiltthetankslightlytowardthedrainplug
areasowaterandsedimentcanbeeasilydrained.
Generally,fuelcontaminationoccursastheresultofimproperfuelhandling.Themost commontypesofcontaminationarewater,dirtandmicrobialgrowth(blackslime). Theformationofvarnishesandgumsresultingfrompoorfuelstabilityorlongstorage (stalefuel)alsoaffectsfuelquality.Thebesttreatmentforcontaminationisprevention bymaintainingacleanstoragesystemandchoosingareputablefuelsupplier.
68Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
FuelFilters
Aprimaryfuelltercanbelocatedontheengineorremotemountedontheframe rail.Thislterconsistsofaltercartridge,awaterseparationbowlandmayhavea fuelheaterbuiltin.
Thesecondaryfuellterislocatedonthelefthandside,belowtheengineelectronic controlunit(EECU).Thelterisaspin-onlter.
MACKMPenginesutilizeaspin-onprimaryandsecondaryfuellters.Bothlters arelocatedontheright-handsideoftheengine.
W0054019
FuelFiltersMACKMPEngine
1.SecondaryFuelFilter2.PrimaryFuelFilter
TheprimaryfuellteronMACKMPenginesincorporatesaplasticwaterseparator bowl.Additionally,theplasticbowlincludesawater-in-fuelsensor.Awarninglamp ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Referto Fuel/WaterSeparatorsection.
Note:Thereareoptionalfuelltersystems(suchasDavco,Conmet,etc.)available forMACKMPengines.Thesefuelltersystemsuseasingleremote-mounted lter,eliminatingthespin-onprimaryandsecondarylters.Forserviceinformation concerningtheselters,refertothespecicfuelltermanufacturersserviceliterature.
Operator’sManualVehicleMaintenanceCXU,
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PrimaryFuelFilterReplacementProcedures MACKMPEngines
Ateachspeciedoilandlterchangeinterval,changetheprimaryfuellteras follows:
MACKMPPrimaryFuelFilter
1.PrimaryFilter
2.WaterSeparatorBowl
W0054023
3.W ater-in-FuelSensorHarness
4.DrainAssembly
70Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
1Thoroughlywashtheareaaroundthefuellterandmountingadaptermatingarea
withasuitablesolventandblowdrywithcompressedair.
2Disconnectthewater-in-fuelsensorharnessconnectorfromtheplasticwater
separatorbowl.
3UsingtoolJ24783,removetheprimarylter.
4Whileholdingthelteraboveasuitablecontainer,openthedrainvalveonthe
plasticwaterseparatorbowlandallowthefuelinthebowltodrain.Disposeof thedrainedfuelinanenvironmentallysafemanner.
5Unscrewtheplasticseparatorbowlfromthebottomofthespin-onprimarylter
cartridge.
6ApplyathinlmofcleanengineoiltothewaterseparatorbowlO-ringonthe
bottomofthenewprimaryltercartridge.
7Installtheplasticwaterseparatorbowltotheprimaryltercartridge,andtighten
thebowlbyhand1/4to1/2turnafterthebowlcontactstheO-ring.
8Applyathinlmofcleanengineoiltothesealinggasketofthenewltercartridge.
9Primethelterbypouringcleanlterfuelthroughtheseriesofsmallholesatthe
topoftheltertotheinstallationllline.DONOTprimethelterthroughthe centerhole.Usecaretoavoiddirtenteringthecenterholeofthelter.
10Installthenewlterandtightenanadditional1/2to3/4turnbyhandafterthe
gasketcontactsthebase.
11Reconnectthewater-in-fuelsensorharnessconnector .
12Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel
SystemMACKMPEngines”,page72).
13Starttheengineandcheckforleaks.
Operator’sManualVehicleMaintenanceCXU,
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SecondaryFuelFilterReplacementProcedures
Ateachspeciedoilandlterchangeinterval,changethesecondaryfuellteras follows:
Note:Becauseoficebuildupinthefuelsystemorfuelwaxingwhichcanclogfuel lters,itmaybenecessarytoreducethetimeormileageintervalbetweenfuellter changesduringextremelycoldweather.
