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
April 2010
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,MRUandLEU 1
Foreword
DONOTRemove thismanualfromthevehicle.Itcontainsimportantoperational
andsafetyinformationthatisneededbyalldriversandownersofthisvehicle.
Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis
extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis
operated.Thismanualalsocontainsaconsiderableamountofinformationconcerning
thevehicle,suchasvehicleidentication,PreventiveMaintenancerecommendations
andalogforyourservicerecords.Pleasekeepthisinthevehicleatalltimes.
Informationfromothercomponentmanufacturersissuppliedinseparatemanuals
intheOwnersPackage.
TheNationalHighwayTrafcSafetyAdministration(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.
2 Operator’sManualVehicleMaintenanceCXU,
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Thefollowingtypesoflabelsareusedthroughoutthismanual:
Note: Anotedenesanoperatingprocedure,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,MRUandLEU 3
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.Forspecic
maintenanceinformationonvendorcomponents,seetherespectivemanufacturers
serviceandmaintenanceliterature.
Thismanual,togetherwithmanualsforspeciccomponentscontainimportant
informationtobeabletooperatethisvehiclesafely.Theycontainadviceand
4 Operator’sManualVehicleMaintenanceCXU,
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instructionswhichwillenableyoutogettheoperatingeconomyandperformance
thatyouexpectfromthisqualityvehicle.
Allinformation,illustrationsandspecicationscontainedinthismanualarebased
uponthelatestproductinformationavailableatthetimeofpublication.Ifany
questionsariseconcerningthecurrentstatusofFederalorstatelaws,theappropriate
Federalorstateagencyshouldbecontacted.
Note: Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactual
vehicle,however,keycomponentsaddressedinthismanualarerepresentedas
accuratelyaspossible.
MACKInc.reservestherighttomakechangesatanytimeortochangespecications
ordesignwithoutnoticeandwithoutincurringobligation.
General
USA
TheFederalCleanAirAct,Section203(a)(3),statesthefollowingconcerningthe
removalofairpollutioncontroldevicesormodicationofacertiedenginetoa
non-certiedconguration:
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.
6 Operator’sManualVehicleMaintenanceCXU,
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TamperingwithGaseousEmissionControl
SystemsProhibited
TheFederalCleanAirActprohibitstheremovalorrenderinginoperativeofany
deviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengine
incompliancewithFederalEmissionRegulationsby:
1Anypersonpriortoitssaleanddeliverytotheultimatepurchaser,or
2Anymanufacturerordistributorafteritssaleanddeliverytotheultimatepurchaser,
or
3Anypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or
tradingmotorvehiclesormotorvehicleenginesfollowingitssaleanddelivery
totheultimatepurchaser,or
4Anypersonwhooperatesaeetofmotorvehiclesfollowingitssaleanddelivery
totheultimatepurchaser.
Note: Forspecicsoftheprohibitedvehicle/enginemodicationsrefertotheMACK
Bodybuilderdocumentation.
EnginesOtherthanMACK
ForspecicinformationonenginesotherthanMACK,refertotheengine
vendorspublications.
NoiseEmissions
MACKInc.warrantstotherstpersonwhopurchasesthisvehicleforpurposesother
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
maintenanceresultsfromaspecicnoisecontrolsysteminspection,oradeciency
identiedduringanothergeneralmaintenanceevent.
Ifadditionallogspaceisneeded,furtherentriesmaybeaddedonaseparatesheetof
paper.Storetheseadditionswiththemainlogtopreserveacomprehensiverecord.It
isrecommendedthatcopiesofallnoiseemissionsrelatedmaintenanceinvoicesbe
retained.
ThefollowingNoiseControlSysteminspectionandmaintenanceinstructionscontain
suggestedmaintenanceintervals.Theseintervalsmayneedadjustmentinorderto
bestaccommodatethespecicvehicleusage.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,includingmufers,
heavyordouble-wallexhausttubing,exibletubingorexhaustpipeclamping.
8 Operator’sManualVehicleMaintenanceCXU,
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•Removal,orrenderinginoperative,ofthetemperature-modulatedcoolingfan
system.
•Removalofthecoolingfanshroud.
•Removal,orrenderinginoperative,oftheaircleanerorairintakein-linesilencer.
•Removalofthesounddeadeningmaterialfromthehoodorcabtunnel.
•Removal,orrenderinginoperative,oftheenginespeedgovernorsoastoallow
enginespeedtoexceedthemanufacturersspecications.
•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,
CHU,GU,TD,MRUandLEU 9
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.Conrmoperationoftemperaturemodulatedfanclutch.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeCoolingSystem:
Removingorrenderinginoperativecoolingsystemcomponents(suchasthe
temperaturemodulatedfanclutch,fanshroud,fanring,recirculationshields,etc.).
ExhaustSystem
WARNING
Hotengine!Avoidallmovablepartsorhotengineparts,exhaustgases,and/or
uids.Ahotengine,exhaust,and/oruidscancauseburns.
10 Operator’sManualVehicleMaintenanceCXU,
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Maintenance
Makesuretheexhaustsystemisintact.Inspectfordamage,misalignmentand/or
leakage.Primarysystemcomponentsrequiringnoiserelatedinspectioninclude
exhaustmanifold,turbocharger,andallexhaustsystem(rigidandexible)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,
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EngineControl,EGRandFuelSystems
ActsthatconstitutetamperingwithEngineControl,EGRandFuelSystems:
Removingrenderinginoperative,ormodifyingtheenginecontrolsystemsuchas
theECU,EGRsystemcomponents,orfuelsystemcomponents,inordertoallow
theenginetooperateoutsideofthemanufacturersspecicationsisnotallowedand
violatesbothwarrantyandlegislation.
12 Operator’sManualVehicleMaintenanceCXU,
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LabelInformation
VehicleIdenticationNumberLabel
Allmotorvehiclesarerequiredtobeidentiedbya17-digitVehicleIdentication
Number(VIN).U.S.andCanadianregulationsdictatetheformatofthenumber.
TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK,
suchastypeofvehicle,model,typeofbrakesystem,grossvehicleweightrange
andmodelyear.
TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations
includeastampingontheverticalfaceoftheright-handframerail(somewhere
betweenthefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge,
thedooropeningareaortheseatriser)andonthevehiclesafetycerticationlabels
andotherlabelsonthedooredgeordooropeningarea.Whenthevehicleisreceived,
checktheVINateachlocationonthevehicleandverifythattheyareidentical.The
vehicleidenticationnumbermustnotbechanged,coveredorobliterated.
VINFrameStamping
W0031972
Operator’sManualVehicleMaintenanceCXU,
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W0031973
VINLabelonDriversSeatRiser
14 Operator’sManualVehicleMaintenanceCXU,
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RegulatoryLabels
Inadditionto,orinplaceofthepreviouslymentionedlabels,MACKTrucks,Inc.
mayafxoneormoreofthefollowinglabelstothecab.
Heater/DefrosterOmissionLabel
Awindshielddefroster,asrequiredbyFMVSS103, WindshieldDefrostingand
Defogging,isnotrequiredforvehiclesdestinedforsaleintheStateofHawaii,
PuertoRico,theNorthernMarianaIslands,Guam,theVirginIslandsandAmerican
Samoa.V ehiclesdestinedforsaleintheseareasmust,however,conformtoallother
applicableFMVSSregulations.Ifavehicledestinedforsaleinoneoftheseareas
doesnothaveafactory-installeddefroster,alabelisafxedtothecabnearthevehicle
certicationlabel(seeillustrationbelow).
OmissionofHeater/DefrosterLabel
W0031974
Operator’sManualVehicleMaintenanceCXU,
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ExportLabel
InordertocomplywithU.S.regulations,allMACKvehiclesintendedforexportfrom
theUnitedStates(includingexporttoCanada)willhaveanExportLabel,similarto
thelabelshownbelow,afxedtotheinsideofthewindshield.
