MACK MP7, MP8, MP10 Service Manual

Mack

MAINTENANCE AND LUBRICATION

®

MAINTENANCE
AND LUBRICATION

MP7, MP8, and MP10 Engines

MAINTENANCE
AND LUBRICATION

MP7, MP8, and MP10 Engines

21394653

© Mack Trucks, Inc. 2010
Printed in U.S.A.

21394653

21394653

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,MRUandLEU1

Foreword

DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperational
andsafetyinformationthatisneededbyalldriversandownersofthisvehicle.

Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis
extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis
operated.Thismanualalsocontainsaconsiderableamountofinformationconcerning
thevehicle,suchasvehicleidentication,PreventiveMaintenancerecommendations
andalogforyourservicerecords.Pleasekeepthisinthevehicleatalltimes.
Informationfromothercomponentmanufacturersissuppliedinseparatemanuals
intheOwnersPackage.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKInc.
shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefectthatcould
causeacrash,injuryordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto
NHTSA,U.S.DepartmentofTransportation,W ashington,DC20590,byTTYat1
[phone],orvisittheirwebsiteatwww.nhtsa.dot.gov.

MACKTrucks,Inc.

Greensboro,NCUSA

Ordernumber:PV776-21394653

Allrightsreserved.Nopartofthispublicationmaybereproduced,storedin
retrievalsystem,ortransmittedinanyformsbyanymeans,electronic,mechanical,
photocopying,recordingorotherwise,withoutthepriorwrittenpermissionofMACK
Inc.

WarningLabelInformation

IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadandthat
youfullyunderstandeachandeverystepofthedrivingandhandlinginformation
inthisOperatorsManual.Becertainthatyoufullyunderstandandfollowall
safetywarnings.Itisextremelyimportantthatthisinformationisreadand
understoodbeforethevehicleisoperated.

ITISIMPOR TANTTHA TTHEFOLLOWINGINFORMA TIONCONCERNING
LABELSBEREAD,UNDERSTOODANDALW AYSFOLLOWED.

2Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Thefollowingtypesoflabelsareusedthroughoutthismanual:

Note:Anotedenesanoperatingprocedure,practice,condition,etc.,whichis
essentialtoproperoperationofthevehicle.

DANGER

Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresult
inseriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablack
backgroundwithablackborder.

WARNING

Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcould
resultinpersonalinjuryorseveredamagetothevehicle.Thewarninglabelisin

blacktypeonagraybackgroundwithablackborder.

CAUTION

Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonal
injuryisnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblack
typeonawhitebackgroundwithablackborder.

WarningandAdvisoryLabels

Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsof
thevehicletoalertdriversandservicetechniciansaboutsituationsthatmaylead
topersonalinjuryorequipmentdamage.Intheeventthatalabelisdamagedor
missingthelabelmustbereplaced.ContactyourauthorizedMACKTruckdealer
forassistanceregardingWarningandAdvisorylabels.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU3

GeneralInformation

InformationFortheOwner

Iftherearequestionsonthemaintenanceandperformanceofyourvehicle,please
discussthemwithyourMACKTruckdealer.Y ourauthorizeddealerisrequiredto
havetrainedmechanics,specialtoolsandsparepartstofullyserviceyourvehicle.
Ifnecessary,yourdealerwillcontactMACKInc.orothermanufacturersforany
assistance.

InadditiontothisMaintenanceManual,theremaybeadditionalinstruction/operators
manualssuppliedbycomponentmanufacturers.Thesemanualsareplacedinthe
OwnersPackageandplacedinthecab.Besuretoreadallthemanualsthoroughly
beforeoperatingthevehicle.

Also,varioussafetylabelsmaybeplacedoncomponentsbythecomponent
manufacturer.Besuretoreadandfollowtheselabelstopreventdamagetothe
vehicle,personalinjuryorevendeath.

InformationinthismanualreferstoMACKcomponentsandMACKdrivetrain.

EstablishaPreventiveMaintenanceProgramwiththehelpofyourlocalMACK
Truckdealer.APreventiveMaintenanceProgrammakesitpossibletomaximize
theamountoftimeyourvehicleisupandrunning,resultinginlongercomponent
life.Thismakesforasafervehiclebyreducinganymechanicalfailuresduetopoor
maintenancepractices.

Note:Federallawrequiresmanufacturerstonotifyownersofitsproductsintheevent
ofaFederalMotorV ehicleSafetyStandardorifasafetyrelateddefectisdiscovered.
Ifyouarenottheoriginalownerofthisvehicle,pleasenotifyusaboutthechangein
ownershipattheaddressbeloworthroughanauthorizedMACKTruckdealer.Thisis
theonlywaywewillbeabletocontactyouifnecessary.

MACKInc.

NortheastRegion

7900NationalServiceRoad,Mail:P .O.Box26259

Greensboro,NC27402

TEL:[phone]

UnitedStatesofAmerica

ThisMaintenanceManualcoversallMACKvehiclesmanufacturedbyMACKInc.,
includingthewholechassisandallMACKmanufacturedcomponents.Forspecic
maintenanceinformationonvendorcomponents,seetherespectivemanufacturers
serviceandmaintenanceliterature.

Thismanual,togetherwithmanualsforspeciccomponentscontainimportant
informationtobeabletooperatethisvehiclesafely.Theycontainadviceand

4Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

instructionswhichwillenableyoutogettheoperatingeconomyandperformance
thatyouexpectfromthisqualityvehicle.

Allinformation,illustrationsandspecicationscontainedinthismanualarebased
uponthelatestproductinformationavailableatthetimeofpublication.Ifany
questionsariseconcerningthecurrentstatusofFederalorstatelaws,theappropriate
Federalorstateagencyshouldbecontacted.

Note:Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactual
vehicle,however,keycomponentsaddressedinthismanualarerepresentedas
accuratelyaspossible.

MACKInc.reservestherighttomakechangesatanytimeortochangespecications
ordesignwithoutnoticeandwithoutincurringobligation.

General

USA

TheFederalCleanAirAct,Section203(a)(3),statesthefollowingconcerningthe
removalofairpollutioncontroldevicesormodicationofacertiedenginetoa
non-certiedconguration:
CAA,Section(a)(3)(A)prohibitsanypersonfromremovingorrenderinginoperative
anyemissioncontroldeviceorelementofdesigninstalledonorinamotorvehicle
ormotorvehicleengineincompliancewithfederalregulationsundertheCleanAir
Actpriortothesaleanddeliveryofthevehicletotheultimatepurchaser.Thestatute
alsoprohibitsanypersonfromknowinglyremovingorrenderinginoperativeany
emissioncontroldeviceorelementofdesignaftersaleanddeliveryofavehicleor
enginetotheultimatepurchaser.Anypersonwhoviolatestheseprovisionseither
byremovingorrenderinginoperativeemissionscontroldevicespriortothesaleor
deliveryofanengineorvehicletoanultimatepurchaser,orbyknowinglyremoving
orrendinginoperativesuchdevicesafterthesaleanddeliveryofanengineorvehicle
toanultimatepurchaser,canbesubjecttopenaltiesofupto$3,750perincident.
Anydealerormanufacturerwhoviolatestheseprovisionscanbesubjecttopenalties
ofupto$37,500perincident.

Canada

ThesameconditionsthatapplyintheUSAapplytoCanada,withoneexception.
Afterthevehicleissoldtoaretailcustomer,thatis,theenduser,thejurisdiction
controllingtheemissioncontroldevicesbecomestheprovinceinwhichthevehicleis
licensed.Nochangesshouldbemadethatrenderanyorallofthedevicesinoperative.

Shouldtheowner/operatorwishtomakeanychangestotheemissioncontroldevices,
checkwiththeprovincialauthoritybeforemakinganysuchchanges.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU5

Mexico

ThesameconditionsthatapplyintheUSAapplytoMexico.RefertotheMexican
FederalLawforEmissionControlwhichadherestoEPAregulations.Nochanges
shouldbemadethatrenderanyoralloftheemissionscontroldevicesinoperative.

Shouldtheowner/operatorwishtomakeanychangestotheemissioncontroldevices,
checkwiththestateauthoritybeforemakinganysuchchanges.

FederalEmissionRequirements

ThissectioncoverstherequirementoftheUnitedStatesCleanAirActwhichstates:

Themanufacturershallfurnishwitheachnewmotorvehicleormotorvehicleengine
suchwritteninstructionsforthemaintenanceanduseofthevehicleorengineby
theultimatepurchaserasmaybereasonableandnecessarytoassuretheproper
functioningofemissioncontroldevicesandsystems.

Thissectionalsocoverstherequirementsoftheemissionsregulationspromulgated
undertheMotorV ehicleSafetyActinCanada.

6Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

TamperingwithGaseousEmissionControl
SystemsProhibited

TheFederalCleanAirActprohibitstheremovalorrenderinginoperativeofany
deviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengine
incompliancewithFederalEmissionRegulationsby:

1Anypersonpriortoitssaleanddeliverytotheultimatepurchaser,or

2Anymanufacturerordistributorafteritssaleanddeliverytotheultimatepurchaser,

or

3Anypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or

tradingmotorvehiclesormotorvehicleenginesfollowingitssaleanddelivery
totheultimatepurchaser,or

4Anypersonwhooperatesaeetofmotorvehiclesfollowingitssaleanddelivery

totheultimatepurchaser.

Note:Forspecicsoftheprohibitedvehicle/enginemodicationsrefertotheMACK
Bodybuilderdocumentation.

EnginesOtherthanMACK

ForspecicinformationonenginesotherthanMACK,refertotheengine
vendorspublications.

NoiseEmissions

MACKInc.warrantstotherstpersonwhopurchasesthisvehicleforpurposesother
thanresaleandtoeachsubsequentpurchaser,thatthisvehicleasmanufacturedby
MACKInc.wasdesigned,builtandequippedtoconform,atthetimeitleftthecontrol
ofMACKInc.,withallapplicableU.S.EP ANoiseControlRegulations.

Thiswarrantycoversthisvehicleasdesigned,builtandequippedbyMACKInc.,and
isnotlimitedtoanyparticularpart,componentorsystemofthevehiclemanufactured
byMACKInc.Defectsindesign,assemblyorinanypart,componentorsystemof
thevehicleasmanufacturedbyMACKInc.,which,atthetimeitleftthecontrolof
MACKInc.causednoiseemissionstoexceedFederalstandards,arecoveredby
thiswarrantyforthelifeofthevehicle.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU7

NoiseControlSystem,OperatorInspectionandMaintenance
Requirements

ANoiseControlSystemMaintenanceLogislocatedinthismanual.Thislogshould
beusedtodocumentallNoiseControlSystemrelatedmaintenance,whetherthe
maintenanceresultsfromaspecicnoisecontrolsysteminspection,oradeciency
identiedduringanothergeneralmaintenanceevent.

Ifadditionallogspaceisneeded,furtherentriesmaybeaddedonaseparatesheetof
paper.Storetheseadditionswiththemainlogtopreserveacomprehensiverecord.It
isrecommendedthatcopiesofallnoiseemissionsrelatedmaintenanceinvoicesbe
retained.

ThefollowingNoiseControlSysteminspectionandmaintenanceinstructionscontain
suggestedmaintenanceintervals.Theseintervalsmayneedadjustmentinorderto
bestaccommodatethespecicvehicleusage.Thefollowinginstructionsonlyconcern
NoiseEmissionsrelateditemsanddonotaddressormodifyanygeneralvehicle
maintenancerequirements.

ThefollowingelementsmakeuptheNoiseControlSystem:

•NoiseShieldingandInsulationDevices

•CoolingSystem

•ExhaustSystem/DPFSystem

•AirIntake/AirInductionSystem

•EngineControl,EGRandFuelSystems

•SelectiveCatalyticReduction(SCR)

TamperingwithNoiseControlSystem

Federallawprohibitsthefollowingactsorthecausingthereof:

(1)Theremovalorrenderinginoperativebyanyperson,otherthanforpurposesof
maintenance,repair,orreplacement,ofanydeviceorelementofdesignincorporated
intoanynewvehicleforthepurposeofnoisecontrolpriortoitssaleordeliverytothe
ultimatepurchaserorwhileitisinuse;

or

(2)theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremoved
orrenderedinoperativebyanyperson.

Amongtheactsthatconstitutetamperingaretheactslistedbelow:

•Removal,orrenderinginoperative,ofanyexhaustcomponents,includingmufers,

heavyordouble-wallexhausttubing,exibletubingorexhaustpipeclamping.

8Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

•Removal,orrenderinginoperative,ofthetemperature-modulatedcoolingfan

system.

•Removalofthecoolingfanshroud.

•Removal,orrenderinginoperative,oftheaircleanerorairintakein-linesilencer.

•Removalofthesounddeadeningmaterialfromthehoodorcabtunnel.

•Removal,orrenderinginoperative,oftheenginespeedgovernorsoastoallow

enginespeedtoexceedthemanufacturersspecications.

•Removalofsplashshieldslocatedinsidethewheelhousings.

•Removalofengineblockshields.

•Removalofenginecrankcaseshieldsorinsulation.

•Removalofinsulatedrockerarmcovers.

•Removaloftransmissionnoiseshields.

NoiseShieldingandInsulationDevices

Maintenance

Ensuresoundshieldingandinsulatingdevicesareintact.Inspectcomponentsfor
damage.Primarysystemcomponentsrequiringnoiserelatedinspectionincludethe
hood,enginecompartmentinsulatingmaterials(includinghoodinsulation,bulkhead
insulation,doghouseinsulation,etc.)splashshields,cabskirts,fendershields,and
bodypanels.Inspectallrelatedfasteners,brackets,andclampsfordamageand
tightness.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeNoiseShieldingandInsulationDevices:

Removingorrenderinginoperativetheengineand/ortransmissionnoisedeadening
panels,shieldsorinsulatingmaterials.