Toinstallanewlter:
1Thoroughlywashtheareaaroundthefuellterandmountingadaptormatingarea
withasuitablesolventandblowdrywithcompressedair.
2UsingtoolJ24783,removetheoldlters.
3Applyathinlmofcleanengineoiltothesealinggasketofthenewlters.
4Primethelterbypouringcleanlteredfuelthroughtheseriesofsmallholesat
thetopofthelter.DONOTprimethelterthroughthecenterhole.Usecareto avoiddirtenteringthecenterholeofthelter.
5Installthenewltersandtightenanadditional3/4to1turnbyhandafterthe
gasketcontactsthebase.
6Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel
SystemMACKMPEngines”,page72).
7Starttheengineandcheckforleaks.
72Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
PrimingtheFuelSystemMACKMPEngines
OnMACKMPengines,theprimingpumpislocatedontheprimaryfuellter mountingadapter.Primethefuelsystemasfollows:
DANGER
Beforeworkingonorinspectinga vehicle,applytheparkingbrakes,place thetransmissioninneutralandblock thewheelstopreventthevehiclefrom moving.Failuretodosocanresult inunexpectedvehiclemovementand causeseverepersonalinjuryordeath.
WARNING
DONOTworknearthefanwhilethe engineisrunning.Theenginefancan engageatanytimewithoutwarning, resultinginseriousinjury.Before turningtheignitionon,makesurethat nooneisnearthefan.
DANGER
Toavoidpotentialrehazard,donot serviceanypartofthefuelsystem whilesmoking,orinthepresenceof ames,sparksorhotsurfaces.Do notservicethefuelsystemwhilethe engineisrunning.Failuretofollow theseprecautionscanresultinare.To guardagainstburnsfromdirectcontact withhotfuel,wearadequateprotective clothing(faceshield,heavygloves, apron,etc.)whenworkingonahot engine.
Note:ThereareNObleednipplesthatmustbeopenedinordertoprimethefuel system.
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1Unlocktheprimerpumphandlebypushingthehandledownwardandthenturning
itcounterclockwise.
W0054026
UnlockingFuelSystemPrimerPumpHandle
2Operatethepumphandleuntilpumpingeffortincreases.
W0054027
PumpingHandPrimerPump
Note:Withafuelsystemthatiscompletelyempty,200ormorestrokesofthe pumpmaybenecessarytoproperlyprimethesystem.
3Whenthefuelsystemisprimed,locktheprimerpumphandlebypushingitfully
intothehousingandturningitclockwise.
4Starttheengineandrunitat1000rpmforapproximately5minutestopurgeany
remainingairfromthesystem.
Note:Iftheenginedoesnotstartafterperformingtheaboveprimingprocedure, contactyourlocalMACKdealerforassistance.
74Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Fuel/WaterSeparatorMACKMPEngines
TheprimaryfuellteronMACKMPenginesincludesaplasticwaterseparator bowlwithanintegralwater-in-fuelsensorandadrainassembly.Awarninglamp ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Whenthe lampilluminates,drainthewaterfromtheseparatorbyopeningthedrainvalveand allowingthewatertodrainfromthebowlintoasuitablecontainer.Whenfuelbegins todrain,closethevalveandtightento0.655Nm(5lb-in).Disposeofthedrained water/fuelinanenvironmentallysafemanner.
WaterSeparatorDrainValveMACKMP
Engines
Note:DONOTdrainthewaterseparator bowlwhiletheengineisrunning.
W0054022
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EngineOil
General
Keeptheengineoilattheproperlevelandchangeitattherecommendedintervals. Alwaysreplacetheoilltersatthesametimeaswhentheoilischanged.
OilQuality
MACKInc.recognizesengineoilsthatmeetorexceedthestandardsgivenby AmericanPetroleumInstitute(API)fortheoilclassicationslistedinthismanual. OnlyoilslicensedtocarrytheAPIsymbolshouldbeused.Lubricantsmeeting APIstandardshaveprovidedmaximumenginelifewhenusedtogetherwiththe recommendedoilandoillterchangeintervals.