TypicalExportLabel(IncludingExport
toCanada)
W0031975
16 Operator’sManualVehicleMaintenanceCXU,
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Export/SpecialApplicationLabel
Export(excludingexporttoCanada)orspecialapplicationvehiclessuppliedfrom
theassemblyplantarenotnecessarilydesignedtoconformtoapplicableFederal
andCanadianmotorvehiclesafetystandards.Onthesevehicles,anExport/Special
ApplicationLabel,similartothelabelshownintheillustrationbelow ,isafxedto
thecab.
Export/SpecialApplicationLabel
W0031976
Operator’sManualVehicleMaintenanceCXU,
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Exportvehicles(otherthanthoseintendedforsaleinCanada)alsohaveanExport
Label,similartothelabelshownbelow,afxedtothedoorarea.
W0031977
TypicalExportLabel(OtherThanExport
toCanada)
18 Operator’sManualVehicleMaintenanceCXU,
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Off-HighwayIdenticationLabel
InadditiontotheExport/SpecialApplicationLabel,vehiclesdesignedstrictlyfor
off-highwayoperationswillhaveanOff-HighwayIdenticationLabel,similartothe
labelshownintheillustrationbelow,afxedtothecab.
W0031978
Off-HighwayIdenticationLabel
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
explosionandre.Seriouspersonalinjuryordeathcouldoccur.
DANGER
Nevertrytooperateorworkonthisvehiclewhileundertheinuenceofalcohol.
Yourreexescanbeaffectedbyevenasmallamountofalcohol.Drinkingand
operatingthisvehiclecanleadtoanaccident,causingseriouspersonalinjuryor
death.
20 Operator’sManualVehicleMaintenanceCXU,
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WARNING
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
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.
•Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.
•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
asbestosberscancreateserioushealthrisks,includingdeath.
FluidPenetration
DANGER
Alwaysuseapieceofpaperorcardboardwhencheckingforaleak.Escapinguid
underhighpressure,evenapin-holesizedleak,canpenetratebodytissue,causing
seriousinjuryordeath.Ifuidisinjectedintoyourskin,immediatetreatmentmust
beadministeredbyadoctorfamiliarwiththistypeofinjury.
22 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
InjuryPrevention
BurnPrevention
EngineParts
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine
and/oruidcancauseseriousburns.
WARNING
DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom
theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardany
longerbeforeraisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.
Also,donotremovethecapwhiletheengineandradiatorarestillhot.Scalding
uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon,
whichcancausepersonalinjuryanddamagetoenginecomponents.
W0001525
DONOTtouchanypartoftheenginewhileitishot.Allowtheenginetocoolbefore
anyrepairormaintenanceisperformedontheengine.
Relieveallpressureinair,oil,fuelorcoolingsystemsbeforeanylines,ttingsor
relateditemsaredisconnectedorremoved.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 23
Coolant
WARNING
Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor
electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.
W0001527
Topreventpersonalinjury,donotclimbupontheenginetoremovethellercap.
Useasuitable,properlypositionedladdertoreachthecap.Atnormaloperating
temperature,theenginecoolantisveryhotandunderpressure.Ifpressureisrelieved
rapidlyinahotcoolingsystem,thehotcoolantcanturnintosteam.Anycontactwith
hotcoolantorsteamcancausesevereburns.Theradiatorandallheatingsystemand
radiatorlinesandhosescontainhotcoolant.
Verifycoolantlevelonlybythemarkingsontheexpansiontank.Opentheller
caponlyaftertheengineisstoppedandcooleddown.Removethellercapslowly
torelievepressure.
Oils
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine
and/oruidcancauseseriousburns.
Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When
changingoil,wearprotectivegloves.
24 Operator’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,MRUandLEU 25
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.Failuretofollowtheseprecautionscanresultinre,
whichcancauseseriousinjuryordeath.
WARNING
DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause
orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe
eventofare.
26 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
W0001527
Theengineshouldnotbeoperatedinanareawherecombustiblegasesaresuspected
tobeintheair.Thesecouldbedrawnintotheenginethroughtheengineairintake
systemandcouldcausetheenginetooverspeedwithpossibleseriousdamagetothe
engineandbodilyinjuryorpropertydamage.
Makeprovisionsforshuttingofftheengineintakeairorfuelsupplytostoptheengine
ifthereisanoverspeedonstart-upafterperformingrepairormaintenanceonit.
ContactyournearestMACKTruckdealerforanynecessaryairconditioningtesting
orrepairs.
Allfuels,mostlubricantsandsomecoolantmixturesareammable.Dieselfuel
isammable.Gasolineisammable.Themixtureofdieselandgasolinefumesis
extremelyexplosive.DONOTsmokewhilerefuelingorwheninarefuelingarea.
Keepallfuelsandlubricantsstoredinproperlymarkedcontainersandawayfromall
unauthorizedpersonnel.Storeoilyragsorotherammablematerialinaprotective
container,inasafeplace.
Removeallammablematerialsuchasfuel,oilandothersubstancesbeforethey
accumulateontheengine.
DONOTexposetheenginetoames,drivingoverburningground.
DONOTweldoramecutonoraroundpipesortubesthatcontainammableuids.
Exhaustheatshieldsmaybeinstalledtoprotectoilorfuelcarryinglinesandpipes
fromhotexhaustparts.Toprotectfrompipeorsealfailure,installheatshields
correctly.
Provideadequateandproperwasteoildisposal.Alwaysdisposeofwasteliquids
accordingtoFederalandlocalregulations.Oilandfuelltersshouldbeproperly
installedandhousingcoverstightenedtothepropertorquewhenbeingchanged.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 27
StartingAids
DANGER
DONOTuseetherorothercombustiblestartingaidsonanyengineequipped
withapreheater .Iftheengineisequippedwithapreheater,introductionofether
orsimilarstartingaidscouldcauseareorexplosionresultinginsevereproperty
damage,seriouspersonalinjuryordeath.
DONOTuseetherorothercombustiblestartingaidsonenginesthathavea
heaterelementorotherheatingdevicesinstalledintheintakemanifoldfor
heatingtheintakeairduringcold-starts.
W0001484
FireExtinguisher
Anytimeworkisbeingdonetothefuelsystemoranyotherareawhereammable
substancesarebeingused,haveareextinguisheravailableandknowhowtouseit.
Inspectandhaveitservicedasrecommendedonitsinstructionlabel.
28 Operator’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,MRUandLEU 29
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
otherdebriscanyoffobjectsthatarestruck.Makesurenoonecanbeinjuredby
yingdebrisbeforestrikinganyobject.
W0001528
30 Operator’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,MRUandLEU 31
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.
32 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
ElectricSystemDamagePrevention
ElectricandElectronicSystems
WARNING
Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskof
injuryduetocontactwithsulfuricacidoranexplosion.
W0001526
Neverdisconnectanychargingunitcircuitorbatterycircuitcablefromthebattery
whenthechargingunitisoperating.Asparkcancausetheammablevapormixture
ofhydrogenandoxygentoexplode.
Topreventpotentialsparksfromignitingcombustiblegasesproducedbysome
batteries,attachthenegative(-)terminallastwhenhookingupandremovethe
negativeterminalrstaftertheenginehasstarted.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,MRUandLEU 33
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.