Removingorrenderinginoperativethecab-tunnelorhoodnoiseinsulatingmaterials.

Removingorrenderinginoperativeanyvehiclebodymountedsoundinsulation
componentsand/orshields(caborfendershields,skirts,wheelhousingsplashshields,
etc.).

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU9

CoolingSystem

WARNING

DONOTworknearthefanwiththeenginerunningortheignitionintheON
position.Theenginefancanengageatanytimewithoutwarning.Anyonenear
thefanwhenitturnsoncouldbeseriouslyinjured.

Maintenance

Visuallyinspectcoolingsystemcomponentsfordamage,and/ormisalignment.

Primarysystemcomponentsrequiringnoiserelatedinspectionincludefanblades,fan
clutch,fanshroud,fanring,andrecirculationshields.Checkfanblades,fanring,fan
shroud,belttensionerandrecirculationshieldsforanydamage.Verifythatfanblades
clearthefanring.Inspectallrelatedfasteners,brackets,andclampsfordamageand
tightness.Conrmoperationoftemperaturemodulatedfanclutch.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeCoolingSystem:

Removingorrenderinginoperativecoolingsystemcomponents(suchasthe
temperaturemodulatedfanclutch,fanshroud,fanring,recirculationshields,etc.).

ExhaustSystem

WARNING

Hotengine!Avoidallmovablepartsorhotengineparts,exhaustgases,and/or
uids.Ahotengine,exhaust,and/oruidscancauseburns.

10Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Maintenance

Makesuretheexhaustsystemisintact.Inspectfordamage,misalignmentand/or
leakage.Primarysystemcomponentsrequiringnoiserelatedinspectioninclude
exhaustmanifold,turbocharger,andallexhaustsystem(rigidandexible)piping.
Closelycheckthesystemforexhaustleaks.Specialattentionshouldbegiventoall
welds,seams,gaskets,supportpoints,clamps,couplingsandconnections.

Inspectallexhaustsystemfasteners,brackets,andclampsfordamageandtightness.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeExhaustSystem:

Removingorrenderinginoperativeexhaustsystemcomponents(suchasthepipes,
clamps,etc.).

AirIntake/AirInductionSystem

Maintenance

Makesuretheairintakesystemisintact.Inspectcomponentsfordamage,
misalignmentand/orleakage.Primarysystemcomponentsrequiringnoiserelated
inspectionincludetheaircleanerhousing,aircleanerelement,turbocharger,charge
aircoolerandintakemanifold.

Alsoinspectallducts,pipes,hoses,tubingandelbowsusedtointerconnectthe
system.Specialattentionshouldbegiventoallwelds,seams,gaskets,supportpoints,
clamps,couplingsandconnections.

Inspectallintakesystemfasteners,brackets,andclampsfordamageandtightness.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeAirIntake/AirInductionSystem:

Removingorrenderinginoperativeairintake/inductionsystemcomponents(lter,
lterhousings,ducts,etc.).

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU11

EngineControl,EGRandFuelSystems

ActsthatconstitutetamperingwithEngineControl,EGRandFuelSystems:

Removingrenderinginoperative,ormodifyingtheenginecontrolsystemsuchas
theECU,EGRsystemcomponents,orfuelsystemcomponents,inordertoallow
theenginetooperateoutsideofthemanufacturersspecicationsisnotallowedand
violatesbothwarrantyandlegislation.

12Operator’sManualVehicleMaintenanceCXU,
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LabelInformation

VehicleIdenticationNumberLabel

Allmotorvehiclesarerequiredtobeidentiedbya17-digitVehicleIdentication
Number(VIN).U.S.andCanadianregulationsdictatetheformatofthenumber.
TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK,
suchastypeofvehicle,model,typeofbrakesystem,grossvehicleweightrange
andmodelyear.

TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations
includeastampingontheverticalfaceoftheright-handframerail(somewhere
betweenthefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge,
thedooropeningareaortheseatriser)andonthevehiclesafetycerticationlabels
andotherlabelsonthedooredgeordooropeningarea.Whenthevehicleisreceived,
checktheVINateachlocationonthevehicleandverifythattheyareidentical.The
vehicleidenticationnumbermustnotbechanged,coveredorobliterated.

VINFrameStamping

W0031972

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU13

W0031973

VINLabelonDriversSeatRiser

14Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

RegulatoryLabels

Inadditionto,orinplaceofthepreviouslymentionedlabels,MACKTrucks,Inc.
mayafxoneormoreofthefollowinglabelstothecab.

Heater/DefrosterOmissionLabel

Awindshielddefroster,asrequiredbyFMVSS103,WindshieldDefrostingand
Defogging,isnotrequiredforvehiclesdestinedforsaleintheStateofHawaii,

PuertoRico,theNorthernMarianaIslands,Guam,theVirginIslandsandAmerican
Samoa.V ehiclesdestinedforsaleintheseareasmust,however,conformtoallother
applicableFMVSSregulations.Ifavehicledestinedforsaleinoneoftheseareas
doesnothaveafactory-installeddefroster,alabelisafxedtothecabnearthevehicle
certicationlabel(seeillustrationbelow).

OmissionofHeater/DefrosterLabel

W0031974

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU15

ExportLabel

InordertocomplywithU.S.regulations,allMACKvehiclesintendedforexportfrom
theUnitedStates(includingexporttoCanada)willhaveanExportLabel,similarto
thelabelshownbelow,afxedtotheinsideofthewindshield.

TypicalExportLabel(IncludingExport

toCanada)

W0031975

16Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Export/SpecialApplicationLabel

Export(excludingexporttoCanada)orspecialapplicationvehiclessuppliedfrom
theassemblyplantarenotnecessarilydesignedtoconformtoapplicableFederal
andCanadianmotorvehiclesafetystandards.Onthesevehicles,anExport/Special
ApplicationLabel,similartothelabelshownintheillustrationbelow ,isafxedto
thecab.

Export/SpecialApplicationLabel

W0031976

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU17

Exportvehicles(otherthanthoseintendedforsaleinCanada)alsohaveanExport
Label,similartothelabelshownbelow,afxedtothedoorarea.

W0031977

TypicalExportLabel(OtherThanExport

toCanada)

18Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Off-HighwayIdenticationLabel

InadditiontotheExport/SpecialApplicationLabel,vehiclesdesignedstrictlyfor
off-highwayoperationswillhaveanOff-HighwayIdenticationLabel,similartothe
labelshownintheillustrationbelow,afxedtothecab.

W0031978

Off-HighwayIdenticationLabel

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU19

SafetyInformation

ProperMaintenanceProcedure

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin
neutral,andchockthewheels.Failuretodosocanresultinunexpectedvehicle
movementandcancauseseriouspersonalinjuryordeath.

DANGER

Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruse
aproperlyventedexhausthose.Prolongedorexcessiveexposuremaycause
seriousillnessordeath.

DANGER

Neveroperatetheengineinanareawherehydrocarbonvapors(gasoline,for
example)arepresentoraresuspectedtobepresent.Hydrocarbonvaporscanenter
theairintakeandoverspeedtheengine,causingsevereenginedamageand/oran
explosionandre.Seriouspersonalinjuryordeathcouldoccur.

DANGER

Nevertrytooperateorworkonthisvehiclewhileundertheinuenceofalcohol.
Yourreexescanbeaffectedbyevenasmallamountofalcohol.Drinkingand
operatingthisvehiclecanleadtoanaccident,causingseriouspersonalinjuryor
death.

20Operator’sManualVehicleMaintenanceCXU,
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WARNING

DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto
personalinjuryormakingyourvehicleunsafe.

WARNING

Dieselengineexhaustandsomeofitsconstituentsareknowntothestateof
Californiatocausecancer,birthdefectsandotherreproductiveharm.

DuringMaintenance

Removekeyfromignitionwhileworkingonvehicleorengine.

DONOTallowunauthorizedpersonnelon,aroundorinthevehiclewhen
maintenanceorrepairisbeingperformed.

•Whenoperatingtheengineinanenclosedarea,venttheexhausttotheoutside.

•Beforeservicingyourvehicle,applytheparkingbrakesandadequatelychockthe

wheelsinordertopreventunintendedvehiclemovement.Iftheserviceprocedure
requirestheparkingbrakestobereleasedrechecktoensurethatthewheelsare
adequatelychockedtopreventanyforwardand/orrearwardmovement.

•DONOTusecombustiblesubstancesinoraroundtheengineeitherduringrepair

ormaintenanceorwhenrunningtheengine.

•DONOTwearlooseclothingorjewelrythatcancatchorgetsnaggedbypartsor

movingcomponentsontheengine.Alsowearallprotectiveequipmentrequiredby
thejobconditions,suchasprotectiveglasses,hearingprotection,etc.

•Makecertainthatallprotectivecoversandguardsareinplaceandproperlysecured.

•Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.

•Reportallproblemsinatimelymannerbeforetheythreatenthesafetyofoperating

thevehicle.

•DONOTworkontheenginewhileitisrunning.

•Makesureprotectivelocksandcoversareintheirproperplace.

•DONOTusehighamperageelectronicstartingdevicesforjump-startingthe

engine.Relyonconventionalbatterychargingforchargingthebatteriesor
jump-startwiththehelpofastartbattery.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU21

•DONOTattemptrepairsyoudonotunderstand.Ifyoudonothavetheproper

tools/knowledgetoperformtherepairscorrectly,MACKrecommendscontacting
yournearestMACKTruckdealerforallnecessaryrepairs.

•Whenstartinganengineafterrepairshavebeenmadetothefuelorinjection

system,prepareequipmentforshuttingofftheengineintakeairand/orfuelsupply
(tostoptheengine),incasethereisanoverspeedonstart-up.

•Starttheengineonlyfromthedriverseat.Neveroperatethestartermotoracross

thestarterterminalsorthebatteriesasthiscouldbypasstheengineneutral-start
systemaswellascausingdamagetotheelectricalorelectronicsystems.

CompressedAirandWater

DANGER

Compressedaircancauseseriouspersonalinjury.Whenusingcompressedairfor
cleaning,wearaprotectivefaceshield,protectiveclothingandprotectiveshoes.
Pressurizedwatercouldcauseparticlesand/orhotwatertobesprayedinyour
directionandcausepersonalinjury.Themaximumairpressuremustbebelow
30psi(200kPa)forcleaningpurposes.

AsbestosInformation

Note:TheMACKengineandreplacementpartsforitshippedfromthefactoryare
asbestosfree.MACKrecommendstheuseofonlygenuineMACKspareparts.
Neveruseanypartsthatcontainorarethoughttocontainasbestos.Exposureto
asbestosberscancreateserioushealthrisks,includingdeath.

FluidPenetration

DANGER

Alwaysuseapieceofpaperorcardboardwhencheckingforaleak.Escapinguid
underhighpressure,evenapin-holesizedleak,canpenetratebodytissue,causing
seriousinjuryordeath.Ifuidisinjectedintoyourskin,immediatetreatmentmust
beadministeredbyadoctorfamiliarwiththistypeofinjury.

22Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

InjuryPrevention

BurnPrevention

EngineParts

WARNING

Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine
and/oruidcancauseseriousburns.

WARNING

DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom
theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardany
longerbeforeraisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.
Also,donotremovethecapwhiletheengineandradiatorarestillhot.Scalding
uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon,
whichcancausepersonalinjuryanddamagetoenginecomponents.

W0001525

DONOTtouchanypartoftheenginewhileitishot.Allowtheenginetocoolbefore
anyrepairormaintenanceisperformedontheengine.

Relieveallpressureinair,oil,fuelorcoolingsystemsbeforeanylines,ttingsor
relateditemsaredisconnectedorremoved.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU23

Coolant

WARNING

Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor
electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.

W0001527

Topreventpersonalinjury,donotclimbupontheenginetoremovethellercap.
Useasuitable,properlypositionedladdertoreachthecap.Atnormaloperating
temperature,theenginecoolantisveryhotandunderpressure.Ifpressureisrelieved
rapidlyinahotcoolingsystem,thehotcoolantcanturnintosteam.Anycontactwith
hotcoolantorsteamcancausesevereburns.Theradiatorandallheatingsystemand
radiatorlinesandhosescontainhotcoolant.

Verifycoolantlevelonlybythemarkingsontheexpansiontank.Opentheller
caponlyaftertheengineisstoppedandcooleddown.Removethellercapslowly
torelievepressure.

Oils

WARNING

Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengine
and/oruidcancauseseriousburns.

Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When
changingoil,wearprotectivegloves.

24Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Batteries

WARNING

Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskof
injuryduetocontactwithsulfuricacidoranexplosion.

WARNING

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm.
Washhandsafterhandling.

Batteryelectrolytecontainsacidandcancauseinjury.Avoidcontactwiththeskin
andeyes.W ashhandsaftertouchingbatteriesandconnectors.Useofglovesis
recommended.Alwayswearprotectiveglasseswhenworkingwithbatteries.

SpeedRestrictiveTires

DANGER

Operatingavehicleequippedwithspeedrestrictivetiresinexcessoftheirstated
ratingmayresultintreadseparationand/orblowoutresultinginthelossofsteering
controlandpossiblecollision.Seriouspersonalinjuryordeathcouldoccur.Always
maintainproperairpressureandneverexceedthetireratings.

Whenavehicleisequippedwithspeedrestrictivetires,DONOToperatethevehicle
inexcessoftheindicatedspeeds.Ifyourvehicleisequippedwithsuchtires,thespeed
restrictionswillbestatedonthesidewallofthetires.Theoperatorofthisvehicleis
urgedtocheckthetiresofthevehicletodetermineifthereareanylimitations.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU25

FireorExplosionPrevention

DANGER

Thedieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritis
fromtheinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedto
ushouttheaircleanerelement,theenginemayoverspeedduringstart-up.Engine
damageandsevereinjuryand/ordeathfromburnsorexplosioncanoccur.