EO-OPremiumPlus(orVDS-4)dieselengineoilismandatoryforuseinall2010 emissioncompliantMACKengines.Chassisequippedwitha2010emission compliantengine,whichcanbeidentiedbythepresenceofaDieselParticulateFilter (DPF),alsorequiretheuseofUltraLowSulfurDiesel(ULSD)fuel.EO-OPremium PlusoilsexceedthenewAPIservicecategoryCJ-4.
CAUTION
DONOTaddextraoiladditives.Additivessuchasbreak-inoils,topoils, graphitizers,andfriction-reducingliquidsarenotnecessaryandcanharmthe engine.
OilChangeIntervals
Thelengthoftimeanenginecanoperatebeforeanoilchangedependsonthequality oilused,thetypeoffuelused,fuelconsumption,engineoilconsumption,vehicle application,levelofdustintheair,andfuelconsumption.Thechangeintervalsgiven inthismanualaremaximumintervals.Ifthevehicleisoperatinginheavy-duty operation,dustyoroff-roadconditions,etc.,reducetheintervalsformorefrequentoil changes.Forthecorrectoilchangeinterval,see“OilCapacityTablesandViscosity Charts”,page142.
Foradditionalinformationaboutoilchangeintervals,seeyourMACKTruckdealer.
Foracompletelistofapprovedoils,seeyourMACKTruckdealer.
Note:Oilltersshouldalwaysbechangedwhenchangingoil.
76Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
OilFilters
Therearethreeltersontheengine,oneofwhichisabypasslter .Thisshouldbe changedatthesametimeasthefull-owlter(s).
CAUTION
MACKbrandedoilltersaredesignedtoprovidetheproperlevelofltration andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent requirementsmayvoidenginewarranty.
Spin-OnOilFilters
1.Spin-OnOilFilters
W0054029
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SyntheticLubrication
Syntheticoilsareofferedbysomeoilsuppliersasanalternativetothetraditional, petroleumbasedoilsforengines.TheseoilsmaybeusedinMACKengines,provided theymeetthequalitylevelsspeciedonthepreviouspages,thatis:bothVDS-4 andEO-OPremiumPlus.
Theuseofsyntheticoilsdoesnotpermittheextensionoftherecommendedoil changeintervals.Itisthecontaminationrate,i.e.,soot,andthedepletionof additives,ratherthanbaseoilqualitythatdeterminestheusefulengineoillife andthereforetheoilchangeintervals.
OilViscosity
Theviscositygradedenesthethicknessoftheoil.Theoilmustbethinenoughat lowtemperaturesforeasycoldstartsandthickenoughtoprotectathightemperatures. AnoilisnotfullydeneduntilboththeAPIqualityclassicationandtheviscosity gradearespecied.
Choosetheviscositygradeforthetypicalambienttemperaturefortheapplication. Multigradeoilshaveabroadrangethatsuitoperationinchangingtemperature.The standardoilweightforMACKenginesis10W/30.
MACKInc.recommendstheviscositiesshownintheviscosity/temperaturetable forMACKengines.
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OilAdditives
CAUTION
Extraoiladditivesmustneverbeaddedtoanyengineoilused.Additivessuchas break-inoils,topoils,graphitizers,andfrictionreducingliquidsarenotnecessary andmayevenharmtheengine.
Usingoilstothequalitystandardsrecommendedinthismanualmakestheuseof extraoiladditivesunnecessary ,astheseoilsalreadycontainabalancedtreatment ofadditives.
OilConsumption
Oncetheengineisstopped,checktheoilleveldaily.Iftheenginehasjustbeen stoppedanditiswarm,waitapproximatelyveminutestoallowtheoiltodrainback totheoilpanbeforechecking.Addoilasnecessary.
Note:DONOToverllenginewithoil.