34 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
ReportingSafetyDefects
USA
TheNationalHighwayTrafcSafetyAdministration(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,MRUandLEU 35
GeneralEngineInformation
EngineOverview,MP7andMP8LeftSideView
MP8EngineShown,MP7EngineSimilar
1.BreatherTube 9.FuelFilter
2.IntakeManifold 10.Hand-PrimingPump
3.AirCompressor 11.CrankcaseVentilator
4.PowerSteeringPump 12.Alternator
5.FuelPump
6.EngineControlModule(ECM) 14.Alternator/ACCompressorBelt
7.FuelFilter 15.Fan/CoolantPumpBelt
8.Fuel/WaterSeparator 16.EGRMixingChamber
13.ACCompressor
W2006034
36 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
EngineOverview,MP7andMP8RightSideView
MP8EngineShown,MP7EngineSimilar
17.ExhaustManifold 24.V enturiPipe
18.V alveCover 25.OilFilters
19.IntakeAirHeater(IAH)optional 26.OilPan
20.Thermostat 27.EGRCooler
21.BeltTensioner 28.Turbocharger
22.CoolantPump
23.CoolantFilter 30.EGRV alve
29.StarterMotor
W2006035
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 37
EngineOverview,MP10LeftSideView
1.BreatherTube 9.Fuel/WaterSeparator
2.IntakeManifold 10.FuelFilter
3.AirCompressor 11.Hand-PrimingPump
4.PowerSteeringPump 12.Alternator
5.FuelPump
6.CrankcaseV entilator 14.Alternator/ACCompressorBelt
7.EngineControlModule(ECM) 15.Fan/CoolantPumpBelt
8.FuelFilter 16.V enturiPipe
13.ACCompressor
17.EGRMixingChamber
W2006037
38 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
EngineOverview,MP10RightSideView
18.ExhaustManifold 24.CoolantFilter
19.V alveCover 25.OilFilters
20.IntakeAirHeater(IAH) 26.EGRCooler
21.Thermostat 27.OilPan
22.BeltTensioner
23.CoolantPump 29.Turbocharger
28.StarterMotor
30.EGRV alve
W2006036
ElectricalSystem
Batteries
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 39
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
40 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Besurethatthebatteriesusedinaparticularvehicleareratedforthespecied
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,MRUandLEU 41
BatteryWarmer
Abatterywarmercanbeaddedtoraisethetemperatureofthebatterycoreand
facilitatequickstartingincoldweather.
BatteryCondition
Therstprocedurewhentestingabatteryistocheckforexternaldamagesuch
asacrackedcase,looseorcorrodedterminals,orsignsofexcessivegassingor
overcharging.
Abatterymustbefullychargedbeforealoadtestisperformed.Testthebatterywitha
hydrometertodeterminethelevelofcharge.
Onmaintenance-freebatteriesequippedwithabuilt-inhydrometer(eye),thebattery
conditionisinterpretedasfollows:
W0054088
BatteryCondition
42 Operator’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
12.6 1.265 100%FullCharge
12.4 1.225 75% 15
12.2 1.190 50% 35
12.0 1.155 25% 50
11.8 1.120 0% 65
Battery
Specic
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,MRUandLEU 43
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
thespeciedtime,itshouldbereplaced.)
ChargerV oltage
16.0ormore Upto4
14.0to15.9 Upto8
13.9orless
Hours
Upto16
44 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
LoadTest
Abatterymustbefullychargedbeforeperformingaloadtest.Toload-testabattery
thatisfullycharged,proceedasfollows:
1Connectaloadtesterandvoltmeteracrossthebatteryterminals.
2Applyaloadsothatagureof300ampsisobtainedfor15secondstoremovethe
batterysurfacecharge.
3Wait60secondstoletthebatteryrecoverandthenapplythepropertestload
tothebatterytodetermineitscondition.Togettheproperload,usehalfthe
crankingperformancerating.Readthevoltageafter15seconds.Rememberthat
theminimumvoltagevariesaccordingtotemperature.Consultthefollowingchart
fortheproperspecication.Ifthebatteryvoltagedoesnotfallbelowtheminimum
testvoltageafter15seconds,thebatteryisacceptableforuse.
LoadTestT emperatureCorrection
MinimumV oltage
C
9.6 21 70
9.5 16 60
9.4 10 50
9.3 4 40
9.1 1 30
8.9
8.7 12 10
8.5 18 0
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,MRUandLEU 45
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.
46 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Lighting
WARNING
Usingincorrectbulbsorlampsmayresultinfailuresthatcouldleadtoareora
vehicleaccidentcausedbyimproperlighting.
Checkalllightsonthevehicledailyforproperfunction.Replaceburnedoutinserts
andbulbs.Replaceanybrokenorcrackedsideorrearreectors.Headlightsshouldbe
checkedforaimatleastonceperyear.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 47
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.
48 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
MACKRoadStabilityAdvantage
TheMACKRoadStabilityAdvantage(RSA)isanavailableoptiononcertain
MACKhighwaytractorsandstraighttrucks.TheRSAsystem,whichisbasedonthe
BendixABS-6AdvancedwithESP(ElectronicStabilityProgram)System,aidsthe
operatorinmaintainingcontrolofthevehicleduringjackknifeorrollovereventsby
applyingselectbrakesandreducingenginepowerasrequiredbythespecicsituation.
Thissystemisintegralwiththeanti-lockbrakesystemandusesthestandardABS
components(suchaswheelspeedsensorsandmodulatorvalves).Additionally ,a
steeringanglesensorandayawrate/lateralaccelerationsensorpackageprovides
informationconcerningvehiclemovementtotheelectroniccontrolunit.
Beforedeliverytotheenduser,aparametersettunedforthespecicvehicleandthe
VINforthechassisareloadedintotheABSelectroniccontrolunit.Thisensures
optimalperformanceoftheMACKRSAsystemforthespecicvehicle.
AlterationsandmodicationstoanRSA-equippedvehicle,suchaswheelbase
changes(eitherlengtheningorshortening),theadditionofanauxiliaryliftaxleorthe
removalofafactory-installedliftaxle,ormajorbodychanges,suchasconversionofa
tractortoatruckoranaxle,suspensionorsteeringsystemcomponentmodication,
areNOTallowed,asthesechangeswilladverselyaffectperformanceoftheroad
stabilitysystem.Shouldsuchchangesbeunavoidable,thesystemmustbedisabledby
havingaqualiedtechnicianreplacetheBendixAdvancedEC-60(ABScontrolunit
withESP)withaBendixPremiumEC-60ECU(ABScontrolunitwithoutESP).
DANGER
FailuretodisabletheRSAsystemona
vehiclethathasbeenmodiedoraltered
willresultinseriousvehiclebraking
andperformanceissues,including
unnecessarysysteminterventions.
Theseinterventionscouldleadtoaloss
ofvehiclecontrol.
Inadditiontodisablingthesystem,any
cablabels,suchaswarningandcaution
labelsrelatingtotheBendixABS-6
AdvancedwithESPsystemlocatedon
thesunvisormustberemoved,and
notationsmustbemadeintheoperators
manualssothatthevehicleoperatorhas
aclearunderstandingastowhichABS
optionsareinstalledonthevehicle.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 49
Thelocationoftheyawrate/lateralaccelerationsensormustnotbealtered.
Aftermarketsteeringwheelsmustnotbeused.OnlyOEM-suppliedreplacement
steeringwheelsshouldbeused.Duringanyprocedurethatinvolvesremovaland
reinstallationorreplacementoftheOEMsteeringwheel,caremustbeusednotto
crushordamagethesteeringanglesensorwhichismountedonthesteeringcolumn.
IncreasingsteeringanglebeyondmaximumisNOTpermitted.However,steering
anglesmaybeincreasedtothemaximumfactorysettingsifrequired.Refertothe
applicablesteeringsystemservicemanualfordetailedinformation.
Thesteeringanglesensormustberecalibratedfollowinganyadjustmentsorchanges
tothesteeringsystem.
Changingsteeraxleand/ordriveaxletrackwidthispermissible.
Changingfrontorrearaxlebrakedrumstodrumshavingadifferentangethickness
ispermissible.