DANGER

Excessiveheatmaycausethepressurizedcomponentsoftheairconditionedsystem
toexplode.SomemixturesofR134arefrigerantcanbecomecombustibleat
elevatedpressures.Neverweld,solder,steamcleanoruseagastorchnearanypart
oftheairconditioningsystem.Severeinjuryordeathmayoccurfromanexplosion.

W0001526

DANGER

DONOTserviceanypartofthefuelsystemwhilesmokingorinthepresenceof
ames,sparksorhotsurfaces.Failuretofollowtheseprecautionscanresultinre,
whichcancauseseriousinjuryordeath.

WARNING

DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause
orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe
eventofare.

26Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

W0001527

Theengineshouldnotbeoperatedinanareawherecombustiblegasesaresuspected
tobeintheair.Thesecouldbedrawnintotheenginethroughtheengineairintake
systemandcouldcausetheenginetooverspeedwithpossibleseriousdamagetothe
engineandbodilyinjuryorpropertydamage.

Makeprovisionsforshuttingofftheengineintakeairorfuelsupplytostoptheengine
ifthereisanoverspeedonstart-upafterperformingrepairormaintenanceonit.

ContactyournearestMACKTruckdealerforanynecessaryairconditioningtesting
orrepairs.

Allfuels,mostlubricantsandsomecoolantmixturesareammable.Dieselfuel
isammable.Gasolineisammable.Themixtureofdieselandgasolinefumesis
extremelyexplosive.DONOTsmokewhilerefuelingorwheninarefuelingarea.

Keepallfuelsandlubricantsstoredinproperlymarkedcontainersandawayfromall
unauthorizedpersonnel.Storeoilyragsorotherammablematerialinaprotective
container,inasafeplace.

Removeallammablematerialsuchasfuel,oilandothersubstancesbeforethey
accumulateontheengine.

DONOTexposetheenginetoames,drivingoverburningground.

DONOTweldoramecutonoraroundpipesortubesthatcontainammableuids.

Exhaustheatshieldsmaybeinstalledtoprotectoilorfuelcarryinglinesandpipes
fromhotexhaustparts.Toprotectfrompipeorsealfailure,installheatshields
correctly.

Provideadequateandproperwasteoildisposal.Alwaysdisposeofwasteliquids
accordingtoFederalandlocalregulations.Oilandfuelltersshouldbeproperly
installedandhousingcoverstightenedtothepropertorquewhenbeingchanged.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU27

StartingAids

DANGER

DONOTuseetherorothercombustiblestartingaidsonanyengineequipped
withapreheater .Iftheengineisequippedwithapreheater,introductionofether
orsimilarstartingaidscouldcauseareorexplosionresultinginsevereproperty
damage,seriouspersonalinjuryordeath.

DONOTuseetherorothercombustiblestartingaidsonenginesthathavea
heaterelementorotherheatingdevicesinstalledintheintakemanifoldfor
heatingtheintakeairduringcold-starts.

W0001484

FireExtinguisher

Anytimeworkisbeingdonetothefuelsystemoranyotherareawhereammable
substancesarebeingused,haveareextinguisheravailableandknowhowtouseit.
Inspectandhaveitservicedasrecommendedonitsinstructionlabel.

28Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

RespiratoryHazardPrevention

DANGER

Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruse
aproperlyventedexhausthose.Prolongedorexcessiveexposuremaycause
seriousillnessordeath.

WARNING

Dieselengineexhaustandsomeofitsconstituentsareknowntothestateof
Californiatocausecancer,birthdefectsandotherreproductiveharm.

W0001523

Alwaysworkinawellventilatedspaceiftheengineneedstoberunningandusea
hosetoroutetheexhausttotheoutside.

PoisonousSubstances

DANGER

Coolantistoxic;riskofpoisoning.
DONOTdrinkcoolant.Useproperhandprotectionwhenhandling.Keepcoolant
outofreachofchildrenandanimals.Failuretofollowtheseprecautionscancause
seriousillnessordeath.

Coolingsystemsupplementaladditivecontainsalkali.Topreventpersonalinjury ,
avoidcontactwiththeskinandeyes.

DONOTdrinkcoolantofanyconcentration.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU29

CrushingorCuttingPrevention

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin
neutralandchockthewheels.Failuretodosocanresultinunexpectedvehicle
movementandcancauseseriouspersonalinjuryordeath.

WARNING

DONOTworknearthefanwiththeenginerunningortheignitionintheON
position.Theenginefancanengageatanytimewithoutwarning.Anyonenear
thefanwhenitturnsoncouldbeseriouslyinjured.

W0001524

Neverattemptadjustmentsorrepairswhiletheengineisrunning,seeyourauthorized
MACKTruckdealer.

Inspectthefanbladeassemblybeforeserviceforcracksorloosemountingbefore
startingtheengine.Neverstandalongsidearotatingfanassembly ,particularlyat
highfanspeeds.

Wearprotectiveglasseswhenstrikingobjectstoavoidinjurytoyoureyes.Chipsor
otherdebriscanyoffobjectsthatarestruck.Makesurenoonecanbeinjuredby
yingdebrisbeforestrikinganyobject.

W0001528

30Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

ClimbingUpandDown

DANGER

Alwayshavethreelimbs(onefootandtwohandsortwofeetandonehand)in
contactwiththevehicleatalltimeswhenenteringorexitingthecaborthearea
behindthecab.Failuretofollowthiswarningcanresultinseriouspersonalinjury
ordeath.

DONOTclimbuponorjumpofffromtheengineorstandoncomponentsthatcannot
supportyourweight.Useanadequateladderorscaffolding,suitablysituated.

DONOTusetopofengineorcowlingledgeasfootholdwhenreachingontopofcab.
Cleansteps,handholdsandareasofthevehicleonwhichyouwillbeworkingorare
around.RefertotheOperatorsManualforproperentryandexitprocedures.

Alwaysuseathree-pointstance(twohandsandonefootoronehandandtwo
feet)wheneverclimbingupordown.

EngineDamagePrevention

BeforeStartingtheEngine

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissionin
neutralandchockthewheels.Failuretodosocanresultinunexpectedvehicle
movementandcancauseseriouspersonalinjuryordeath.

Inspectengineforpotentialhazards.Makesureallprotectiveguardsandcoversare
properlyinstalledifanengineneedstobestartedtomakeadjustmentsorchecks.To
helppreventanaccidentbymovingparts,workcarefullyaroundthem.

DONOTdisableorbypassautomaticalarm/shutoffcircuits.Theyareprovidedto
preventpersonalinjuryandenginedamage.

OnlyproperlytrainedandauthorizedMACKServiceTechniciansmayattemptrepairs
onthisvehicle.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU31

EngineStarting

DONOTstarttheengineormoveanyofthecontrolsordisengagetheparkingbrake
ifthewarningtagDONOTOPERATEisattachedtotheignitionkeyorlocatedon
thedash.Checkwiththepersonwhoattachedthetagbeforestarting.

Makesurenooneisworkingonorclosetotheengineorcomponentsdrivenbythe
enginebeforestartingit.Alwaysmakeaninspectionoftheenginebeforeandafter
starting.

Dieselengineexhaustcontainsproductsofcombustionwhichmaybeharmfultoyour
health.Alwaysstartandoperatetheengineinawell-ventilatedarea,andifinan
enclosedarea,venttheexhausttotheoutside.

Starttheengineonlyfromthedriverseatinthecab.Neverstarttheengineby
shortingacrossthestartermotorterminalsorbatteriestostarttheengineasthiscould
bypasstheengineneutral-startsystemaswellasdamagetheelectricalandelectronic
system.Alwaysstarttheengineaccordingtotherequiredenginestartingprocedure
describedinthisoperatorsmanualtopreventmajorenginecomponentdamageand
personalinjury.

32Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

ElectricSystemDamagePrevention

ElectricandElectronicSystems

WARNING

Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskof
injuryduetocontactwithsulfuricacidoranexplosion.

W0001526

Neverdisconnectanychargingunitcircuitorbatterycircuitcablefromthebattery
whenthechargingunitisoperating.Asparkcancausetheammablevapormixture
ofhydrogenandoxygentoexplode.

Topreventpotentialsparksfromignitingcombustiblegasesproducedbysome
batteries,attachthenegative(-)terminallastwhenhookingupandremovethe
negativeterminalrstaftertheenginehasstarted.Checkregularlyaroundtheengine
andenginecompartmentforlooseorfrayedwires.Havealllooseorfrayedelectrical
wirestightened,repairedorreplacedbeforeoperatingthevehicle.

GroundingPractices

Propergroundingforvehicleandengineelectricalandelectronicsystemsisnecessary
forpropervehicleandengineperformanceandreliability.Impropergroundingwill
resultinuncontrolledandunreliableelectricalpaths.

Uncontrolledengineelectricalcircuitpathscanresultindamagetomainbearings,
crankshaftjournalssurfacesandaluminumcomponents.Uncontrolledelectrical
circuitpathscanalsocauseelectricalnoisewhichmaydegradevehicleandradio
performance.

Operatingengineswithouttheengine-to-framegroundstrapinstalledcancause
damagetotheengine.Topreventelectricaldischargedamage,checktomakesure
theengineselectricalsystemhasanengine-to-framegroundstrap.Allground
connectionsshouldbetightandfreeofcorrosion.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU33

ElectronicEngineControlSystem

DANGER

Theengineuseshighvoltagetotheelectronicunitinjectors.
DONOTcomeincontactwiththeunitinjectorterminalswhiletheengineis
running.Anelectricshockcancauseaninvoluntarymusclespasmandcauseloss
ofbalanceandfallsleadingtoseverepersonalinjuryordeath.

W0001522

Tamperingwiththeelectronicsysteminstallationcanbedangerousandcouldresultin
personalinjuryordeathand/orenginedamage.Itisveryimportanttotaketheproper
precautionswiththeelectricalandelectronicsystemwhenchargingthebatteries,
jump-startingorperformingelectricweldingonthevehicle.SeethevehicleOperators
Manualforcorrectprocedures.

Thisengineisequippedwithmonitoringfeaturesthatmaycausereducedpoweror
shutdownundercertainconditions.Thepoweroutput,monitoringandidlingfeatures
canonlybeprogrammedand/orchangedwithelectronicservicetoolsandpasswords.

Certainfeatures,suchaslowoilpressure,highcoolanttemperatureorlowcoolant
levelcouldcausetheenginepowerand/orvehiclespeedtobelimitedandtheengine
mayalsoshutdown.Theshutdownwilltakeapproximately30secondsfromthe
timethewarningfeatureisactivated.SeethevehicleOperatorsManualformore
information.

34Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

ReportingSafetyDefects

USA

TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKInc.
shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefectthatcould
causeavehicleaccident,injuryordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto
NHTSA,U.S.DepartmentofTransportation,W ashington,DC20590,byTTYat1
[phone],orvisittheirwebsiteatwww.nhtsa.dot.gov.

Canada

RefercustomercomplaintstoMACKTrucksCanada,Inc.ortoTransportCanada,
DefectInvestigationsandRecalls.

Canadiancustomerswhowishtoreportasafety-relateddefecttoTransportCanada,
DefectInvestigationsandRecalls,maytelephonethetollfreehotline1(800)
333-0510(withinCanadaonly)orcall1(613)993-9851(fromOttawaregionor
outsideCanada).ContactTransportCanadabymailat:TransportCanada,ASFAD,
PlacedeV illeTowerC,330SparksStreet,OttawaONK1A0N5.

Foradditionalroadsafetyinformation,pleasevisittheRoadSafetywebsiteat:
http://www.tc.gc.ca/roadsafety/menu.htm

Mexico

MACKTrucksdeMexico,S.A.deC.V .shouldbeinformedimmediatelyifyou
believethevehiclehasadefectthatcouldcauseavehicleaccident,injuryordeath.
ContactMACKTrucksdeMexicobycalling:01(800)9094900(withinMexico
only)or011-52-55-50-81-68-50,orbywritingto:MACKTrucksdeMexico,S.A.
deC.V .,Prol.PaseodelaReforma600,1er .Piso121,Col.SantaFePeaBlanca,
C.P.01210,Mexico,D.F.

Note:ForRoadsideassistanceinformationsee“CUSTOMERSERVICE”,page158.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU35

GeneralEngineInformation

EngineOverview,MP7andMP8LeftSideView

MP8EngineShown,MP7EngineSimilar

1.BreatherTube9.FuelFilter

2.IntakeManifold10.Hand-PrimingPump

3.AirCompressor11.CrankcaseVentilator

4.PowerSteeringPump12.Alternator

5.FuelPump

6.EngineControlModule(ECM)14.Alternator/ACCompressorBelt

7.FuelFilter15.Fan/CoolantPumpBelt

8.Fuel/WaterSeparator16.EGRMixingChamber

13.ACCompressor

W2006034

36Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

EngineOverview,MP7andMP8RightSideView

MP8EngineShown,MP7EngineSimilar

17.ExhaustManifold24.V enturiPipe

18.V alveCover25.OilFilters

19.IntakeAirHeater(IAH)optional26.OilPan

20.Thermostat27.EGRCooler

21.BeltTensioner28.Turbocharger

22.CoolantPump

23.CoolantFilter30.EGRV alve

29.StarterMotor

W2006035

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU37

EngineOverview,MP10LeftSideView

1.BreatherTube9.Fuel/WaterSeparator

2.IntakeManifold10.FuelFilter

3.AirCompressor11.Hand-PrimingPump

4.PowerSteeringPump12.Alternator

5.FuelPump

6.CrankcaseV entilator14.Alternator/ACCompressorBelt

7.EngineControlModule(ECM)15.Fan/CoolantPumpBelt

8.FuelFilter16.V enturiPipe

13.ACCompressor

17.EGRMixingChamber

W2006037

38Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

EngineOverview,MP10RightSideView

18.ExhaustManifold24.CoolantFilter

19.V alveCover25.OilFilters

20.IntakeAirHeater(IAH)26.EGRCooler

21.Thermostat27.OilPan

22.BeltTensioner

23.CoolantPump29.Turbocharger

28.StarterMotor

30.EGRV alve

W2006036

ElectricalSystem

Batteries

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU39

WARNING

Batteryposts,terminalsandrelated
accessoriescontainleadandlead
compounds,chemicalsknowntothe
StateofCaliforniatocausecancerand
reproductiveharm.Washhandsafter
handling.