Alldieselenginesaredesignedtoconsumesomeoil,soitisnormaltoaddoil periodically.Anengineusedinheavy-dutyoperationwillconsumemoreoilthan oneinnormaloperation.
ToassistyouinmeasuringyouroilusagepleaserefertotheFuelandOilRecordon “FuelandOilRecord”,page155.
Operator’sManualVehicleMaintenanceCXU,
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OilChange
WARNING
Ahotengineorengineoilcanbedangerous.Seriousburnscanresultfromcontact withahotengineoroil.T akeprecautionswhendrainingtheoil.Wearglovesorlet theenginecooldownbeforedraining.
WARNING
Whendrainingtheoil,usethepropertoolsandkeepawayasfaraspossible.Raise theelbowsotheforearmisparalleltothegroundtopreventoilrunningdown thearm,causingburns.
CAUTION
Alwaysdisposeofalllubricants(motoroil,coolant,gearboxoils,etc.)and ltersaccordingtoFederalorlocalregulations.Usedoildisposedofinnatureor waterwayscontaminatesourdrinkingwaterandkillswildlife.
CAUTION
Prolongedcontactwithusedengineoilmaybeharmful.Userubbergloveswhen handlingusedoil.Washskinthoroughlyifitcomesincontactwithusedoil.
Forinformationonthetypeofoilrecommendedforyourengine,see“OilQuality”, page75and“OilCapacityTablesandViscosityCharts”,page142forquantitiesand viscosities,orrefertotheenginemanufacturersoperatorsmanual.
Itisimportanttodrainasmuchoilaspossible.Trytochangeoilimmediatelyafter driving,whentheoiliswarm.Alwaysreplacetheoillterswhenchangingoil.
80Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
OilFiltersChange
WARNING
Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When changingoil,wearprotectivegloves.
CAUTION
MACK-brandedoilltersaredesignedtoprovidetheproperlevelofltration andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent requirementsmaycauseunsatisfactoryresults.
1Coattheltergasketwithoil.
2Installthelterandturnitbyhanduntilthegasketmakescontactwiththesealing
surface.
3Manuallyturnthelteranadditional3/4toonefullturn.
Operator’sManualVehicleMaintenanceCXU,
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CheckingOilLevel
CAUTION
DONOTlettheoillevelfallbelowthemarkingonthedipstick.DONOToverll sothelevelisabovetheuppermarkingonthedipstick.Thiscouldleadtoexcessive oiltemperatureand/orpoorcrankcasebreatherperformance.
Ensurethatthevehicleisparkedonlevelgroundbeforecheckingtheoillevel.Wait veminutesaftershuttingofftheengine,thenproceedwithcheckingoil.
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EngineAirFilter
Theaircleanerpreventsdust,dirtandotherharmfulcontaminantsfromentering theenginethroughtheairintakesystem.Maximumengineprotectioncanonlybe achievedthroughregularlyscheduledmaintenancepracticesthatincludeperiodicair intakesysteminspectionsandairlterelementchanges.
Themostefcientmethodofdeterminingairlterelementchangeintervalsisby regularlycheckingtheairlterrestrictiongauge,whichmayeitherbemounted directlytotheaircleanercanister,ontheaircleaneroutlettubeorinsidethecab.The restrictiongaugemeasurestheamountofrestrictionintheairlterelement.Some chassismayhaveadash-mounteddial-typerestrictiongaugewhichmeasureslter restrictioninmm/inchesofwater.
Changetheairlterelementinaccordancewiththeproceduresasoutlined,whenthe restrictiongaugeredsignallocksinfullview,orthedash-mountedgaugeindicates inletrestrictionasfollows:
MountedGaugeInletRestriction Indication
EngineMillimeters(Inches)Water/kPa
MP7,MP8andMP10510mm(20)/5kPa
AirFilterRestrictionGauge
W0054007
Operator’sManualVehicleMaintenanceCXU,
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Damagetotheairlterelement,suchasholesintheltermedium,willgivean inaccuraterestrictionreading.Therefore,evenifmaximumrestrictionisnotindicated, theairlterelementshouldbechangedyearlyorat160000Km(100,000mile) intervals,whichevercomesrst.