TheABSwithESPECUrequiresapreciserollingcircumferenceratiobetweenthe
frontsteeraxleandthereardriveaxlesforoptimumperformanceofthesystem.
Forthisreason,thesystemcontinuouslycalculatesthepreciseratioandstoresthe
informationintheECUmemory .
CAUTION
EffectivenessoftheRSAsystemrelies
ontheaccuracyofthereportedvehicle
speed.Ifmajorchangestotiresizesare
made,suchthatchangestothevehicle
speedometer/odometersettingsare
required,theABSwithESPECUmust
bereprogrammedwiththenewvalues
byaqualiedtechnician.
50 Operator’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.Checkalluidlevelsandifnecessaryreplaceengineoil
contaminatedbycondensation.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 51
MaintenanceandService
MaintenanceHazards
DANGER
Beforeworkingonorinspectingavehicle,settheparkingbrakes,placethe
transmissioninneutralandchockthewheels.Failuretodosocanresultin
unexpectedvehiclemovementandcancauseseriouspersonalinjuryordeath.
DANGER
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto
personalinjuryordeath,ormakingyourvehicleunsafe.
Note: Readallsafetyinformationbeforeworkingonthevehicle.
EngineComponents,ServiceSchedules
Component
FuelFilter
(MP7,MP8and
MP10)
WaterSeparator
(MP7,MP8and
MP10)
AirFilterEP A
2010
AirFilterEuro4 Change Atmaximumrestrictionasindicated
Coolant
(MP7,MP8and
MP10)
Coolant,
ExtendedLife
(ELC)
(MP7,MP8and
MP10)
Operation Km(Miles)/MaximumMonths/Hours
Change Eachoilchange*
Filterchange Eachoilchange*
Change 160000(100,000)or12months,
whichevercomesrst
ongauge,or12months
Change 500000(300,000)6000or24months,
whichevercomesrst
Change 1000000(600,000)or48months,
whichevercomesrst
52 Operator’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)
Operation Km(Miles)/MaximumMonths/Hours
Change 80000(50,000)or6months,
whichevercomesrst
Change 240000(150,000)or12months,
whichevercomesrst
(MP7,MP8andMP10)
Change Traditionalcoolantsrequiring
SupplementalCoolantAdditive
(SCA)
80000(50,000)or6months
InitialAdjust
Adjust
InitialAdjust
Adjust
Change 500000(300,000)or36months,
Change 240000(150,000)or12months,
Change 240000(150,000)or4,500hours,
Clean 240000(150,000)or4,500hours,
200000(125,000)or12months,
whichevercomesrst
400000(250,000)or24months,
whichevercomesrst
100000(60,000)or6months,
whichevercomesrst
200000(125,000)or12months,
whichevercomesrst
whichevercomesrst
whichevercomesrst
whichevercomesrst
whichevercomesrst
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 53
Component
DieselExhaust
Fluid(DEF)
PumpFilter
(MP7,MP8and
MP10)
DieselExhaust
Fluid(DEF)Tank
FillerNeckFilter
Cleaning
(MP7,MP8and
MP10)
*Undercertainconditions(forexample,irregularfuelquality),thefuel/water
separatorltersmayrequiremorefrequentreplacement.
**Valvesmustbeadjustedwhenevertherockershafthasbeenremovedand
reinstalledforanyreason.
Operation Km(Miles)/MaximumMonths/Hours
Change FirstChange;161000(100,000)or
3200hours,whichevercomesrst
241000(150,000)or4800hoursor
three(3)years,whichevercomesrst
Clean 280000(175,000)or12months,
whichevercomesrst
54 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
CoolingSystem
GeneralCoolantInformation
DANGER
Coolantistoxic;riskofpoisoning.DONOTdrinkcoolant.Useproperhand
protectionwhenhandling.Keepcoolantoutofreachofchildrenandanimals.
Failuretofollowtheseprecautionscancauseseriousillnessordeath.
WARNING
DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom
theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardbefore
raisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.
Also,DONOTremovethecapwhiletheengineandradiatorarestillhot.Scalding
uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon
andcancausepersonalinjury.
WARNING
Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor
electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.
CAUTION
MACKInc.doesnotrecommendusingplainwaterinthecoolingsystem.W ater
aloneiscorrosiveatengineoperatingtemperaturesanddoesnotprovideadequate
boilingprotection.Theenginemaydevelopcorrosionandcavitationproblemsin
theengineandradiator,andtheboilingpointofthecoolantisloweredcompared
toaproperantifreezeandwatermixture.FailuretofollowMACKInc.cooling
systemcare/maintenancerecommendationscanrenderthewarrantyinvalid.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 55
Thecoolingsystemplaysanimportantroleinoverallengineperformancebykeeping
theenginewithinthenormaloperatingtemperaturerangehotenoughforefcient
combustion,andcoolenoughtopreventenginedamagecausedbyoverheating.
Goodpreventivemaintenancepractices,alongwithmonitoringcoolingsystem
performance,goalongwayinpreventingenginedamagethatcouldresultfrom
coolingsystemproblems.Themaintenanceitemsandtestsoutlinedinthissection
shouldbeperformedattheintervalsspeciedtoensureoptimumperformancefrom
thecoolingsystem.
SurgeTankCap
MACKconventionalmodels(CXU,CHU,GUandTD)utilizeacoolantsurgetank
mountedontopoftheradiator.Thesurgetankhasallcaplocatedonthetop
right-handsideofthetank,andapressurecapratedat16lb.whichincorporates
anoverowtubelocatedontheleft-handsideofthetank.Checkthecoolantlevel
regularly,makingsurethecoolantlevelisbetweentheCOLDMINandCOLD
MAXlinesonthebackofthetank.AteachCandDinspectioninterval,inspectthe
rubbergasketsoneachofthecaps.Replacethecap(s)ifthegasketsshowevidence
ofdamagewhichcouldaffectsealing.
WARNING
DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystemto
coolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseand
waitforthepressureinthesystemtodissipate.Afterthepressurehasdissipated,
completelyremovethecap.
W0054042
SurgeTankConventionalModels
1.PressureCap
2.FillCap
56 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
MACKlowcabforwardmodels(MRU,LEU)utilizeasurgetankwhichislocatedon
theleft-handsideofthechassis,mountedonastanchiontotherearofthecab.This
surgetankutilizesastandardradiatorpressurecap.Checkthecoolantlevelregularly,
makingsurethecoolantisvisibleinthesightglasslocatedonthesideofthetank.
AteachCandDinspectioninterval,removetheradiatorcapandinspectthegasket
foranydefectsthatwouldaffectsealing.Also,pressure-testthecapusingasuitable
coolingsystemandradiatorcaptester.Surgetankcappressurespecicationsareas
follows:
•MP7Engines(MRUandLEUModels)16-lb.pressurecap
•MP8Engines(MRUModelsonly)16-lb.pressurecap
WARNING
DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystem
tocoolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseto
therststop,andthenwaitforthepressureinthesystemtodissipate.Afterthe
pressurehasdissipated,completelyremovethecap.
Themainpurposeofcoolantistotransportheatfromthehotpartsoftheenginetothe
radiatorandtoprotectthecoolingsystemfromcorrosion.
Inadditiontothis,thecoolantmust:
•Protectagainstpittingandcavitationerosiondamageofthewaterpumpand
cylinderliners.
•Protectagainstfreezingandboiling.
•Preventformationofscale,sludgedepositsandclogging.
•Beharmlesstopolymermaterialsandsealsinthecoolingsystem.
•Maintainitsliquidpropertiesincoldclimates.
Manyenginefailurescanbetracedbacktoaprobleminthecoolingsystem.Ifthe
coolantlevelisallowedtogobelowthebottomofthetank,thereistheriskofthe
engineshuttingdown.Seetheoperatorsmanualformoreinformationonthewarning
functions.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 57
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.