CAUTION

Disconnectingbatterycableswhen
vehicleisequippedwithpowerdoor
lockswillresultinautomaticlocking
ofdoors.

CAUTION

WARNING

Alwaysweareyeprotectionwhen
workingaroundbatteriestoprevent
theriskofinjuryduetocontactwith
sulfuricacidoranexplosion.

Amaintenance-freebatterydoesnotrequiretheadditionofwaterforitsnormal
expectedlife.Typicalfeaturesincludeheavy-dutyconstructionandawrought
lead-calciumgridtoresistvibration,shock,overcharge,heatandthermalrunaway.
Nevertheless,thesebatteriesarevulnerabletotheravagesofcoldweatheroperation
iftotallyignored.

Whenusingapressurewashertoclean
thevehicle,donotdirectthesprayat
electricalcomponentsintheengine
compartmentsuchasthealternator,
starterandcompressors.Waterspray
frompressurewasherscandamage
electricalcomponents.

W0054087

Battery

40Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Besurethatthebatteriesusedinaparticularvehicleareratedforthespecied
ColdCrankingAmperes(CCAs)necessarytoensurereliablecoldweatherstarts.
Thisisimportant,sinceevenwell-maintainedbatterieschilledto18°C(0°F)may
temporarilybecapableofprovidingonly40%oftheirratedcapacityat27°C(80°F).

Keeptheterminalscleantopreventformationofpower-robbingcorrosion.

Inwinter,toavoidfreezingtheelectrolyte,thebatterymustbefullycharged.Afully
dischargedbatterywillfreezesolidat5°C(23°F)andpossiblysustainpermanent
damage.

Beforetheonsetofcoldweather,besuretoprotectthisvitalcomponentbymonitoring
itsconditionaswellasinspectingthechargingandstartingsystems.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU41

BatteryWarmer

Abatterywarmercanbeaddedtoraisethetemperatureofthebatterycoreand
facilitatequickstartingincoldweather.

BatteryCondition

Therstprocedurewhentestingabatteryistocheckforexternaldamagesuch
asacrackedcase,looseorcorrodedterminals,orsignsofexcessivegassingor
overcharging.

Abatterymustbefullychargedbeforealoadtestisperformed.Testthebatterywitha
hydrometertodeterminethelevelofcharge.

Onmaintenance-freebatteriesequippedwithabuilt-inhydrometer(eye),thebattery
conditionisinterpretedasfollows:

W0054088

BatteryCondition

42Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

•GreendotvisibleAnygreenappearanceshouldbeinterpretedasagreendotand

meansthatthebatteryisatorabovea65%stateofchargeandisreadyforuseor
testing.Thisdoesnotautomaticallymeanthatthebatteryisingoodcondition.

•Darkgreendotnotvisible(blackdot)Thisindicatesthatthebatteryisbelowa

65%stateofchargeandmustbechargedbeforetesting.Ablackdotdoesnotmean
thatthebatteryisautomaticallybad.

•ClearorlightyellowThismeansthattheelectrolytelevelisbelowthelevelof

thebuilt-inhydrometer,whichmayhavebeencausedbytippingofthebattery,a
crackedcase,orovercharging.Thisbatteryshouldbereplaced.

Charging

Chargingshouldbeconductedcarefullyundercontrolledconditions.Nevercharge
afrozenbattery .Ifafrozenbatteryissuspected,thawitinawarmareaforseveral
hoursbeforecharging.

Thefollowingchartshowsthenormalchargingtimesnecessarytoreachafullcharge
at26°C(80°F).Incoldertemperatures,thenecessarychargingtimemayincrease.

Open

Circuit

V oltage

12.61.265100%FullCharge

12.41.22575%15

12.21.19050%35

12.01.15525%50

11.81.1200%65

Battery

Spe­cic

Grav-

ity*

Stateof

Charge

*Correctfortemperature.

**Ifcolder,itwilltakelonger.

ChargingTimetoFullChargeat80°F**

at60
amps

min.

min.

min.

min.

at50
amps

at40
amps

20

min.

45

min.

65

min.

85

min.

at30
amps

27

min.

min.

min.

min.

min.

55

min.

85

min.

110

min.

at20
amps

35

min.

75

min.

115

min.

150

min.

at10
amps

48

95

145

195

90

min.

180

min.

280

min.

370

min.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU43

CompletelyDischargedBatteries

Extremelycoldorcompletelydischargedbatteriesmaynotinitiallyshowacharge
sincetheelectrolyteisnearlypurewaterand,therefore,apoorconductor.Asthe
acidlevelintheelectrolyteincreasesduringcharging,thechargingcurrentwillalso
increase.Usethefollowingprocedurewhenchargingacompletelydischargedbattery:

1Measurethevoltageatthebatteryterminals.Ifitisbelow10volts,currentwillbe

verylowandmaynotshowuponmanybatterychargerammeters.

2Setthechargeronthehighsetting.

3Somechargershaveapolarityprotectionfeaturewhichpreventsaccidentalreversal

ofthechargerleads.Acompletelydischargedbatterywillnothaveenoughvoltage
tooverridethisfeature,makingitappearthatthebatterywillnotacceptacharge.
Checkthechargermanufacturersinstructionsonhowtobypassthisfeature.

4Oncethebatterystartstoacceptacharge,thechargingratewillriseveryrapidly.

Carefullymonitortheammetertopreventtoo-highachargingrate.

5Proceedtochargebatteryatone-tenthofitsratedcapacityforone-halfhour.

Example:Forbatteryratedat64(amps-hour),chargeat6.4ampsetting.

Note:Batterieswithverylowvoltage(below11.6volts)orthosethatdonot
initiallyacceptachargearenotnecessarilydefective.Batteriesthathavebeen
dischargedforlongperiodsoftimemaybeheavilysulfatedorhydrated(containing
leadshortsthatcausethebatterytoself-discharge).T oacceptacharge,batteries
witheitheroftheseconditionsmayrequirealongerchargingtimeoraveryhigh
initialcharge.

Usethefollowingcharttodeterminethetimerequiredforthebatterytobegin
acceptingameasurablecharge.(Ifthebatteryhasnotstartedtoacceptachargeafter
thespeciedtime,itshouldbereplaced.)

ChargerV oltage

16.0ormoreUpto4

14.0to15.9Upto8

13.9orless

Hours

Upto16

44Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

LoadTest

Abatterymustbefullychargedbeforeperformingaloadtest.Toload-testabattery
thatisfullycharged,proceedasfollows:

1Connectaloadtesterandvoltmeteracrossthebatteryterminals.

2Applyaloadsothatagureof300ampsisobtainedfor15secondstoremovethe

batterysurfacecharge.

3Wait60secondstoletthebatteryrecoverandthenapplythepropertestload

tothebatterytodetermineitscondition.Togettheproperload,usehalfthe
crankingperformancerating.Readthevoltageafter15seconds.Rememberthat
theminimumvoltagevariesaccordingtotemperature.Consultthefollowingchart
fortheproperspecication.Ifthebatteryvoltagedoesnotfallbelowtheminimum
testvoltageafter15seconds,thebatteryisacceptableforuse.

LoadTestT emperatureCorrection

MinimumV oltage

C

9.62170

9.51660

9.41050

9.3440

9.1130

8.9

8.71210

8.5180

7

Temperature

F

20

ElectricalConnectionProtection

Ifcorrosionisseenatanyexternalring-typeterminalconnections,suchasthoseused
atthestarter,alternator,chassisand/orenginegrounds,etc.,LPSHardCoatCorrosion
Protectantmustbeappliedtotheconnectionafterdisconnecting,cleaningand
reconnectingtheringterminal.Additionally ,LPSHardCoatshouldbeappliedtoany
ring-typeterminalconnectorfollowinganytypeofserviceprocedurewhichinvolved
disconnecting/reconnectingtheringterminals(suchascomponentreplacement,
troubleshooting,serviceandrepair,etc.).

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU45

WiringHarness/CableandConnectorProtection

Tohelpprotectyourvehicle’sexternalhighamperageelectricalcablesand
connectionsfromcorrosionduetotheeffectsofnewersalts(calciumchlorideand
magnesiumchloride)ontheroadways,MACKisofferingacorrosioninhibitorpart
20916273forpurchasethroughthePDC.
MACKrecommendscoatingallhighamperage(positiveandground)exposed
electricalconnectionsataminimumofevery6monthsor,whenevertheconnector
hasbeendisassembled.Thefollowinglistcontainstherecommendedconnectionsthat
shouldbeliberallycoatedwiththecorrosioninhibitor;

•Batteryconnections

•Batterymainshutoffswitchconnections

•Maxiand/orMegafuseconnections

•Allgroundstudconnections

•Electricalpneumaticpass-thruconnections

•Allalternatorconnections

•Allstarterconnections

•Intakepreheaterandpreheaterrelayconnections

•Electricalpowerinverterconnections

Allconnectionsshouldbecleanedandfreeofpreviouslyappliedinhibitors,oil,dirt,
dustorothercontaminantspriortoapplication.Allowtimefortheproducttodry
beforeuse(dryingtimemayvarydependingtemperature,humidity,etc.).

FormoreinformationregardingthiscorrosioninhibitorproducedbyLPSWorldwide,
visittheirwebsiteatwww.lpslabs.com.

46Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Lighting

WARNING

Usingincorrectbulbsorlampsmayresultinfailuresthatcouldleadtoareora
vehicleaccidentcausedbyimproperlighting.

Checkalllightsonthevehicledailyforproperfunction.Replaceburnedoutinserts
andbulbs.Replaceanybrokenorcrackedsideorrearreectors.Headlightsshouldbe
checkedforaimatleastonceperyear.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU47

PrecautionsWhenInstallingElectricalEquipment

Connectingelectricallypoweredorelectricallycontrolledequipmenttoavehicle
maycauseinterferencewithothervehicleelectricalorelectronicequipment(suchas
ABSsystems,RolloverStabilitySystems,etc.).Theamountofinterferencedepends
upontheoperatingfrequencyofanynewsignalsandthedegreetowhichtransient
signalsarecoupledtothevehiclesystem.

Note:Whenevernewelectricalequipmentisinstalled,itistheobligationofthe
installertoensurethatthenewequipmentdoesnotinterferewiththeproperoperation
ofallotherelectricalsystemsonthevehicle.

Ifnewelectricalequipmentisinstalled,avehiclecheckoutprocedureshouldbe
performed.

1Performthecheckoutprocedureunderthefollowingconditions:

•Enginerunning

•Brakesystemairpressureinoperatingrange

•Vehiclestationary

•Brakepedalfullydepressed

2Operatethenewequipmentunderallstarting,runningandsutdownconditions.

3ListenforsignsofairexhaustingfromtheABSmodulatorvalves(whichisan

indicationofaninterferencecondition).

4Correctallinterferenceconditionsbeforeoperatingthevehicle.

Note:Thecenterpinofthestandardseven-pintrailerelectricalconnectorhasbeen
standardizedasthededicatedconnectionforuninterruptedpowerfortrailerABS.This
pinisalwayshotwhenthetractorignitionisturnedon.

DANGER

Sometrailersmanufacturedpriorto
thetrailerABSregulationsmayuse
thecenterpintopowercertaintrailer
auxiliaryequipment.Thepossibility
existsthatthisauxiliaryequipmentmay
beunexpectedlyactivatedbythetruck
ortractorelectricalsystem,resultingin
personalinjuryordamagetoequipment.
Cautionmustbeusedwhenconnecting
thetrailerelectricalconnectortoensure
thatpowertothecenterpinwillnot
unintentionallyactivateanytrailer
auxiliaryequipment.

48Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

MACKRoadStabilityAdvantage

TheMACKRoadStabilityAdvantage(RSA)isanavailableoptiononcertain
MACKhighwaytractorsandstraighttrucks.TheRSAsystem,whichisbasedonthe
BendixABS-6AdvancedwithESP(ElectronicStabilityProgram)System,aidsthe
operatorinmaintainingcontrolofthevehicleduringjackknifeorrollovereventsby
applyingselectbrakesandreducingenginepowerasrequiredbythespecicsituation.
Thissystemisintegralwiththeanti-lockbrakesystemandusesthestandardABS
components(suchaswheelspeedsensorsandmodulatorvalves).Additionally ,a
steeringanglesensorandayawrate/lateralaccelerationsensorpackageprovides
informationconcerningvehiclemovementtotheelectroniccontrolunit.

Beforedeliverytotheenduser,aparametersettunedforthespecicvehicleandthe
VINforthechassisareloadedintotheABSelectroniccontrolunit.Thisensures
optimalperformanceoftheMACKRSAsystemforthespecicvehicle.

AlterationsandmodicationstoanRSA-equippedvehicle,suchaswheelbase
changes(eitherlengtheningorshortening),theadditionofanauxiliaryliftaxleorthe
removalofafactory-installedliftaxle,ormajorbodychanges,suchasconversionofa
tractortoatruckoranaxle,suspensionorsteeringsystemcomponentmodication,
areNOTallowed,asthesechangeswilladverselyaffectperformanceoftheroad
stabilitysystem.Shouldsuchchangesbeunavoidable,thesystemmustbedisabledby
havingaqualiedtechnicianreplacetheBendixAdvancedEC-60(ABScontrolunit
withESP)withaBendixPremiumEC-60ECU(ABScontrolunitwithoutESP).