Whenreplacingtheairlterelement,orwhenevertheairinletsystemhasbeen disassembled,inspecttheinletairductsbetweentheaircleanercanisteroutletandthe turbochargerinletasfollows:
Inspecttherubberelbowsforcracks,splittingand/orholes.Rubbercomponents
mustbeexiblesothattheyconformtotheplasticductsandensureatightseal.
Inspectplasticductsforcracksand/orholes.
Ensurethatallhoseclampsareproperlyinstalledandtightenedtospecications.
Makesuretheplasticductsdonotrubagainstanycomponentssuchasair
conditioninghoses,wireharnesses,etc.
Toproperlyinstallanewlterelement:
1Wipetheaircleanerhousingclean.
2Removethelterelement(s).
3Inspectsealingareasfordirttrackswhichwouldindicatethatdusthasleakedpast
theseal.Ifdirttracksarefound,thecausemustbedeterminedandcorrected.
4Thoroughlycleantheinsideoftheaircleanercanisterwithadampclothor
vacuumcleaner.
5Ifequippedwithametalcanister,inspectinsidethecanisterforrust.Ifrustis
present:
1Removetheaircleanercanisterfromthechassis.
2RemovealllooserustwithawirebrushoracoarseScotchBritepad.
3Sandwith180/240gritwetordrysandpaper.
4ThoroughlywashtheareawithPPGDX-440,DX-436,DX-437orequivalent,
waxandgreaseremoverandwipedry.
5PrimeimmediatelywithPPGDEP-351epoxyprimer .
6Reinstalltheaircleanercanister.
6Inspectthesealingareasofthehousingfordamage.Repairorreplaceasnecessary.
7UseMACK-approvedreplacementelementsandgaskets.Makesurethenew
elementsandgasketsarenotdamaged.Besuretousenewgasketseachtimethe elementischanged.Installthecoverand,dependinguponcoverconguration, tightenasfollows:
Aircleanerwithlargewingnutincenterofcoverhand-tightenwingnut.
Aircleanerwiththreethumbscrewsaroundouteredgeofcoverhand-tighten
thumbscrews.
Aircleanerwithretainingnutsaroundouteredgeofcovertightenretainingnuts
between11–14Nm(8–10lb-ft).
84Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Note:DONOTattempttocleantheairlterelementwithcompressedair,asthis coulddamagetheltermediumandpossiblyresultinsevereenginedamage.
ReplacementPartsandFilters
W0053982
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ExhaustAfter-TreatmentSystem
CHU,CXU,GUandTDStandardSystemView
1.SelectiveCatalyticReduction(SCR) Catalyst
2.AftertreatmentDEFDosingUnit
3.AftertreatmentDieselParticulate Filter(DPF)
4.AftertreatmentDEFT ank
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LEUandMRUStandardSystemView
1.SelectiveCatalyticReduction(SCR) Catalyst
2.AftertreatmentDEFDosingUnit
3.AftertreatmentDieselParticulate Filter(DPF)
4.AftertreatmentDEFT ank
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DANGER
TheSCR/DPFshieldshouldnotbe removedwhilethevehicleisinuse. Also,onlyremovetheshield,oncethe vehicleisoutofuseandtheSCR/DPF issufcientlycooled.Failuretofollow theseinstructionscanresultinre, whichcancausecomponentdamage, personalinjuryordeath.
CheckifthevehicleisequippedwithaDieselParticulateFilter(DPF)oraDPF andSelectiveCatalyticReductionunit(SCR).Thesecomponentsarepartofthe overallvehicleemissionscontrolsystem.Innormaloperation,thesecomponentscan experiencesurfacetemperaturesashighas350°C(662°F).Itisimportanttoverify thetemperatureatwhichthematerialorsubstancein,orassociatedwith,thebodycan ignite.Ifitispossibleforthematerialorsubstancetofallorleakfromthebody,take stepstopreventthemfromcontactingorcollectingontheDPForSCR.Failureto dosomayresultinre.