58 Operator’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
EngineModel CoolantCapacityin
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,
CHU,GU,TD,MRUandLEU 59
Usethefollowingantifreezeprotectionchartstodeterminethepercentageof
antifreezeneededtoachievespecicprotectionlevelsforvariouscoolantsystems.
Ethylene-GlycolProtectionChart
EthyleneGlycol AmbientAirTemperature
40%
50%
60%
Propylene-GlycolProtectionChart
PropyleneGlycol AmbientAirTemperature
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.
60 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Inspectionofthewholecoolingsystemisimportant.Checkforswollenordeteriorated
heaterandradiatorhoses,loosehoseclampsandconnections,andradiatorleaks.
DANGER
DONOTworknearthefanwiththeenginerunning.Theenginefancanengageat
anytimewithoutwarning.Anyonenearthefanwhenitturnsoncouldbeseriously
injured.Beforeturningontheignition,besurethatnooneisnearthefan.
CAUTION
Neveraddcoolanttoahotoroverheatedengine.Enginedamagecanresult.Allow
theenginetocoolrst.
Additives
Additiveshelppreventrust,scaleandmineraldepositsfromforming.Additivesalso
protectmetalsfromcorrosion,preventwaterpumpandcylinderlinercavitationand
containanti-foamingagents.Additivesaredepletedduringnormalengineoperation
andneedtobereplaced.Fornon-extendedlifecoolantmixture,thismeansthe
additionofSupplementalCoolantAdditives(SCA)atanytimetheadditivegoes
belowtherecommendedlevel.Forextendedlifecoolantmixture,thismeansan
extenderpackageaddedhalfwaythroughthecoolantlifetime.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 61
RegularCoolantChangeInterval
CoolantSCAlevelmustbetestedatleasttwiceperyearorwhenevercoolantloss
occurs.Formaximumcoolantsystemefciency ,testthesystemateveryengineoil
changeinterval,every1,000hoursorevery6months(whichevercomesrst).For
properSCAlevels,consultServiceManual.
RegularCoolantFilterChangeIntervals
WARNING
Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids
cancauseseriousburns.
Thechargedcoolantltercontains8unitsofSCAthatarereleasedslowlyovertime
tomaintaintherecommendedlevelduringoperation.Consultengineservicemanual
forproperSCAlevelandchangeintervals.
62 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
ExtendedLifeCoolantChangeInterval
CAUTION
Extendedlifecoolantwilltestasoutofadditives(SCA),butSCAshouldnotbe
added.ShortenedenginelifemaybetheresultofaddingSCA.
Note:DONOTaddsupplementcoolantadditives(SCA)toextendedlifecoolant.
Shouldtheextendedlifecoolantsystembecomecontaminatedwithregularcoolant
exceeding10%ofthesystemstotalcapacityorifSCAisaddedtoextendedlife
coolant,drainthesystemandrellwithnewextendedlifecoolantorregularcoolant.
ExtendedLiftCoolantFilterChangeInterval
WARNING
Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids
cancauseseriousburns.
CAUTION
DONOTusealterthatcontainsSCA.Damagetocomponentscanresult.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 63
FuelSystem
FuelSafetyReminders
DANGER
Adieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritis
fromtheinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedto
ushouttheaircleanerelement,theenginemayoverspeedduringstart-up.Engine
damage,severepersonalinjuryordeathfromburnsorexplosionmayoccur.
DANGER
DONOTmixgasolineoralcoholwithdieseloilfuel.Thismixturecancausean
explosionandresultinseverepersonalinjuryordeath.
DANGER
DONOTremovethefueltankcapnearanopename.Dieselfumesare
combustibleandcancauseanexplosionorreresultinginseverepersonalinjury
ordeath.
WARNING
Ifafuelleakisdetected,stoptheengineimmediately.Thevaporsfromhotfuelare
highlyammablewhichmayresultinare.
WARNING
DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause
orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe
eventofare.
64 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
DieselFuelSpecication
Quality
CAUTION
Dieselenginesfor2007andlatermodelyearvehiclesaredesignedtooperate
onlywithUltraLowSulfurDiesel(ULSD)fuel.UseoffuelotherthanULSD
willreducetheefciencyanddurabilityoftheengine,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
requiredtomeetemissioncerticationforEuro4emissionengines.Usingapproved
dieselfuelwithamaximumsulfurcontentof500ppminEuro4emissionengines
willmeetallreliabilitystandards.
Thefuelsusedmustbeclean,completelydistilled,stableandnon-corrosive.Always
trytokeepthefueltankfull.DONOTputalcoholintothefueltank.Fillthetank
aftercompletingdrivingfortheday.
FuelSulfurContent
Fuelsoldforuseindiesel-poweredenginesfor2007andlatermodelyearvehicles
mayonlycontainamaximumsulfurcontentof0.0015%byweight.Thiswasdoneto
reduceparticleemissionsintheexhaust.
Note: Theuseofultra-lowsulfurdieselfueldoesnotpermitextensionofengine
oilchangeintervalsoroillterchanges.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 65
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 .Theygenerallyincreaseoperatingcostwithoutprovidingbenets.
Includedareavarietyofindependentlymarketedproductswhichclaimtobe:
•Cetaneimprovers
•Emissioncontroladditives
•Detergents
•Combustionimprovers
•Smokesuppressants
•Coldweatherowimprovers
Note: Repairexpensesresultingfrommalfunctionsinthefuelsystemorwithengine
componentswhenfuelenhancershavebeenusedarenotcoveredunderwarranty.
66 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Somefueladditivescanbeusedtoprovidetemporaryrelief,buttheydonotreplace
goodfuelhandlingpractices.Theseproductscanbeused:
•IsopropylAlcoholUse1/2literper450liters(1pintper125gallons)offuelfor
winterfreeze-upprotection.
•BiocideFortreatmentofmicrobegrowthorblackslime.Followmanufacturers
instructionfortreatment.
ProhibitedAdditives
WARNING
Theadditionofgasolinetodieselfuelwillcreateaseriousrehazard.Serious
personalinjurycanresult.
ThefollowingadditivesarespecicallyNOTallowedandmustNOTbemixed
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
fuelunlessspecicallyauthorizedbyMACKInc.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 67
BioDiesel
TheonlyBioDieselFuelapprovedbyMACKInc.foruseinEPA2010MACK
EnginesisSoyMethylEster(SMEorSOME)inblendsuptoB5Concentration
(5%blend).
Note: Althoughhigherconcentrationsareavailable,concentrationuptoB5
(maximum)aretheonlyblendscurrentlyapprovedbyMACKInc.
FuelStorage
Iffuelisstoredonsite:
•Keepstoragetankcoveredtopreventwaterentry.
•DONOTuseatankmadeofgalvanizedmetaloranygalvanizedpipingfordiesel
oilstorage.Dieselwillreactwiththezinc,formingsolidsthatcanclogfuellters
andcauseenginedamage.
•Fuelstoredforalongtimemayoxidizeandformsolids,causinglteringproblems.
•Keeptheareaaroundthellcapclean.Tiltthetankslightlytowardthedrainplug
areasowaterandsedimentcanbeeasilydrained.
Generally,fuelcontaminationoccursastheresultofimproperfuelhandling.Themost
commontypesofcontaminationarewater,dirtandmicrobialgrowth(blackslime).
Theformationofvarnishesandgumsresultingfrompoorfuelstabilityorlongstorage
(stalefuel)alsoaffectsfuelquality.Thebesttreatmentforcontaminationisprevention
bymaintainingacleanstoragesystemandchoosingareputablefuelsupplier.
68 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
FuelFilters
Aprimaryfuelltercanbelocatedontheengineorremotemountedontheframe
rail.Thislterconsistsofaltercartridge,awaterseparationbowlandmayhavea
fuelheaterbuiltin.