DANGER

FailuretodisabletheRSAsystemona
vehiclethathasbeenmodiedoraltered
willresultinseriousvehiclebraking
andperformanceissues,including
unnecessarysysteminterventions.
Theseinterventionscouldleadtoaloss
ofvehiclecontrol.
Inadditiontodisablingthesystem,any
cablabels,suchaswarningandcaution
labelsrelatingtotheBendixABS-6
AdvancedwithESPsystemlocatedon
thesunvisormustberemoved,and
notationsmustbemadeintheoperators
manualssothatthevehicleoperatorhas
aclearunderstandingastowhichABS
optionsareinstalledonthevehicle.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU49

Thelocationoftheyawrate/lateralaccelerationsensormustnotbealtered.

Aftermarketsteeringwheelsmustnotbeused.OnlyOEM-suppliedreplacement
steeringwheelsshouldbeused.Duringanyprocedurethatinvolvesremovaland
reinstallationorreplacementoftheOEMsteeringwheel,caremustbeusednotto
crushordamagethesteeringanglesensorwhichismountedonthesteeringcolumn.

IncreasingsteeringanglebeyondmaximumisNOTpermitted.However,steering
anglesmaybeincreasedtothemaximumfactorysettingsifrequired.Refertothe
applicablesteeringsystemservicemanualfordetailedinformation.

Thesteeringanglesensormustberecalibratedfollowinganyadjustmentsorchanges
tothesteeringsystem.

Changingsteeraxleand/ordriveaxletrackwidthispermissible.

Changingfrontorrearaxlebrakedrumstodrumshavingadifferentangethickness
ispermissible.

TheABSwithESPECUrequiresapreciserollingcircumferenceratiobetweenthe
frontsteeraxleandthereardriveaxlesforoptimumperformanceofthesystem.
Forthisreason,thesystemcontinuouslycalculatesthepreciseratioandstoresthe
informationintheECUmemory .

CAUTION

EffectivenessoftheRSAsystemrelies
ontheaccuracyofthereportedvehicle
speed.Ifmajorchangestotiresizesare
made,suchthatchangestothevehicle
speedometer/odometersettingsare
required,theABSwithESPECUmust
bereprogrammedwiththenewvalues
byaqualiedtechnician.

50Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

EngineStorage

EngineStorage

Ifthevehiclemustbeparkedforaperiod(morethan30days),protectitasfollows:

1Draintheengineoil.

2Filluptotheproperlevelwithoiloftherecommendedqualityandviscosity.

3Fillupthefueltankswiththerecommendedgradeoffuel.

4Runtheenginefortwominutesaround1000rpm.Shuttheenginedown.DO

NOTdraintheoilafterthisrun.

5Checkthecoolantforproperlevelsofantifreezeandinhibitor(SCA)protection.

Serviceasnecessary.

6Sealallengineopeningsusingprotectivecovers.

Toreturntoserviceanenginepreservedinthismanner,removepreviouslyinstalled
protectivecovers.Checkalluidlevelsandifnecessaryreplaceengineoil
contaminatedbycondensation.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU51

MaintenanceandService

MaintenanceHazards

DANGER

Beforeworkingonorinspectingavehicle,settheparkingbrakes,placethe
transmissioninneutralandchockthewheels.Failuretodosocanresultin
unexpectedvehiclemovementandcancauseseriouspersonalinjuryordeath.

DANGER

DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto
personalinjuryordeath,ormakingyourvehicleunsafe.

Note:Readallsafetyinformationbeforeworkingonthevehicle.

EngineComponents,ServiceSchedules

Component

FuelFilter
(MP7,MP8and
MP10)

WaterSeparator
(MP7,MP8and
MP10)

AirFilterEP A
2010

AirFilterEuro4ChangeAtmaximumrestrictionasindicated

Coolant
(MP7,MP8and
MP10)

Coolant,
ExtendedLife
(ELC)
(MP7,MP8and
MP10)

OperationKm(Miles)/MaximumMonths/Hours

ChangeEachoilchange*

FilterchangeEachoilchange*

Change160000(100,000)or12months,

whichevercomesrst

ongauge,or12months

Change500000(300,000)6000or24months,

whichevercomesrst

Change1000000(600,000)or48months,

whichevercomesrst

52Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Component

CoolantFilter
(MP7,MP8and
MP10)

CoolantFilter,
ExtendedLife
(ELC)
(MP7,MP8and
MP10)

Coolant
ConditionerEuro
4

Valves/Injectors
(MP7and
MP8)**

Valves/Injectors
(MP7andMP8)
**

Valves/Injectors
(MP10)**

Valves/Injectors
(MP10)**

DriveBeltsCXU,
CHUandTD
Euro4(Highway)

DriveBelts
GU,LEUand
MRUEuro4
(V ocational)

Catalyzed
DPFFilter(If
equipped)
(MP7,MP8and
MP10)

Aftertreatment
Doser(If
equipped)
(MP7,MP8and
MP10)

OperationKm(Miles)/MaximumMonths/Hours

Change80000(50,000)or6months,

whichevercomesrst

Change240000(150,000)or12months,

whichevercomesrst
(MP7,MP8andMP10)

ChangeTraditionalcoolantsrequiring

SupplementalCoolantAdditive
(SCA)
80000(50,000)or6months

InitialAdjust

Adjust

InitialAdjust

Adjust

Change500000(300,000)or36months,

Change240000(150,000)or12months,

Change240000(150,000)or4,500hours,

Clean240000(150,000)or4,500hours,

200000(125,000)or12months,
whichevercomesrst

400000(250,000)or24months,
whichevercomesrst

100000(60,000)or6months,
whichevercomesrst

200000(125,000)or12months,
whichevercomesrst

whichevercomesrst

whichevercomesrst

whichevercomesrst

whichevercomesrst

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU53

Component

DieselExhaust
Fluid(DEF)
PumpFilter
(MP7,MP8and
MP10)

DieselExhaust
Fluid(DEF)Tank
FillerNeckFilter
Cleaning
(MP7,MP8and
MP10)

*Undercertainconditions(forexample,irregularfuelquality),thefuel/water
separatorltersmayrequiremorefrequentreplacement.

**Valvesmustbeadjustedwhenevertherockershafthasbeenremovedand
reinstalledforanyreason.

OperationKm(Miles)/MaximumMonths/Hours

ChangeFirstChange;161000(100,000)or

3200hours,whichevercomesrst
241000(150,000)or4800hoursor
three(3)years,whichevercomesrst

Clean280000(175,000)or12months,

whichevercomesrst

54Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

CoolingSystem

GeneralCoolantInformation

DANGER

Coolantistoxic;riskofpoisoning.DONOTdrinkcoolant.Useproperhand
protectionwhenhandling.Keepcoolantoutofreachofchildrenandanimals.
Failuretofollowtheseprecautionscancauseseriousillnessordeath.

WARNING

DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfrom
theenginecompartment.Waituntilsteamorcoolantcannotbeseenorheardbefore
raisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.
Also,DONOTremovethecapwhiletheengineandradiatorarestillhot.Scalding
uidandsteammaybeblownoutunderpressureifthecapistakenofftoosoon
andcancausepersonalinjury.

WARNING

Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesor
electricalcomponentscancauseare.Cleanupcoolantspillsimmediately.

CAUTION

MACKInc.doesnotrecommendusingplainwaterinthecoolingsystem.W ater
aloneiscorrosiveatengineoperatingtemperaturesanddoesnotprovideadequate
boilingprotection.Theenginemaydevelopcorrosionandcavitationproblemsin
theengineandradiator,andtheboilingpointofthecoolantisloweredcompared
toaproperantifreezeandwatermixture.FailuretofollowMACKInc.cooling
systemcare/maintenancerecommendationscanrenderthewarrantyinvalid.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU55

Thecoolingsystemplaysanimportantroleinoverallengineperformancebykeeping
theenginewithinthenormaloperatingtemperaturerangehotenoughforefcient
combustion,andcoolenoughtopreventenginedamagecausedbyoverheating.
Goodpreventivemaintenancepractices,alongwithmonitoringcoolingsystem
performance,goalongwayinpreventingenginedamagethatcouldresultfrom
coolingsystemproblems.Themaintenanceitemsandtestsoutlinedinthissection
shouldbeperformedattheintervalsspeciedtoensureoptimumperformancefrom
thecoolingsystem.

SurgeTankCap

MACKconventionalmodels(CXU,CHU,GUandTD)utilizeacoolantsurgetank
mountedontopoftheradiator.Thesurgetankhasallcaplocatedonthetop
right-handsideofthetank,andapressurecapratedat16lb.whichincorporates
anoverowtubelocatedontheleft-handsideofthetank.Checkthecoolantlevel
regularly,makingsurethecoolantlevelisbetweentheCOLDMINandCOLD
MAXlinesonthebackofthetank.AteachCandDinspectioninterval,inspectthe
rubbergasketsoneachofthecaps.Replacethecap(s)ifthegasketsshowevidence
ofdamagewhichcouldaffectsealing.

WARNING

DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystemto
coolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseand
waitforthepressureinthesystemtodissipate.Afterthepressurehasdissipated,
completelyremovethecap.

W0054042

SurgeTankConventionalModels

1.PressureCap

2.FillCap

56Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

MACKlowcabforwardmodels(MRU,LEU)utilizeasurgetankwhichislocatedon
theleft-handsideofthechassis,mountedonastanchiontotherearofthecab.This
surgetankutilizesastandardradiatorpressurecap.Checkthecoolantlevelregularly,
makingsurethecoolantisvisibleinthesightglasslocatedonthesideofthetank.
AteachCandDinspectioninterval,removetheradiatorcapandinspectthegasket
foranydefectsthatwouldaffectsealing.Also,pressure-testthecapusingasuitable
coolingsystemandradiatorcaptester.Surgetankcappressurespecicationsareas
follows:

•MP7Engines(MRUandLEUModels)16-lb.pressurecap

•MP8Engines(MRUModelsonly)16-lb.pressurecap

WARNING

DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystem
tocoolsufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseto
therststop,andthenwaitforthepressureinthesystemtodissipate.Afterthe
pressurehasdissipated,completelyremovethecap.

Themainpurposeofcoolantistotransportheatfromthehotpartsoftheenginetothe
radiatorandtoprotectthecoolingsystemfromcorrosion.

Inadditiontothis,thecoolantmust:

•Protectagainstpittingandcavitationerosiondamageofthewaterpumpand

cylinderliners.

•Protectagainstfreezingandboiling.

•Preventformationofscale,sludgedepositsandclogging.

•Beharmlesstopolymermaterialsandsealsinthecoolingsystem.

•Maintainitsliquidpropertiesincoldclimates.

Manyenginefailurescanbetracedbacktoaprobleminthecoolingsystem.Ifthe
coolantlevelisallowedtogobelowthebottomofthetank,thereistheriskofthe
engineshuttingdown.Seetheoperatorsmanualformoreinformationonthewarning
functions.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU57

Note:AlwaysdisposeofcoolantaccordingtoFederalorlocalregulations.T akeall
usedcoolanttoarecyclingorwastecollectioncenter.

Coolantmixtureconsistingofanantifreezesolutioninwatershouldbeused
year-roundtoprovidefreezeandboil-overprotectionaswellasprovidingastable
environmentforsealsandhoses.

Note:DONOTuseantifreezeformulatedforautomobilegasolineengines.These
haveaveryhighsilicatecontentthatwillclogtheradiatorandleaveunwanted
depositsintheengine.

CoolantSystemCapacities

CAUTION

Capacitiesmayvaryduetohosesand
sizeofradiator,aswellasaccessory
coolingequipment.Afterrunning
theengineuntilnormaloperating
temperatureisreached,checkthe
coolantlevelandaddcoolantasneeded.

UsethechartshowninconjunctionwiththeEthylene-GlycolandPropylene-Glycol
ProtectionChartsinthissectiontodeterminetheamountofantifreezeneededto
protectyourvehicle.

58Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Chassis

Model

CXU

CHU

TD7

GU7

GU8

MRU

LEU***MP7Automatictransmissionwithout

*Coolantcapacitieslistedareforchassisequippedwithmanualtransmissions.
Forautomatictransmissions,add9.5liters(10qts).
**AllisonautomatictransmissionisnotanavailableoptionforMRUmodels
equippedwithanMP8engine.
***LEUmodelsarenotavailablewithamanualtransmission.

MP7*
MP8*

MP7*
MP8*

MP10*53(56)

MP7*
MP8*

MP7*
MP8*

MP7Manualtransmissionwithout
auxiliarycoolingpackage
MP7Manualtransmissionwithauxiliary
coolingpackage
MP7Automatictransmissionwithout
auxiliarycoolingpackage
MP7Automatictransmissionwithauxiliary
coolingpackage
MP8**

auxiliarycoolingpackage
MP7Automatictransmissionwithauxiliary
coolingpackage

EngineModelCoolantCapacityin

52(55)
54(57)

52(55)
54(57)

52(55)
54(57)

52(55)
54(57)

39(41)
48(51)
48(51)
58(61)
52(55)

48(51)
58(61)

Liters(Quarts)

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU59

Usethefollowingantifreezeprotectionchartstodeterminethepercentageof
antifreezeneededtoachievespecicprotectionlevelsforvariouscoolantsystems.