Itisimportanttonotethatadditionalshieldingmay ,dependinguponconditionsand thematerialorsubstance,trapammablesubstancesbetweentheadditionalshield andtheDPF/SCR.Ifthisconditioncandevelop,advisetheuserofthevehicleto periodicallychecktoensuretherearenotrappedsubstances.
Note:TheDPF/SCRandassociatedcomponentsarepartofaU.S.EPAand CaliforniaAirResourcesBoard(CARB)certiedengineemissionssystem.These componentsmustnotbemoved,alteredormodiedinanyway.T amperingwith thesesystemsrendertheemissionswarrantyvoidandmayresultinpossible tamperingchargesbytheEPAorCARB.
CAUTION
TheDieselparticulateltersandtheir components,cannotbemovedor alteredfromtheOEMinstallationin anyfashion.Anyalterationsmaycause componentdamageandisprohibitedby thelaw.
88Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Newstringentstandardsforexhaustemissioncontrolbeginwiththe2010modelyear. TheDieselParticulateFilter(DPF)systemhasbeendevelopedtoactincombination withUltraLowSulphurDiesel(ULSD)fueltoreduceparticulateemissionstomeet therequirement.TheExhaustAfter-TreatmentSystem(EATS)includesalltheengine andexhaustemissionscontrolcomponentsthatarerequiredtomeetthestringent 2010standard.
ParticulatematterconsistsofsootandashintheexhaustthatengineswithanEGR systemalone,arenotequippedtohandle.Theparticulatematterisconsidered acontaminantthatcontainsundesirableelements.TheDPFsystemreducesthe unwantedelementstoamoreacceptableleveldenedintheregulations.Thereare multiplemethodsofreducingtheseemissions.MACKhasselectedtouseaDiesel OxidationCatalyst(DOC)withacatalyzeddieselparticulatelter.Theotheruses adieselparticulatelterofadifferentkindwithoutaDOCandinitsplaceusesa combustionchambertoheattheexhaustmixturethuscausingactiveregeneration.
Theparticulatematterremovedfromtheexhaustcollectsontheltersurfaces.T o avoideventualblockage,whichwouldincreaseexhaustbackpressureandaffectpower andfueleconomy,theltermustbecleaned.TheDPFiscleanedautomatically.The sootbreaksdowntosafersubstancesbeforebeingreleasedtotheatmosphere.Some oftheashremains,buttakesalongtimetoreachthepointwhereashclogsthelter.
Cleaningaltersoitcancontinuetofunctioniscalled“regeneration.”Eithersystem useshighheattobreakdownthechemicalproperties.Dependingonvehicleusage, theengineisequippedwithapassiveoractiveregenerationsystem.
In“passiveregeneration,”theexhaustproducesenoughheatcontinuouslytoconvert thesoot,withapproximately260°C(500°F)beingrequired.Theprocessisslowand continuesindenitely.Passiveregenerationispossibleonlyinvehicleapplications wherethetemperatureislikelytoremainatorabovetherequiredtemperaturelevel, makingactiveregenerationunnecessary .
Duringanactiveregeneration,thetemperatureoftheltermustberaisedto500°C (932°F).Toproducethistemperature,thesystemusesahydrocarboninjectoror AftertreatmentFuel(AF)injectortointroducefuelintotheexhauststreamasitleaves theturbocharger.Thehotexhaustignitesthefuelwhichproducestheregeneration temperature.WhentheDPFbecomesrestrictedtoaminimumvolume,theengine ECUstartsthefuelinjectionintotheexhaust.Whentheairowratereturnstonormal throughtheDPF ,theengineECUturnstheinjectoroff.
WARNING
Priortoeverworkingontheexhaust, allowtimefortheentireexhaustsystem tocool.Failuretodosomayresultin personalinjury .Severeburnscanoccur.