Thesecondaryfuellterislocatedonthelefthandside,belowtheengineelectronic
controlunit(EECU).Thelterisaspin-onlter.
MACKMPenginesutilizeaspin-onprimaryandsecondaryfuellters.Bothlters
arelocatedontheright-handsideoftheengine.
W0054019
FuelFiltersMACKMPEngine
1.SecondaryFuelFilter 2.PrimaryFuelFilter
TheprimaryfuellteronMACKMPenginesincorporatesaplasticwaterseparator
bowl.Additionally,theplasticbowlincludesawater-in-fuelsensor.Awarninglamp
ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Referto
Fuel/WaterSeparatorsection.
Note: Thereareoptionalfuelltersystems(suchasDavco,Conmet,etc.)available
forMACKMPengines.Thesefuelltersystemsuseasingleremote-mounted
lter,eliminatingthespin-onprimaryandsecondarylters.Forserviceinformation
concerningtheselters,refertothespecicfuelltermanufacturersserviceliterature.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 69
PrimaryFuelFilterReplacementProcedures
MACKMPEngines
Ateachspeciedoilandlterchangeinterval,changetheprimaryfuellteras
follows:
MACKMPPrimaryFuelFilter
1.PrimaryFilter
2.WaterSeparatorBowl
W0054023
3.W ater-in-FuelSensorHarness
4.DrainAssembly
70 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
1Thoroughlywashtheareaaroundthefuellterandmountingadaptermatingarea
withasuitablesolventandblowdrywithcompressedair.
2Disconnectthewater-in-fuelsensorharnessconnectorfromtheplasticwater
separatorbowl.
3UsingtoolJ24783,removetheprimarylter.
4Whileholdingthelteraboveasuitablecontainer,openthedrainvalveonthe
plasticwaterseparatorbowlandallowthefuelinthebowltodrain.Disposeof
thedrainedfuelinanenvironmentallysafemanner.
5Unscrewtheplasticseparatorbowlfromthebottomofthespin-onprimarylter
cartridge.
6ApplyathinlmofcleanengineoiltothewaterseparatorbowlO-ringonthe
bottomofthenewprimaryltercartridge.
7Installtheplasticwaterseparatorbowltotheprimaryltercartridge,andtighten
thebowlbyhand1/4to1/2turnafterthebowlcontactstheO-ring.
8Applyathinlmofcleanengineoiltothesealinggasketofthenewltercartridge.
9Primethelterbypouringcleanlterfuelthroughtheseriesofsmallholesatthe
topoftheltertotheinstallationllline.DONOTprimethelterthroughthe
centerhole.Usecaretoavoiddirtenteringthecenterholeofthelter.
10Installthenewlterandtightenanadditional1/2to3/4turnbyhandafterthe
gasketcontactsthebase.
11Reconnectthewater-in-fuelsensorharnessconnector .
12Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel
SystemMACKMPEngines”,page72).
13Starttheengineandcheckforleaks.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 71
SecondaryFuelFilterReplacementProcedures
Ateachspeciedoilandlterchangeinterval,changethesecondaryfuellteras
follows:
Note: Becauseoficebuildupinthefuelsystemorfuelwaxingwhichcanclogfuel
lters,itmaybenecessarytoreducethetimeormileageintervalbetweenfuellter
changesduringextremelycoldweather.
Toinstallanewlter:
1Thoroughlywashtheareaaroundthefuellterandmountingadaptormatingarea
withasuitablesolventandblowdrywithcompressedair.
2UsingtoolJ24783,removetheoldlters.
3Applyathinlmofcleanengineoiltothesealinggasketofthenewlters.
4Primethelterbypouringcleanlteredfuelthroughtheseriesofsmallholesat
thetopofthelter.DONOTprimethelterthroughthecenterhole.Usecareto
avoiddirtenteringthecenterholeofthelter.
5Installthenewltersandtightenanadditional3/4to1turnbyhandafterthe
gasketcontactsthebase.
6Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel
SystemMACKMPEngines”,page72).
7Starttheengineandcheckforleaks.
72 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
PrimingtheFuelSystemMACKMPEngines
OnMACKMPengines,theprimingpumpislocatedontheprimaryfuellter
mountingadapter.Primethefuelsystemasfollows:
DANGER
Beforeworkingonorinspectinga
vehicle,applytheparkingbrakes,place
thetransmissioninneutralandblock
thewheelstopreventthevehiclefrom
moving.Failuretodosocanresult
inunexpectedvehiclemovementand
causeseverepersonalinjuryordeath.
WARNING
DONOTworknearthefanwhilethe
engineisrunning.Theenginefancan
engageatanytimewithoutwarning,
resultinginseriousinjury.Before
turningtheignitionon,makesurethat
nooneisnearthefan.
DANGER
Toavoidpotentialrehazard,donot
serviceanypartofthefuelsystem
whilesmoking,orinthepresenceof
ames,sparksorhotsurfaces.Do
notservicethefuelsystemwhilethe
engineisrunning.Failuretofollow
theseprecautionscanresultinare.To
guardagainstburnsfromdirectcontact
withhotfuel,wearadequateprotective
clothing(faceshield,heavygloves,
apron,etc.)whenworkingonahot
engine.
Note: ThereareNObleednipplesthatmustbeopenedinordertoprimethefuel
system.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 73
1Unlocktheprimerpumphandlebypushingthehandledownwardandthenturning
itcounterclockwise.
W0054026
UnlockingFuelSystemPrimerPumpHandle
2Operatethepumphandleuntilpumpingeffortincreases.
W0054027
PumpingHandPrimerPump
Note: Withafuelsystemthatiscompletelyempty,200ormorestrokesofthe
pumpmaybenecessarytoproperlyprimethesystem.
3Whenthefuelsystemisprimed,locktheprimerpumphandlebypushingitfully
intothehousingandturningitclockwise.
4Starttheengineandrunitat1000rpmforapproximately5minutestopurgeany
remainingairfromthesystem.
Note: Iftheenginedoesnotstartafterperformingtheaboveprimingprocedure,
contactyourlocalMACKdealerforassistance.
74 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Fuel/WaterSeparatorMACKMPEngines
TheprimaryfuellteronMACKMPenginesincludesaplasticwaterseparator
bowlwithanintegralwater-in-fuelsensorandadrainassembly.Awarninglamp
ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Whenthe
lampilluminates,drainthewaterfromtheseparatorbyopeningthedrainvalveand
allowingthewatertodrainfromthebowlintoasuitablecontainer.Whenfuelbegins
todrain,closethevalveandtightento0.655Nm(5lb-in).Disposeofthedrained
water/fuelinanenvironmentallysafemanner.
WaterSeparatorDrainValveMACKMP
Engines
Note: DONOTdrainthewaterseparator
bowlwhiletheengineisrunning.
W0054022
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 75
EngineOil
General
Keeptheengineoilattheproperlevelandchangeitattherecommendedintervals.
Alwaysreplacetheoilltersatthesametimeaswhentheoilischanged.
OilQuality
MACKInc.recognizesengineoilsthatmeetorexceedthestandardsgivenby
AmericanPetroleumInstitute(API)fortheoilclassicationslistedinthismanual.
OnlyoilslicensedtocarrytheAPIsymbolshouldbeused.Lubricantsmeeting
APIstandardshaveprovidedmaximumenginelifewhenusedtogetherwiththe
recommendedoilandoillterchangeintervals.
EO-OPremiumPlus(orVDS-4)dieselengineoilismandatoryforuseinall2010
emissioncompliantMACKengines.Chassisequippedwitha2010emission
compliantengine,whichcanbeidentiedbythepresenceofaDieselParticulateFilter
(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: Oilltersshouldalwaysbechangedwhenchangingoil.
76 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
OilFilters
Therearethreeltersontheengine,oneofwhichisabypasslter .Thisshouldbe
changedatthesametimeasthefull-owlter(s).