Ethylene-GlycolProtectionChart

EthyleneGlycolAmbientAirTemperature

40%

50%

60%

Propylene-GlycolProtectionChart

PropyleneGlycolAmbientAirTemperature

40%

50%

60%

Awellfunctioningandmaintainedcoolingsystemisasimportanttotheengineas
performingregularoilchangesorusinggoodfuel.T ogetthebestresultusequality
productsandservicethesystematthecorrectintervals.Pleasereadthissection
carefully.

24°C(12°F)

37°C(34°F)

52°C(62°F)

21°C(6°F)

33°C(27°F)

49°C(56°F)

Keeptheradiator(includingchargeaircooler)andthefrontalareafreefrombugs,
dirt,leaves,etc.(see“CleaningChargeAirCoolerandRadiatorPackage”,page
107forcleaninginformation).

Checkthecoolantlevelinthetankregularly.Fillthetankasnecessarywiththe
correctcoolant.

60Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Inspectionofthewholecoolingsystemisimportant.Checkforswollenordeteriorated
heaterandradiatorhoses,loosehoseclampsandconnections,andradiatorleaks.

DANGER

DONOTworknearthefanwiththeenginerunning.Theenginefancanengageat
anytimewithoutwarning.Anyonenearthefanwhenitturnsoncouldbeseriously
injured.Beforeturningontheignition,besurethatnooneisnearthefan.

CAUTION

Neveraddcoolanttoahotoroverheatedengine.Enginedamagecanresult.Allow
theenginetocoolrst.

Additives

Additiveshelppreventrust,scaleandmineraldepositsfromforming.Additivesalso
protectmetalsfromcorrosion,preventwaterpumpandcylinderlinercavitationand
containanti-foamingagents.Additivesaredepletedduringnormalengineoperation
andneedtobereplaced.Fornon-extendedlifecoolantmixture,thismeansthe
additionofSupplementalCoolantAdditives(SCA)atanytimetheadditivegoes
belowtherecommendedlevel.Forextendedlifecoolantmixture,thismeansan
extenderpackageaddedhalfwaythroughthecoolantlifetime.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU61

RegularCoolantChangeInterval

CoolantSCAlevelmustbetestedatleasttwiceperyearorwhenevercoolantloss
occurs.Formaximumcoolantsystemefciency ,testthesystemateveryengineoil
changeinterval,every1,000hoursorevery6months(whichevercomesrst).For
properSCAlevels,consultServiceManual.

RegularCoolantFilterChangeIntervals

WARNING

Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids
cancauseseriousburns.

Thechargedcoolantltercontains8unitsofSCAthatarereleasedslowlyovertime
tomaintaintherecommendedlevelduringoperation.Consultengineservicemanual
forproperSCAlevelandchangeintervals.

62Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

ExtendedLifeCoolantChangeInterval

CAUTION

Extendedlifecoolantwilltestasoutofadditives(SCA),butSCAshouldnotbe
added.ShortenedenginelifemaybetheresultofaddingSCA.

Note:DONOTaddsupplementcoolantadditives(SCA)toextendedlifecoolant.

Shouldtheextendedlifecoolantsystembecomecontaminatedwithregularcoolant
exceeding10%ofthesystemstotalcapacityorifSCAisaddedtoextendedlife
coolant,drainthesystemandrellwithnewextendedlifecoolantorregularcoolant.

ExtendedLiftCoolantFilterChangeInterval

WARNING

Hotengine.Keepclearofallhotenginepartsanduids.Ahotengineanduids
cancauseseriousburns.

CAUTION

DONOTusealterthatcontainsSCA.Damagetocomponentscanresult.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU63

FuelSystem

FuelSafetyReminders

DANGER

Adieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritis
fromtheinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedto
ushouttheaircleanerelement,theenginemayoverspeedduringstart-up.Engine
damage,severepersonalinjuryordeathfromburnsorexplosionmayoccur.

DANGER

DONOTmixgasolineoralcoholwithdieseloilfuel.Thismixturecancausean
explosionandresultinseverepersonalinjuryordeath.

DANGER

DONOTremovethefueltankcapnearanopename.Dieselfumesare
combustibleandcancauseanexplosionorreresultinginseverepersonalinjury
ordeath.

WARNING

Ifafuelleakisdetected,stoptheengineimmediately.Thevaporsfromhotfuelare
highlyammablewhichmayresultinare.

WARNING

DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcause
orfeedare.Emptyorfull,theypresentahazardthatmayleadtoburnsinthe
eventofare.

64Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

DieselFuelSpecication

Quality

CAUTION

Dieselenginesfor2007andlatermodelyearvehiclesaredesignedtooperate
onlywithUltraLowSulfurDiesel(ULSD)fuel.UseoffuelotherthanULSD
willreducetheefciencyanddurabilityoftheengine,permanentlydamagethe
advancedemissioncontrolsystems,reducefueleconomyandpossiblypreventthe
enginefromrunningatall.Manufacturerswarrantiesarelikelytoberenderedvoid
byusageofimproperorincorrectfuel,andusageoffuelsotherthanULSDfuelin
diesel-poweredvehiclesisillegalandpunishablewithcivilpenalties.Useoffuel
additivestocompensateforthelowersulfurcontentisNOTrecommendedby
MACKInc.

Theproperselectionoffuelisessentialforgoodeconomy,performanceandengine
life.No.2DULSDshouldbeusedwhenclimaticconditionspermit.No.1DULSD
canbeusedduringcoldweatherconditions.BlendsofNo.1DandNo.2DULSD
fuelscanbeusedtosuitvariousclimaticconditions.

Note:Theuseoflighterfuels(gradeNo.1-D)canreducefueleconomy.

Note:Euro4Engines

UltraLowSulfurDiesel(ULSD)fuelwithamaximumsulfurcontentof15ppmis
requiredtomeetemissioncerticationforEuro4emissionengines.Usingapproved
dieselfuelwithamaximumsulfurcontentof500ppminEuro4emissionengines
willmeetallreliabilitystandards.

Thefuelsusedmustbeclean,completelydistilled,stableandnon-corrosive.Always
trytokeepthefueltankfull.DONOTputalcoholintothefueltank.Fillthetank
aftercompletingdrivingfortheday.

FuelSulfurContent

Fuelsoldforuseindiesel-poweredenginesfor2007andlatermodelyearvehicles
mayonlycontainamaximumsulfurcontentof0.0015%byweight.Thiswasdoneto
reduceparticleemissionsintheexhaust.

Note:Theuseofultra-lowsulfurdieselfueldoesnotpermitextensionofengine
oilchangeintervalsoroillterchanges.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU65

CetaneNumber

Directinjecteddieselenginesrequireaminimumcetanenumberof43undernormal
startingconditions.Fuelwithahighercetanevaluemayberequiredforhigh-altitude
orcold-weatheroperation.

Filtration

Fuelshouldbecleanandfreeofcontamination.Cleanfuelsshouldhavenomorethan

0.05%ofsedimentandwater.

FuelAdditives

Fueladditivesaregenerallynotrecommendedorneededforfuelslistedearlier.
Cetaneimproverscanbeusedasnecessary.Biocidesmaybeneededtoeliminate
microorganismgrowthinstoragetanks.Incoldconditions,treatmentforwaterin
thevehicletanksmayalsobenecessary.

Consultyourfuelsupplierabouttheuseofadditivestopreventincompatibilityamong
additivesalreadyinthefuelandtheadditivestobeused.

SupplementalFuelEnhancers

CAUTION

Supplementaladditivesarenotrecommendedbecauseofahighriskofinjection
systemproblemsorenginedamage.

Therearemanyaftermarketproductsavailabletodaywhichareintendedtobeadded
bythecustomer .Theygenerallyincreaseoperatingcostwithoutprovidingbenets.
Includedareavarietyofindependentlymarketedproductswhichclaimtobe:

•Cetaneimprovers

•Emissioncontroladditives

•Detergents

•Combustionimprovers

•Smokesuppressants

•Coldweatherowimprovers

Note:Repairexpensesresultingfrommalfunctionsinthefuelsystemorwithengine
componentswhenfuelenhancershavebeenusedarenotcoveredunderwarranty.

66Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Somefueladditivescanbeusedtoprovidetemporaryrelief,buttheydonotreplace
goodfuelhandlingpractices.Theseproductscanbeused:

•IsopropylAlcoholUse1/2literper450liters(1pintper125gallons)offuelfor

winterfreeze-upprotection.

•BiocideFortreatmentofmicrobegrowthorblackslime.Followmanufacturers

instructionfortreatment.

ProhibitedAdditives

WARNING

Theadditionofgasolinetodieselfuelwillcreateaseriousrehazard.Serious
personalinjurycanresult.

ThefollowingadditivesarespecicallyNOTallowedandmustNOTbemixed
inwiththevehicledieselfuel:

•GasolineAddinggasolinetodieselfuelwillreducethecetanenumberandincrease

combustiontemperature.Ifatankcontainsadieselfuel/gasolinemixture,itshould
bedrainedandcleanedassoonaspossible.

•UsedlubricatingoilMACKInc.doesnotrecommendtheuseofanytypeofused

lubricatingoilasanextenderinthedieselfuel.Usedlubricationoilcontains
solidsandacidsfromthecombustionprocessthatcanseverelycorrodepartsof
theinjectionsystem,resultinginreducedpowerandhighermaintenancecost
overtime.

AlternativeFuels

Alternativefuelscanbeofseveraldifferenttypes.Therearevegetablebasedfuels,
aviationfuelandrecycledpetroleumbasedfuelsthatareusedincombustionengines.
Theseareingeneralnotcompatiblewithmodernheavy-dutyover-the-roaddiesel
engines.

Theuseofunauthorizedfuelsmaycompromisethelevelsofpollutantsintheexhaust
tothepointwheretheenginedoesnotmeettheemissionrequirements.Thiswould
makethevehicleillegaltodriveonpublicroads.DONOTuseanykindofalternative
fuelunlessspecicallyauthorizedbyMACKInc.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU67

BioDiesel

TheonlyBioDieselFuelapprovedbyMACKInc.foruseinEPA2010MACK
EnginesisSoyMethylEster(SMEorSOME)inblendsuptoB5Concentration
(5%blend).

Note:Althoughhigherconcentrationsareavailable,concentrationuptoB5
(maximum)aretheonlyblendscurrentlyapprovedbyMACKInc.

FuelStorage

Iffuelisstoredonsite:

•Keepstoragetankcoveredtopreventwaterentry.

•DONOTuseatankmadeofgalvanizedmetaloranygalvanizedpipingfordiesel

oilstorage.Dieselwillreactwiththezinc,formingsolidsthatcanclogfuellters
andcauseenginedamage.

•Fuelstoredforalongtimemayoxidizeandformsolids,causinglteringproblems.

•Keeptheareaaroundthellcapclean.Tiltthetankslightlytowardthedrainplug

areasowaterandsedimentcanbeeasilydrained.

Generally,fuelcontaminationoccursastheresultofimproperfuelhandling.Themost
commontypesofcontaminationarewater,dirtandmicrobialgrowth(blackslime).
Theformationofvarnishesandgumsresultingfrompoorfuelstabilityorlongstorage
(stalefuel)alsoaffectsfuelquality.Thebesttreatmentforcontaminationisprevention
bymaintainingacleanstoragesystemandchoosingareputablefuelsupplier.

68Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

FuelFilters

Aprimaryfuelltercanbelocatedontheengineorremotemountedontheframe
rail.Thislterconsistsofaltercartridge,awaterseparationbowlandmayhavea
fuelheaterbuiltin.

Thesecondaryfuellterislocatedonthelefthandside,belowtheengineelectronic
controlunit(EECU).Thelterisaspin-onlter.

MACKMPenginesutilizeaspin-onprimaryandsecondaryfuellters.Bothlters
arelocatedontheright-handsideoftheengine.

W0054019

FuelFiltersMACKMPEngine

1.SecondaryFuelFilter2.PrimaryFuelFilter

TheprimaryfuellteronMACKMPenginesincorporatesaplasticwaterseparator
bowl.Additionally,theplasticbowlincludesawater-in-fuelsensor.Awarninglamp
ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Referto
Fuel/WaterSeparatorsection.

Note:Thereareoptionalfuelltersystems(suchasDavco,Conmet,etc.)available
forMACKMPengines.Thesefuelltersystemsuseasingleremote-mounted
lter,eliminatingthespin-onprimaryandsecondarylters.Forserviceinformation
concerningtheselters,refertothespecicfuelltermanufacturersserviceliterature.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU69

PrimaryFuelFilterReplacementProcedures
MACKMPEngines

Ateachspeciedoilandlterchangeinterval,changetheprimaryfuellteras
follows:

MACKMPPrimaryFuelFilter

1.PrimaryFilter

2.WaterSeparatorBowl

W0054023

3.W ater-in-FuelSensorHarness

4.DrainAssembly

70Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

1Thoroughlywashtheareaaroundthefuellterandmountingadaptermatingarea

withasuitablesolventandblowdrywithcompressedair.

2Disconnectthewater-in-fuelsensorharnessconnectorfromtheplasticwater

separatorbowl.

3UsingtoolJ24783,removetheprimarylter.

4Whileholdingthelteraboveasuitablecontainer,openthedrainvalveonthe

plasticwaterseparatorbowlandallowthefuelinthebowltodrain.Disposeof
thedrainedfuelinanenvironmentallysafemanner.

5Unscrewtheplasticseparatorbowlfromthebottomofthespin-onprimarylter

cartridge.

6ApplyathinlmofcleanengineoiltothewaterseparatorbowlO-ringonthe

bottomofthenewprimaryltercartridge.

7Installtheplasticwaterseparatorbowltotheprimaryltercartridge,andtighten

thebowlbyhand1/4to1/2turnafterthebowlcontactstheO-ring.

8Applyathinlmofcleanengineoiltothesealinggasketofthenewltercartridge.