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SelectiveCatalyticReduction(SCR)
SelectiveCatalyticReduction(SCR)isanemissions-reductiontechnologywiththe abilitytodelivernear-zeroemissionsofnitrogenoxides(NOx),asmog-causing pollutantandgreenhousegas.SCR’ sperformancehasbeenprovedinmillionsof milesofreal-worldtruckoperationsinothercountries,aswellasinlong-termeld testsintheU.S. SCRreducesNOxemissionstoverylowlevels,whileatthesametimedelivering excellentfueleconomyandreliability .Thesystemdoesn’tchangethedesignor operationofthebasicengine.Rather,SCRisanaftertreatmentsystemwhichconverts NOxintheexhauststreamintoharmlessgases.Moderndieselsalreadyuseexhaust aftertreatmentsystems,calleddieselparticulatelters,tocontrolemissionsofanother pollutant,soot(alsoknownasparticulatematterorPM). SCRworksbyinjectingDieselExhaustFluid(DEF)intotheexhauststeam,afterthe DPF.DEFisasafe,simplesolutionofwaterandurea.DEFworkswiththeheat oftheexhaustandacatalysttoconvertNOxintonitrogenandwatervapor-two harmlessandnaturalcomponentsoftheairwebreathe.Theendresultiscleanerair, excellentfuelefciencyandareliableemissionscontrolsystemfortoday’smodern dieselengine.
1.DieselEngine
2.AftertreatmentDEFT ank
3.AftertreatmentDEFPump
4.AftertreatmentDEFDosingUnit
5.AftertreatmentDieselParticulateFilter(DPF)
6.SelectiveCatalyticReduction(SCR)Catalyst
7.AftertreatmentDEFTankGauge
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CAUTION
Donotputdieselfuelinthe AftertreatmentDEFtank.Diesel fuel,ifsprayedintothehotexhaust alongwiththeDEF,couldignite explosivelycausingareresulting inpersonalinjuryordamagetothe exhaustsystem.
TherearetwodifferentcongurationsfortheSCRcatalysts,theyareverticaland horizontal.ThehorizontalSCRcatalystcomesintwodifferentsizes,oneforthe MP7/MP8enginesandlargersizefortheMP10engine.TheverticalSCRcatalyst alsocomesintwodifferentsizes,onefortheMP7/MP8enginesandlargersizeforthe MP10engine. TheMACKSCRsystemissimpleandeffective,withfewcomponents.Itconsists ofaAftertreatmentDEFtankpositionednearthestandarddieseltank,plusa AftertreatmentDEFpump,AftertreatmentDEFDosingunitandSCRcatalyst.The advantageofusingDEFisthatitenablestheenginetouselessEGR--andhigher oxygenlevels--forbettercombustion,whilemeetingtheEP Anear-zeroNOx emissionsrequirementof0.2g/hp-hrNOx.ByusingDEF,weavoidthedisadvantages ofincreasingEGRtomassivelevels.Thisresultsinbetterfueleconomyfromyour MACKengine.
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DieselExhaustFluid(DEF)
DieselExhaustFluid(DEF)isareactantthat’skeytotheSCRprocess.It’sanontoxic, aqueoussolutionofureaandwater.Ureaisacompoundofnitrogenthatturnsto ammoniawhenheated.Itisusedinavarietyofindustries,perhapsmostcommonly asafertilizerinagriculture.Theuidisnotammable,norisitdangerouswhen handlednormally.However,itishighlycorrosivetometal,particularlycopperand aluminium.ReadtheseparatesectionconcerningthehandlingofDEFsolution.Only useapprovedDEFuid.
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DieselExhaustFluid(DEF)Handling
WhenhandlingDEFsolution,itisimportantthatelectricalconnectorstobeconnected orwellencapsulated.OtherwisethereisariskthattheDEFwillcauseoxidationthat cannotberemoved.Waterorcompressedairdonothelp,sinceDEFquicklyoxidizes metal.IfaconnectorcomesintocontactwiththeDEFsolutionitmustbereplaced immediatelytopreventtheDEFsolutionfromcreepingfurtherintothecopperwiring, whichtakesplaceataspeedofabout60cm(2.4in)perhour.