CAUTION
MACKbrandedoilltersaredesignedtoprovidetheproperlevelofltration
andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent
requirementsmayvoidenginewarranty.
Spin-OnOilFilters
1.Spin-OnOilFilters
W0054029
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 77
SyntheticLubrication
Syntheticoilsareofferedbysomeoilsuppliersasanalternativetothetraditional,
petroleumbasedoilsforengines.TheseoilsmaybeusedinMACKengines,provided
theymeetthequalitylevelsspeciedonthepreviouspages,thatis:bothVDS-4
andEO-OPremiumPlus.
Theuseofsyntheticoilsdoesnotpermittheextensionoftherecommendedoil
changeintervals.Itisthecontaminationrate,i.e.,soot,andthedepletionof
additives,ratherthanbaseoilqualitythatdeterminestheusefulengineoillife
andthereforetheoilchangeintervals.
OilViscosity
Theviscositygradedenesthethicknessoftheoil.Theoilmustbethinenoughat
lowtemperaturesforeasycoldstartsandthickenoughtoprotectathightemperatures.
AnoilisnotfullydeneduntilboththeAPIqualityclassicationandtheviscosity
gradearespecied.
Choosetheviscositygradeforthetypicalambienttemperaturefortheapplication.
Multigradeoilshaveabroadrangethatsuitoperationinchangingtemperature.The
standardoilweightforMACKenginesis10W/30.
MACKInc.recommendstheviscositiesshownintheviscosity/temperaturetable
forMACKengines.
W1000144
78 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
OilAdditives
CAUTION
Extraoiladditivesmustneverbeaddedtoanyengineoilused.Additivessuchas
break-inoils,topoils,graphitizers,andfrictionreducingliquidsarenotnecessary
andmayevenharmtheengine.
Usingoilstothequalitystandardsrecommendedinthismanualmakestheuseof
extraoiladditivesunnecessary ,astheseoilsalreadycontainabalancedtreatment
ofadditives.
OilConsumption
Oncetheengineisstopped,checktheoilleveldaily.Iftheenginehasjustbeen
stoppedanditiswarm,waitapproximatelyveminutestoallowtheoiltodrainback
totheoilpanbeforechecking.Addoilasnecessary.
Note: DONOToverllenginewithoil.
Alldieselenginesaredesignedtoconsumesomeoil,soitisnormaltoaddoil
periodically.Anengineusedinheavy-dutyoperationwillconsumemoreoilthan
oneinnormaloperation.
ToassistyouinmeasuringyouroilusagepleaserefertotheFuelandOilRecordon
“FuelandOilRecord”,page155.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 79
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.Alwaysreplacetheoillterswhenchangingoil.
80 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
OilFiltersChange
WARNING
Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When
changingoil,wearprotectivegloves.
CAUTION
MACK-brandedoilltersaredesignedtoprovidetheproperlevelofltration
andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent
requirementsmaycauseunsatisfactoryresults.
1Coattheltergasketwithoil.
2Installthelterandturnitbyhanduntilthegasketmakescontactwiththesealing
surface.
3Manuallyturnthelteranadditional3/4toonefullturn.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 81
CheckingOilLevel
CAUTION
DONOTlettheoillevelfallbelowthemarkingonthedipstick.DONOToverll
sothelevelisabovetheuppermarkingonthedipstick.Thiscouldleadtoexcessive
oiltemperatureand/orpoorcrankcasebreatherperformance.
Ensurethatthevehicleisparkedonlevelgroundbeforecheckingtheoillevel.Wait
veminutesaftershuttingofftheengine,thenproceedwithcheckingoil.
W2056443
82 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
EngineAirFilter
Theaircleanerpreventsdust,dirtandotherharmfulcontaminantsfromentering
theenginethroughtheairintakesystem.Maximumengineprotectioncanonlybe
achievedthroughregularlyscheduledmaintenancepracticesthatincludeperiodicair
intakesysteminspectionsandairlterelementchanges.
Themostefcientmethodofdeterminingairlterelementchangeintervalsisby
regularlycheckingtheairlterrestrictiongauge,whichmayeitherbemounted
directlytotheaircleanercanister,ontheaircleaneroutlettubeorinsidethecab.The
restrictiongaugemeasurestheamountofrestrictionintheairlterelement.Some
chassismayhaveadash-mounteddial-typerestrictiongaugewhichmeasureslter
restrictioninmm/inchesofwater.
Changetheairlterelementinaccordancewiththeproceduresasoutlined,whenthe
restrictiongaugeredsignallocksinfullview,orthedash-mountedgaugeindicates
inletrestrictionasfollows:
MountedGaugeInletRestriction
Indication
Engine Millimeters(Inches)Water/kPa
MP7,MP8andMP10 510mm(20)/5kPa
AirFilterRestrictionGauge
W0054007
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 83
Damagetotheairlterelement,suchasholesintheltermedium,willgivean
inaccuraterestrictionreading.Therefore,evenifmaximumrestrictionisnotindicated,
theairlterelementshouldbechangedyearlyorat160000Km(100,000mile)
intervals,whichevercomesrst.
Whenreplacingtheairlterelement,orwhenevertheairinletsystemhasbeen
disassembled,inspecttheinletairductsbetweentheaircleanercanisteroutletandthe
turbochargerinletasfollows:
•Inspecttherubberelbowsforcracks,splittingand/orholes.Rubbercomponents
mustbeexiblesothattheyconformtotheplasticductsandensureatightseal.
•Inspectplasticductsforcracksand/orholes.
•Ensurethatallhoseclampsareproperlyinstalledandtightenedtospecications.
•Makesuretheplasticductsdonotrubagainstanycomponentssuchasair
conditioninghoses,wireharnesses,etc.
Toproperlyinstallanewlterelement:
1Wipetheaircleanerhousingclean.
2Removethelterelement(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,dependinguponcoverconguration,
tightenasfollows:
•Aircleanerwithlargewingnutincenterofcoverhand-tightenwingnut.
•Aircleanerwiththreethumbscrewsaroundouteredgeofcoverhand-tighten
thumbscrews.
•Aircleanerwithretainingnutsaroundouteredgeofcovertightenretainingnuts
between11–14Nm(8–10lb-ft).
84 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
Note: DONOTattempttocleantheairlterelementwithcompressedair,asthis
coulddamagetheltermediumandpossiblyresultinsevereenginedamage.
ReplacementPartsandFilters
W0053982
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 85
ExhaustAfter-TreatmentSystem
CHU,CXU,GUandTDStandardSystemView
1.SelectiveCatalyticReduction(SCR)
Catalyst
2.AftertreatmentDEFDosingUnit
3.AftertreatmentDieselParticulate
Filter(DPF)
4.AftertreatmentDEFT ank
W2029933
86 Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU
LEUandMRUStandardSystemView
1.SelectiveCatalyticReduction(SCR)
Catalyst
2.AftertreatmentDEFDosingUnit
3.AftertreatmentDieselParticulate
Filter(DPF)
4.AftertreatmentDEFT ank
W2031562
Operator’sManualVehicleMaintenanceCXU,
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DANGER
TheSCR/DPFshieldshouldnotbe
removedwhilethevehicleisinuse.
Also,onlyremovetheshield,oncethe
vehicleisoutofuseandtheSCR/DPF
issufcientlycooled.Failuretofollow
theseinstructionscanresultinre,
whichcancausecomponentdamage,
personalinjuryordeath.
CheckifthevehicleisequippedwithaDieselParticulateFilter(DPF)oraDPF
andSelectiveCatalyticReductionunit(SCR).Thesecomponentsarepartofthe
overallvehicleemissionscontrolsystem.Innormaloperation,thesecomponentscan
experiencesurfacetemperaturesashighas350°C(662°F).Itisimportanttoverify
thetemperatureatwhichthematerialorsubstancein,orassociatedwith,thebodycan
ignite.Ifitispossibleforthematerialorsubstancetofallorleakfromthebody,take
stepstopreventthemfromcontactingorcollectingontheDPForSCR.Failureto
dosomayresultinre.