9Primethelterbypouringcleanlterfuelthroughtheseriesofsmallholesatthe

topoftheltertotheinstallationllline.DONOTprimethelterthroughthe
centerhole.Usecaretoavoiddirtenteringthecenterholeofthelter.

10Installthenewlterandtightenanadditional1/2to3/4turnbyhandafterthe

gasketcontactsthebase.

11Reconnectthewater-in-fuelsensorharnessconnector .

12Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel

SystemMACKMPEngines”,page72).

13Starttheengineandcheckforleaks.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU71

SecondaryFuelFilterReplacementProcedures

Ateachspeciedoilandlterchangeinterval,changethesecondaryfuellteras
follows:

Note:Becauseoficebuildupinthefuelsystemorfuelwaxingwhichcanclogfuel
lters,itmaybenecessarytoreducethetimeormileageintervalbetweenfuellter
changesduringextremelycoldweather.

Toinstallanewlter:

1Thoroughlywashtheareaaroundthefuellterandmountingadaptormatingarea

withasuitablesolventandblowdrywithcompressedair.

2UsingtoolJ24783,removetheoldlters.

3Applyathinlmofcleanengineoiltothesealinggasketofthenewlters.

4Primethelterbypouringcleanlteredfuelthroughtheseriesofsmallholesat

thetopofthelter.DONOTprimethelterthroughthecenterhole.Usecareto
avoiddirtenteringthecenterholeofthelter.

5Installthenewltersandtightenanadditional3/4to1turnbyhandafterthe

gasketcontactsthebase.

6Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel

SystemMACKMPEngines”,page72).

7Starttheengineandcheckforleaks.

72Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

PrimingtheFuelSystemMACKMPEngines

OnMACKMPengines,theprimingpumpislocatedontheprimaryfuellter
mountingadapter.Primethefuelsystemasfollows:

DANGER

Beforeworkingonorinspectinga
vehicle,applytheparkingbrakes,place
thetransmissioninneutralandblock
thewheelstopreventthevehiclefrom
moving.Failuretodosocanresult
inunexpectedvehiclemovementand
causeseverepersonalinjuryordeath.

WARNING

DONOTworknearthefanwhilethe
engineisrunning.Theenginefancan
engageatanytimewithoutwarning,
resultinginseriousinjury.Before
turningtheignitionon,makesurethat
nooneisnearthefan.

DANGER

Toavoidpotentialrehazard,donot
serviceanypartofthefuelsystem
whilesmoking,orinthepresenceof
ames,sparksorhotsurfaces.Do
notservicethefuelsystemwhilethe
engineisrunning.Failuretofollow
theseprecautionscanresultinare.To
guardagainstburnsfromdirectcontact
withhotfuel,wearadequateprotective
clothing(faceshield,heavygloves,
apron,etc.)whenworkingonahot
engine.

Note:ThereareNObleednipplesthatmustbeopenedinordertoprimethefuel
system.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU73

1Unlocktheprimerpumphandlebypushingthehandledownwardandthenturning

itcounterclockwise.

W0054026

UnlockingFuelSystemPrimerPumpHandle

2Operatethepumphandleuntilpumpingeffortincreases.

W0054027

PumpingHandPrimerPump

Note:Withafuelsystemthatiscompletelyempty,200ormorestrokesofthe
pumpmaybenecessarytoproperlyprimethesystem.

3Whenthefuelsystemisprimed,locktheprimerpumphandlebypushingitfully

intothehousingandturningitclockwise.

4Starttheengineandrunitat1000rpmforapproximately5minutestopurgeany

remainingairfromthesystem.

Note:Iftheenginedoesnotstartafterperformingtheaboveprimingprocedure,
contactyourlocalMACKdealerforassistance.

74Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Fuel/WaterSeparatorMACKMPEngines

TheprimaryfuellteronMACKMPenginesincludesaplasticwaterseparator
bowlwithanintegralwater-in-fuelsensorandadrainassembly.Awarninglamp
ontheinstrumentpanelilluminateswhenwaterisdetectedinthefuel.Whenthe
lampilluminates,drainthewaterfromtheseparatorbyopeningthedrainvalveand
allowingthewatertodrainfromthebowlintoasuitablecontainer.Whenfuelbegins
todrain,closethevalveandtightento0.655Nm(5lb-in).Disposeofthedrained
water/fuelinanenvironmentallysafemanner.

WaterSeparatorDrainValveMACKMP

Engines

Note:DONOTdrainthewaterseparator
bowlwhiletheengineisrunning.

W0054022

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU75

EngineOil

General

Keeptheengineoilattheproperlevelandchangeitattherecommendedintervals.
Alwaysreplacetheoilltersatthesametimeaswhentheoilischanged.

OilQuality

MACKInc.recognizesengineoilsthatmeetorexceedthestandardsgivenby
AmericanPetroleumInstitute(API)fortheoilclassicationslistedinthismanual.
OnlyoilslicensedtocarrytheAPIsymbolshouldbeused.Lubricantsmeeting
APIstandardshaveprovidedmaximumenginelifewhenusedtogetherwiththe
recommendedoilandoillterchangeintervals.

EO-OPremiumPlus(orVDS-4)dieselengineoilismandatoryforuseinall2010
emissioncompliantMACKengines.Chassisequippedwitha2010emission
compliantengine,whichcanbeidentiedbythepresenceofaDieselParticulateFilter
(DPF),alsorequiretheuseofUltraLowSulfurDiesel(ULSD)fuel.EO-OPremium
PlusoilsexceedthenewAPIservicecategoryCJ-4.

CAUTION

DONOTaddextraoiladditives.Additivessuchasbreak-inoils,topoils,
graphitizers,andfriction-reducingliquidsarenotnecessaryandcanharmthe
engine.

OilChangeIntervals

Thelengthoftimeanenginecanoperatebeforeanoilchangedependsonthequality
oilused,thetypeoffuelused,fuelconsumption,engineoilconsumption,vehicle
application,levelofdustintheair,andfuelconsumption.Thechangeintervalsgiven
inthismanualaremaximumintervals.Ifthevehicleisoperatinginheavy-duty
operation,dustyoroff-roadconditions,etc.,reducetheintervalsformorefrequentoil
changes.Forthecorrectoilchangeinterval,see“OilCapacityTablesandViscosity
Charts”,page142.

Foradditionalinformationaboutoilchangeintervals,seeyourMACKTruckdealer.

Foracompletelistofapprovedoils,seeyourMACKTruckdealer.

Note:Oilltersshouldalwaysbechangedwhenchangingoil.

76Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

OilFilters

Therearethreeltersontheengine,oneofwhichisabypasslter .Thisshouldbe
changedatthesametimeasthefull-owlter(s).

CAUTION

MACKbrandedoilltersaredesignedtoprovidetheproperlevelofltration
andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent
requirementsmayvoidenginewarranty.

Spin-OnOilFilters

1.Spin-OnOilFilters

W0054029

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU77

SyntheticLubrication

Syntheticoilsareofferedbysomeoilsuppliersasanalternativetothetraditional,
petroleumbasedoilsforengines.TheseoilsmaybeusedinMACKengines,provided
theymeetthequalitylevelsspeciedonthepreviouspages,thatis:bothVDS-4
andEO-OPremiumPlus.

Theuseofsyntheticoilsdoesnotpermittheextensionoftherecommendedoil
changeintervals.Itisthecontaminationrate,i.e.,soot,andthedepletionof
additives,ratherthanbaseoilqualitythatdeterminestheusefulengineoillife
andthereforetheoilchangeintervals.

OilViscosity

Theviscositygradedenesthethicknessoftheoil.Theoilmustbethinenoughat
lowtemperaturesforeasycoldstartsandthickenoughtoprotectathightemperatures.
AnoilisnotfullydeneduntilboththeAPIqualityclassicationandtheviscosity
gradearespecied.

Choosetheviscositygradeforthetypicalambienttemperaturefortheapplication.
Multigradeoilshaveabroadrangethatsuitoperationinchangingtemperature.The
standardoilweightforMACKenginesis10W/30.

MACKInc.recommendstheviscositiesshownintheviscosity/temperaturetable
forMACKengines.

W1000144

78Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

OilAdditives

CAUTION

Extraoiladditivesmustneverbeaddedtoanyengineoilused.Additivessuchas
break-inoils,topoils,graphitizers,andfrictionreducingliquidsarenotnecessary
andmayevenharmtheengine.

Usingoilstothequalitystandardsrecommendedinthismanualmakestheuseof
extraoiladditivesunnecessary ,astheseoilsalreadycontainabalancedtreatment
ofadditives.

OilConsumption

Oncetheengineisstopped,checktheoilleveldaily.Iftheenginehasjustbeen
stoppedanditiswarm,waitapproximatelyveminutestoallowtheoiltodrainback
totheoilpanbeforechecking.Addoilasnecessary.

Note:DONOToverllenginewithoil.

Alldieselenginesaredesignedtoconsumesomeoil,soitisnormaltoaddoil
periodically.Anengineusedinheavy-dutyoperationwillconsumemoreoilthan
oneinnormaloperation.

ToassistyouinmeasuringyouroilusagepleaserefertotheFuelandOilRecordon
“FuelandOilRecord”,page155.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU79

OilChange

WARNING

Ahotengineorengineoilcanbedangerous.Seriousburnscanresultfromcontact
withahotengineoroil.T akeprecautionswhendrainingtheoil.Wearglovesorlet
theenginecooldownbeforedraining.

WARNING

Whendrainingtheoil,usethepropertoolsandkeepawayasfaraspossible.Raise
theelbowsotheforearmisparalleltothegroundtopreventoilrunningdown
thearm,causingburns.

CAUTION

Alwaysdisposeofalllubricants(motoroil,coolant,gearboxoils,etc.)and
ltersaccordingtoFederalorlocalregulations.Usedoildisposedofinnatureor
waterwayscontaminatesourdrinkingwaterandkillswildlife.

CAUTION

Prolongedcontactwithusedengineoilmaybeharmful.Userubbergloveswhen
handlingusedoil.Washskinthoroughlyifitcomesincontactwithusedoil.

Forinformationonthetypeofoilrecommendedforyourengine,see“OilQuality”,
page75and“OilCapacityTablesandViscosityCharts”,page142forquantitiesand
viscosities,orrefertotheenginemanufacturersoperatorsmanual.

Itisimportanttodrainasmuchoilaspossible.Trytochangeoilimmediatelyafter
driving,whentheoiliswarm.Alwaysreplacetheoillterswhenchangingoil.

80Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

OilFiltersChange

WARNING

Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.When
changingoil,wearprotectivegloves.

CAUTION

MACK-brandedoilltersaredesignedtoprovidetheproperlevelofltration
andprotectionforMACKengines.Filtersthatdonotmeetthesamestringent
requirementsmaycauseunsatisfactoryresults.

1Coattheltergasketwithoil.

2Installthelterandturnitbyhanduntilthegasketmakescontactwiththesealing

surface.

3Manuallyturnthelteranadditional3/4toonefullturn.

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU81

CheckingOilLevel

CAUTION

DONOTlettheoillevelfallbelowthemarkingonthedipstick.DONOToverll
sothelevelisabovetheuppermarkingonthedipstick.Thiscouldleadtoexcessive
oiltemperatureand/orpoorcrankcasebreatherperformance.

Ensurethatthevehicleisparkedonlevelgroundbeforecheckingtheoillevel.Wait
veminutesaftershuttingofftheengine,thenproceedwithcheckingoil.

W2056443

82Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

EngineAirFilter

Theaircleanerpreventsdust,dirtandotherharmfulcontaminantsfromentering
theenginethroughtheairintakesystem.Maximumengineprotectioncanonlybe
achievedthroughregularlyscheduledmaintenancepracticesthatincludeperiodicair
intakesysteminspectionsandairlterelementchanges.

Themostefcientmethodofdeterminingairlterelementchangeintervalsisby
regularlycheckingtheairlterrestrictiongauge,whichmayeitherbemounted
directlytotheaircleanercanister,ontheaircleaneroutlettubeorinsidethecab.The
restrictiongaugemeasurestheamountofrestrictionintheairlterelement.Some
chassismayhaveadash-mounteddial-typerestrictiongaugewhichmeasureslter
restrictioninmm/inchesofwater.

Changetheairlterelementinaccordancewiththeproceduresasoutlined,whenthe
restrictiongaugeredsignallocksinfullview,orthedash-mountedgaugeindicates
inletrestrictionasfollows:

MountedGaugeInletRestriction
Indication

EngineMillimeters(Inches)Water/kPa

MP7,MP8andMP10510mm(20)/5kPa

AirFilterRestrictionGauge

W0054007

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU83

Damagetotheairlterelement,suchasholesintheltermedium,willgivean
inaccuraterestrictionreading.Therefore,evenifmaximumrestrictionisnotindicated,
theairlterelementshouldbechangedyearlyorat160000Km(100,000mile)
intervals,whichevercomesrst.

Whenreplacingtheairlterelement,orwhenevertheairinletsystemhasbeen
disassembled,inspecttheinletairductsbetweentheaircleanercanisteroutletandthe
turbochargerinletasfollows:

•Inspecttherubberelbowsforcracks,splittingand/orholes.Rubbercomponents

mustbeexiblesothattheyconformtotheplasticductsandensureatightseal.

•Inspectplasticductsforcracksand/orholes.

•Ensurethatallhoseclampsareproperlyinstalledandtightenedtospecications.

•Makesuretheplasticductsdonotrubagainstanycomponentssuchasair

conditioninghoses,wireharnesses,etc.

Toproperlyinstallanewlterelement:

1Wipetheaircleanerhousingclean.

2Removethelterelement(s).

3Inspectsealingareasfordirttrackswhichwouldindicatethatdusthasleakedpast

theseal.Ifdirttracksarefound,thecausemustbedeterminedandcorrected.