CAUTION
Whendetachinghosesandcomponents, donotspillDEFondisconnected connectors.IfDEFisspilledona connector,theconnectormustbe replacedimmediately
ThingstoknowaboutspilledDieselExhaustFluid(DEF)
Ifureasolutioncomesintocontactwiththeskin,rinsewithplentyofwaterand removecontaminatedclothing.
Ifureasolutioncomesintocontactwiththeeyesrinseforseveralminutesandcall formedicalhelpifnecessary.
Ifinhaledbreathefreshairandcallformedicalhelpifnecessary.
DonotallowtheDEFsolutiontocomeintocontactwithotherchemicals.
TheDEFsolutionisnotammable.IftheDEFsolutionisexposedtohigh temperatures,itbreaksdownintoammoniaandcarbondioxide.
TheDEFsolutionishighlycorrosivetocertainmetals,includingcopperand aluminium.
IftheDEFsolutionisspilledontothevehicle,wipeofftheexcessandrinsewith water.SpilledDEFsolutioncanformconcentratedwhitecrystalsonthevehicle. Rinseoffthesecrystalswithwater.
Note:DonotushDEFspillsintothenormaldrainsystem.
WARNING
DEFspiltontohotcomponentswill quicklyvaporize.Turnyourfaceaway!
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU93
DieselExhaustFluid(DEF)Consumption
DEFconsumptionisrelatedtofuelconsumption.Ahighwaytruckmaytravel 225-300milesormoreononegallonofDEF.Agaugemuchlikeafuelgaugewill indicatethelevelofDEFinthetank.ADEFlow-levelwarningwillactivatewhen DEFislow.IfadriverrunsoutofDEFcompletely ,vehiclepowerwillbereducedto deratemode.WhentheDEFtankisrelled,theenginewillresumenormalpower.
Note:DEFtanksaresizedforatwotoonefueltoDEFratioinordertomeetEPA 2010requirements.
DieselExhaustFluid(DEF)Availability
DEFwillbeavailablein2.5galloncontainers,55gallondrums,275gallonIBCand inbulkstorageforeetlocations,truckstopsanddealerships.Allmajortruckstops, dealersanddistributorswillcarryDEF.FormoreinformationonDEFandavailability pleasevisitthewebsitewww.Mackscr.com.
94Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
DriveBeltReplacementIntervals
Ifbeltssqueakorsqueal,cleanwithhydraulicbrakeuidoranapprovedcleaning uid.Replacebeltsthatareseverelywornorfrayed.
RibCracking
Anin-servicepolyV-beltwillgothroughseveralphasesofcrackingduringitslife. Afteranextendedtimeinservice,minorribcracksmayappear,usuallyoneortwo cracksperinch.Thiscrackingisnormal.
BeltwithMinorRibCracks
W0054003
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU95
Beltsshouldnotbereplacedunlesstheribsexhibitseveremultiplecrackingasshown below.Multiplecrackingwillleadtoribchunking.
W0054004
BeltwithMultipleCracking
BeltwithSevereCrackingandRib
Chunking
W0054005
96Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
RibSidewallGlazing
Whenthebeltribsappeartohaveashinysurfacethatishardandbrittle,itisusually anindicationofbeltslippage.Thisisattributedtoinadequatetensionand/orextreme temperature.Boththeseconditionswillleadtoseverecrackingandbeltfailure, oftenwithlittleadvancewarning.Ifthisoccurs,locatethecauseandcorrectbefore installinganewbelt.
BeltWear
Acceleratedwearonanypartofthebelt(fabricbacking,tensilecordorribrubber) isaconcernandshouldbeinvestigatedforcause,andcorrectedbeforeinstallinga newbelt.
PossibleCausesofAcceleratedBeltWear
DriveMisalignmentBeltperformancewillbeadverselyaffectedwhen
misalignmentexceeds1/16inchforevery12inchesofbeltspan.
BeltLengthMustbecorrect.
EnvironmentalConditionsT emperature,exposuretoengineuids,etc.
AbrasiveMaterialsSmallstones,metalshavings,etc.
W0054006
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