Itisimportanttonotethatadditionalshieldingmay ,dependinguponconditionsand
thematerialorsubstance,trapammablesubstancesbetweentheadditionalshield
andtheDPF/SCR.Ifthisconditioncandevelop,advisetheuserofthevehicleto
periodicallychecktoensuretherearenotrappedsubstances.
Note:TheDPF/SCRandassociatedcomponentsarepartofaU.S.EPAand
CaliforniaAirResourcesBoard(CARB)certiedengineemissionssystem.These
componentsmustnotbemoved,alteredormodiedinanyway.T amperingwith
thesesystemsrendertheemissionswarrantyvoidandmayresultinpossible
tamperingchargesbytheEPAorCARB.
CAUTION
TheDieselparticulateltersandtheir
components,cannotbemovedor
alteredfromtheOEMinstallationin
anyfashion.Anyalterationsmaycause
componentdamageandisprohibitedby
thelaw.
88 Operator’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
unwantedelementstoamoreacceptableleveldenedintheregulations.Thereare
multiplemethodsofreducingtheseemissions.MACKhasselectedtouseaDiesel
OxidationCatalyst(DOC)withacatalyzeddieselparticulatelter.Theotheruses
adieselparticulatelterofadifferentkindwithoutaDOCandinitsplaceusesa
combustionchambertoheattheexhaustmixturethuscausingactiveregeneration.
Theparticulatematterremovedfromtheexhaustcollectsontheltersurfaces.T o
avoideventualblockage,whichwouldincreaseexhaustbackpressureandaffectpower
andfueleconomy,theltermustbecleaned.TheDPFiscleanedautomatically.The
sootbreaksdowntosafersubstancesbeforebeingreleasedtotheatmosphere.Some
oftheashremains,buttakesalongtimetoreachthepointwhereashclogsthelter.
Cleaningaltersoitcancontinuetofunctioniscalled“regeneration.”Eithersystem
useshighheattobreakdownthechemicalproperties.Dependingonvehicleusage,
theengineisequippedwithapassiveoractiveregenerationsystem.
In“passiveregeneration,”theexhaustproducesenoughheatcontinuouslytoconvert
thesoot,withapproximately260°C(500°F)beingrequired.Theprocessisslowand
continuesindenitely.Passiveregenerationispossibleonlyinvehicleapplications
wherethetemperatureislikelytoremainatorabovetherequiredtemperaturelevel,
makingactiveregenerationunnecessary .
Duringanactiveregeneration,thetemperatureoftheltermustberaisedto500°C
(932°F).Toproducethistemperature,thesystemusesahydrocarboninjectoror
AftertreatmentFuel(AF)injectortointroducefuelintotheexhauststreamasitleaves
theturbocharger.Thehotexhaustignitesthefuelwhichproducestheregeneration
temperature.WhentheDPFbecomesrestrictedtoaminimumvolume,theengine
ECUstartsthefuelinjectionintotheexhaust.Whentheairowratereturnstonormal
throughtheDPF ,theengineECUturnstheinjectoroff.
WARNING
Priortoeverworkingontheexhaust,
allowtimefortheentireexhaustsystem
tocool.Failuretodosomayresultin
personalinjury .Severeburnscanoccur.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU 89
SelectiveCatalyticReduction(SCR)
SelectiveCatalyticReduction(SCR)isanemissions-reductiontechnologywiththe
abilitytodelivernear-zeroemissionsofnitrogenoxides(NOx),asmog-causing
pollutantandgreenhousegas.SCR’ sperformancehasbeenprovedinmillionsof
milesofreal-worldtruckoperationsinothercountries,aswellasinlong-termeld
testsintheU.S.
SCRreducesNOxemissionstoverylowlevels,whileatthesametimedelivering
excellentfueleconomyandreliability .Thesystemdoesn’tchangethedesignor
operationofthebasicengine.Rather,SCRisanaftertreatmentsystemwhichconverts
NOxintheexhauststreamintoharmlessgases.Moderndieselsalreadyuseexhaust
aftertreatmentsystems,calleddieselparticulatelters,tocontrolemissionsofanother
pollutant,soot(alsoknownasparticulatematterorPM).
SCRworksbyinjectingDieselExhaustFluid(DEF)intotheexhauststeam,afterthe
DPF.DEFisasafe,simplesolutionofwaterandurea.DEFworkswiththeheat
oftheexhaustandacatalysttoconvertNOxintonitrogenandwatervapor-two
harmlessandnaturalcomponentsoftheairwebreathe.Theendresultiscleanerair,
excellentfuelefciencyandareliableemissionscontrolsystemfortoday’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
explosivelycausingareresulting
inpersonalinjuryordamagetothe
exhaustsystem.
TherearetwodifferentcongurationsfortheSCRcatalysts,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.Theuidisnotammable,norisitdangerouswhen
handlednormally.However,itishighlycorrosivetometal,particularlycopperand
aluminium.ReadtheseparatesectionconcerningthehandlingofDEFsolution.Only
useapprovedDEFuid.
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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.
TheDEFsolutionisnotammable.IftheDEFsolutionisexposedtohigh
temperatures,itbreaksdownintoammoniaandcarbondioxide.
TheDEFsolutionishighlycorrosivetocertainmetals,includingcopperand
aluminium.
IftheDEFsolutionisspilledontothevehicle,wipeofftheexcessandrinsewith
water.SpilledDEFsolutioncanformconcentratedwhitecrystalsonthevehicle.
Rinseoffthesecrystalswithwater.
Note:DonotushDEFspillsintothenormaldrainsystem.
WARNING
DEFspiltontohotcomponentswill
quicklyvaporize.Turnyourfaceaway!
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DieselExhaustFluid(DEF)Consumption
DEFconsumptionisrelatedtofuelconsumption.Ahighwaytruckmaytravel
225-300milesormoreononegallonofDEF.Agaugemuchlikeafuelgaugewill
indicatethelevelofDEFinthetank.ADEFlow-levelwarningwillactivatewhen
DEFislow.IfadriverrunsoutofDEFcompletely ,vehiclepowerwillbereducedto
deratemode.WhentheDEFtankisrelled,theenginewillresumenormalpower.
Note: DEFtanksaresizedforatwotoonefueltoDEFratioinordertomeetEPA
2010requirements.
DieselExhaustFluid(DEF)Availability
DEFwillbeavailablein2.5galloncontainers,55gallondrums,275gallonIBCand
inbulkstorageforeetlocations,truckstopsanddealerships.Allmajortruckstops,
dealersanddistributorswillcarryDEF.FormoreinformationonDEFandavailability
pleasevisitthewebsitewww.Mackscr.com.
94 Operator’sManualVehicleMaintenanceCXU,
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DriveBeltReplacementIntervals
Ifbeltssqueakorsqueal,cleanwithhydraulicbrakeuidoranapprovedcleaning
uid.Replacebeltsthatareseverelywornorfrayed.
RibCracking
Anin-servicepolyV-beltwillgothroughseveralphasesofcrackingduringitslife.
Afteranextendedtimeinservice,minorribcracksmayappear,usuallyoneortwo
cracksperinch.Thiscrackingisnormal.
BeltwithMinorRibCracks
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Beltsshouldnotbereplacedunlesstheribsexhibitseveremultiplecrackingasshown
below.Multiplecrackingwillleadtoribchunking.
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BeltwithMultipleCracking
BeltwithSevereCrackingandRib
Chunking
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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,exposuretoengineuids,etc.
•AbrasiveMaterialsSmallstones,metalshavings,etc.
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