4Thoroughlycleantheinsideoftheaircleanercanisterwithadampclothor

vacuumcleaner.

5Ifequippedwithametalcanister,inspectinsidethecanisterforrust.Ifrustis

present:

1Removetheaircleanercanisterfromthechassis.

2RemovealllooserustwithawirebrushoracoarseScotchBritepad.

3Sandwith180/240gritwetordrysandpaper.

4ThoroughlywashtheareawithPPGDX-440,DX-436,DX-437orequivalent,

waxandgreaseremoverandwipedry.

5PrimeimmediatelywithPPGDEP-351epoxyprimer .

6Reinstalltheaircleanercanister.

6Inspectthesealingareasofthehousingfordamage.Repairorreplaceasnecessary.

7UseMACK-approvedreplacementelementsandgaskets.Makesurethenew

elementsandgasketsarenotdamaged.Besuretousenewgasketseachtimethe
elementischanged.Installthecoverand,dependinguponcoverconguration,
tightenasfollows:

•Aircleanerwithlargewingnutincenterofcoverhand-tightenwingnut.

•Aircleanerwiththreethumbscrewsaroundouteredgeofcoverhand-tighten

thumbscrews.

•Aircleanerwithretainingnutsaroundouteredgeofcovertightenretainingnuts

between11–14Nm(8–10lb-ft).

84Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Note:DONOTattempttocleantheairlterelementwithcompressedair,asthis
coulddamagetheltermediumandpossiblyresultinsevereenginedamage.

ReplacementPartsandFilters

W0053982

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU85

ExhaustAfter-TreatmentSystem

CHU,CXU,GUandTDStandardSystemView

1.SelectiveCatalyticReduction(SCR)
Catalyst

2.AftertreatmentDEFDosingUnit

3.AftertreatmentDieselParticulate
Filter(DPF)

4.AftertreatmentDEFT ank

W2029933

86Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

LEUandMRUStandardSystemView

1.SelectiveCatalyticReduction(SCR)
Catalyst

2.AftertreatmentDEFDosingUnit

3.AftertreatmentDieselParticulate
Filter(DPF)

4.AftertreatmentDEFT ank

W2031562

Operator’sManualVehicleMaintenanceCXU,

CHU,GU,TD,MRUandLEU87

DANGER

TheSCR/DPFshieldshouldnotbe
removedwhilethevehicleisinuse.
Also,onlyremovetheshield,oncethe
vehicleisoutofuseandtheSCR/DPF
issufcientlycooled.Failuretofollow
theseinstructionscanresultinre,
whichcancausecomponentdamage,
personalinjuryordeath.

CheckifthevehicleisequippedwithaDieselParticulateFilter(DPF)oraDPF
andSelectiveCatalyticReductionunit(SCR).Thesecomponentsarepartofthe
overallvehicleemissionscontrolsystem.Innormaloperation,thesecomponentscan
experiencesurfacetemperaturesashighas350°C(662°F).Itisimportanttoverify
thetemperatureatwhichthematerialorsubstancein,orassociatedwith,thebodycan
ignite.Ifitispossibleforthematerialorsubstancetofallorleakfromthebody,take
stepstopreventthemfromcontactingorcollectingontheDPForSCR.Failureto
dosomayresultinre.

Itisimportanttonotethatadditionalshieldingmay ,dependinguponconditionsand
thematerialorsubstance,trapammablesubstancesbetweentheadditionalshield
andtheDPF/SCR.Ifthisconditioncandevelop,advisetheuserofthevehicleto
periodicallychecktoensuretherearenotrappedsubstances.

Note:TheDPF/SCRandassociatedcomponentsarepartofaU.S.EPAand
CaliforniaAirResourcesBoard(CARB)certiedengineemissionssystem.These
componentsmustnotbemoved,alteredormodiedinanyway.T amperingwith
thesesystemsrendertheemissionswarrantyvoidandmayresultinpossible
tamperingchargesbytheEPAorCARB.

CAUTION

TheDieselparticulateltersandtheir
components,cannotbemovedor
alteredfromtheOEMinstallationin
anyfashion.Anyalterationsmaycause
componentdamageandisprohibitedby
thelaw.

88Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU

Newstringentstandardsforexhaustemissioncontrolbeginwiththe2010modelyear.
TheDieselParticulateFilter(DPF)systemhasbeendevelopedtoactincombination
withUltraLowSulphurDiesel(ULSD)fueltoreduceparticulateemissionstomeet
therequirement.TheExhaustAfter-TreatmentSystem(EATS)includesalltheengine
andexhaustemissionscontrolcomponentsthatarerequiredtomeetthestringent
2010standard.

ParticulatematterconsistsofsootandashintheexhaustthatengineswithanEGR
systemalone,arenotequippedtohandle.Theparticulatematterisconsidered
acontaminantthatcontainsundesirableelements.TheDPFsystemreducesthe
unwantedelementstoamoreacceptableleveldenedintheregulations.Thereare
multiplemethodsofreducingtheseemissions.MACKhasselectedtouseaDiesel
OxidationCatalyst(DOC)withacatalyzeddieselparticulatelter.Theotheruses
adieselparticulatelterofadifferentkindwithoutaDOCandinitsplaceusesa
combustionchambertoheattheexhaustmixturethuscausingactiveregeneration.

Theparticulatematterremovedfromtheexhaustcollectsontheltersurfaces.T o
avoideventualblockage,whichwouldincreaseexhaustbackpressureandaffectpower
andfueleconomy,theltermustbecleaned.TheDPFiscleanedautomatically.The
sootbreaksdowntosafersubstancesbeforebeingreleasedtotheatmosphere.Some
oftheashremains,buttakesalongtimetoreachthepointwhereashclogsthelter.

Cleaningaltersoitcancontinuetofunctioniscalled“regeneration.”Eithersystem
useshighheattobreakdownthechemicalproperties.Dependingonvehicleusage,
theengineisequippedwithapassiveoractiveregenerationsystem.

In“passiveregeneration,”theexhaustproducesenoughheatcontinuouslytoconvert
thesoot,withapproximately260°C(500°F)beingrequired.Theprocessisslowand
continuesindenitely.Passiveregenerationispossibleonlyinvehicleapplications
wherethetemperatureislikelytoremainatorabovetherequiredtemperaturelevel,
makingactiveregenerationunnecessary .

Duringanactiveregeneration,thetemperatureoftheltermustberaisedto500°C
(932°F).Toproducethistemperature,thesystemusesahydrocarboninjectoror
AftertreatmentFuel(AF)injectortointroducefuelintotheexhauststreamasitleaves
theturbocharger.Thehotexhaustignitesthefuelwhichproducestheregeneration
temperature.WhentheDPFbecomesrestrictedtoaminimumvolume,theengine
ECUstartsthefuelinjectionintotheexhaust.Whentheairowratereturnstonormal
throughtheDPF ,theengineECUturnstheinjectoroff.

WARNING

Priortoeverworkingontheexhaust,
allowtimefortheentireexhaustsystem
tocool.Failuretodosomayresultin
personalinjury .Severeburnscanoccur.

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SelectiveCatalyticReduction(SCR)

SelectiveCatalyticReduction(SCR)isanemissions-reductiontechnologywiththe
abilitytodelivernear-zeroemissionsofnitrogenoxides(NOx),asmog-causing
pollutantandgreenhousegas.SCR’ sperformancehasbeenprovedinmillionsof
milesofreal-worldtruckoperationsinothercountries,aswellasinlong-termeld
testsintheU.S.
SCRreducesNOxemissionstoverylowlevels,whileatthesametimedelivering
excellentfueleconomyandreliability .Thesystemdoesn’tchangethedesignor
operationofthebasicengine.Rather,SCRisanaftertreatmentsystemwhichconverts
NOxintheexhauststreamintoharmlessgases.Moderndieselsalreadyuseexhaust
aftertreatmentsystems,calleddieselparticulatelters,tocontrolemissionsofanother
pollutant,soot(alsoknownasparticulatematterorPM).
SCRworksbyinjectingDieselExhaustFluid(DEF)intotheexhauststeam,afterthe
DPF.DEFisasafe,simplesolutionofwaterandurea.DEFworkswiththeheat
oftheexhaustandacatalysttoconvertNOxintonitrogenandwatervapor-two
harmlessandnaturalcomponentsoftheairwebreathe.Theendresultiscleanerair,
excellentfuelefciencyandareliableemissionscontrolsystemfortoday’smodern
dieselengine.

1.DieselEngine

2.AftertreatmentDEFT ank

3.AftertreatmentDEFPump

4.AftertreatmentDEFDosingUnit

5.AftertreatmentDieselParticulateFilter(DPF)

6.SelectiveCatalyticReduction(SCR)Catalyst

7.AftertreatmentDEFTankGauge

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CAUTION

Donotputdieselfuelinthe
AftertreatmentDEFtank.Diesel
fuel,ifsprayedintothehotexhaust
alongwiththeDEF,couldignite
explosivelycausingareresulting
inpersonalinjuryordamagetothe
exhaustsystem.

TherearetwodifferentcongurationsfortheSCRcatalysts,theyareverticaland
horizontal.ThehorizontalSCRcatalystcomesintwodifferentsizes,oneforthe
MP7/MP8enginesandlargersizefortheMP10engine.TheverticalSCRcatalyst
alsocomesintwodifferentsizes,onefortheMP7/MP8enginesandlargersizeforthe
MP10engine.
TheMACKSCRsystemissimpleandeffective,withfewcomponents.Itconsists
ofaAftertreatmentDEFtankpositionednearthestandarddieseltank,plusa
AftertreatmentDEFpump,AftertreatmentDEFDosingunitandSCRcatalyst.The
advantageofusingDEFisthatitenablestheenginetouselessEGR--andhigher
oxygenlevels--forbettercombustion,whilemeetingtheEP Anear-zeroNOx
emissionsrequirementof0.2g/hp-hrNOx.ByusingDEF,weavoidthedisadvantages
ofincreasingEGRtomassivelevels.Thisresultsinbetterfueleconomyfromyour
MACKengine.

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DieselExhaustFluid(DEF)

DieselExhaustFluid(DEF)isareactantthat’skeytotheSCRprocess.It’sanontoxic,
aqueoussolutionofureaandwater.Ureaisacompoundofnitrogenthatturnsto
ammoniawhenheated.Itisusedinavarietyofindustries,perhapsmostcommonly
asafertilizerinagriculture.Theuidisnotammable,norisitdangerouswhen
handlednormally.However,itishighlycorrosivetometal,particularlycopperand
aluminium.ReadtheseparatesectionconcerningthehandlingofDEFsolution.Only
useapprovedDEFuid.

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DieselExhaustFluid(DEF)Handling

WhenhandlingDEFsolution,itisimportantthatelectricalconnectorstobeconnected
orwellencapsulated.OtherwisethereisariskthattheDEFwillcauseoxidationthat
cannotberemoved.Waterorcompressedairdonothelp,sinceDEFquicklyoxidizes
metal.IfaconnectorcomesintocontactwiththeDEFsolutionitmustbereplaced
immediatelytopreventtheDEFsolutionfromcreepingfurtherintothecopperwiring,
whichtakesplaceataspeedofabout60cm(2.4in)perhour.

CAUTION

Whendetachinghosesandcomponents,
donotspillDEFondisconnected
connectors.IfDEFisspilledona
connector,theconnectormustbe
replacedimmediately

ThingstoknowaboutspilledDieselExhaustFluid(DEF)

Ifureasolutioncomesintocontactwiththeskin,rinsewithplentyofwaterand
removecontaminatedclothing.

Ifureasolutioncomesintocontactwiththeeyesrinseforseveralminutesandcall
formedicalhelpifnecessary.

Ifinhaledbreathefreshairandcallformedicalhelpifnecessary.

DonotallowtheDEFsolutiontocomeintocontactwithotherchemicals.

TheDEFsolutionisnotammable.IftheDEFsolutionisexposedtohigh
temperatures,itbreaksdownintoammoniaandcarbondioxide.

TheDEFsolutionishighlycorrosivetocertainmetals,includingcopperand
aluminium.

IftheDEFsolutionisspilledontothevehicle,wipeofftheexcessandrinsewith
water.SpilledDEFsolutioncanformconcentratedwhitecrystalsonthevehicle.
Rinseoffthesecrystalswithwater.

Note:DonotushDEFspillsintothenormaldrainsystem.

WARNING

DEFspiltontohotcomponentswill
quicklyvaporize.Turnyourfaceaway!

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DieselExhaustFluid(DEF)Consumption

DEFconsumptionisrelatedtofuelconsumption.Ahighwaytruckmaytravel
225-300milesormoreononegallonofDEF.Agaugemuchlikeafuelgaugewill
indicatethelevelofDEFinthetank.ADEFlow-levelwarningwillactivatewhen
DEFislow.IfadriverrunsoutofDEFcompletely ,vehiclepowerwillbereducedto
deratemode.WhentheDEFtankisrelled,theenginewillresumenormalpower.

Note:DEFtanksaresizedforatwotoonefueltoDEFratioinordertomeetEPA
2010requirements.

DieselExhaustFluid(DEF)Availability

DEFwillbeavailablein2.5galloncontainers,55gallondrums,275gallonIBCand
inbulkstorageforeetlocations,truckstopsanddealerships.Allmajortruckstops,
dealersanddistributorswillcarryDEF.FormoreinformationonDEFandavailability
pleasevisitthewebsitewww.Mackscr.com.

94Operator’sManualVehicleMaintenanceCXU,
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DriveBeltReplacementIntervals

Ifbeltssqueakorsqueal,cleanwithhydraulicbrakeuidoranapprovedcleaning
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,exposuretoengineuids,etc.

•AbrasiveMaterialsSmallstones,metalshavings,etc.

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