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MACK MP7, MP8, MP10 Service Manual

Mack
MAINTENANCE AND LUBRICATION
®
MAINTENANCE AND LUBRICATION
MP7, MP8, and MP10 Engines
MAINTENANCE AND LUBRICATION
MP7, MP8, and MP10 Engines
21394653
© Mack Trucks, Inc. 2010 Printed in U.S.A.
21394653
21394653
Contents
Operator’sManualVehicleMaintenanceCXU,CHU,GU,TD,MRUandLEU...1
Foreword..............................................................................................1
WarningLabelInformation........................................................................1
GeneralInformation................................................................................3
InformationFortheOwner........................................................................3
FederalEmissionRequirements..................................................................5
LabelInformation..................................................................................12
SafetyInformation.................................................................................19
ProperMaintenanceProcedure..................................................................19
InjuryPrevention...................................................................................22
EngineDamagePrevention.......................................................................30
ElectricSystemDamagePrevention............................................................32
ReportingSafetyDefects.........................................................................34
GeneralEngineInformation......................................................................35
EngineOverview,MP7andMP8LeftSideView...........................................35
EngineOverview,MP7andMP8RightSideView..........................................36
EngineOverview,MP10LeftSideView......................................................37
EngineOverview,MP10RightSideView....................................................38
ElectricalSystem...................................................................................39
Batteries..............................................................................................39
BatteryW armer.....................................................................................41
BatteryCondition...................................................................................41
Charging..............................................................................................42
LoadTest.............................................................................................44
ElectricalConnectionProtection................................................................44
PrecautionsWhenInstallingElectricalEquipment..........................................47
EngineStorage......................................................................................50
EngineStorage......................................................................................50
MaintenanceandService.........................................................................51
MaintenanceHazards..............................................................................51
EngineComponents,ServiceSchedules.......................................................51
CoolingSystem.....................................................................................54
FuelSystem..........................................................................................63
EngineOil............................................................................................75
EngineAirFilter....................................................................................82
ExhaustAfter-TreatmentSystem................................................................85
DriveBeltReplacementIntervals...............................................................94
AutomaticBeltTensionerMaintenance......................................................102
TurbochargerandChargeAirCooler.........................................................106
PreventiveMaintenanceAirSuspensions...................................................109
SteeringandBrakesMaintenance.............................................................110
Tires,WheelsandHubMaintenance.........................................................114
ChassisMaintenance.............................................................................128
CabMaintenance.................................................................................130
Lubrication.........................................................................................136
OilCapacityTablesandViscosityCharts...................................................142
ServiceCheckList...............................................................................146
PreventiveMaintenance.........................................................................146
ServiceCharts.....................................................................................150
ScheduledServices...............................................................................150
TireRecord........................................................................................154
FuelandOilRecord..............................................................................155
EngineData........................................................................................156
Literature...........................................................................................157
ServiceAssistanceandManuals..............................................................157
CUSTOMERSER VICE........................................................................158
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU1
Foreword
DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperational andsafetyinformationthatisneededbyalldriversandownersofthisvehicle.
Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis operated.Thismanualalsocontainsaconsiderableamountofinformationconcerning thevehicle,suchasvehicleidentication,PreventiveMaintenancerecommendations andalogforyourservicerecords.Pleasekeepthisinthevehicleatalltimes. Informationfromothercomponentmanufacturersissuppliedinseparatemanuals intheOwnersPackage.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)andMACKInc. shouldbeinformedimmediatelyifyoubelievethatthevehiclehasadefectthatcould causeacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)327-4236,bywritingto NHTSA,U.S.DepartmentofTransportation,W ashington,DC20590,byTTYat1 (800)424-9153,orvisittheirwebsiteatwww.nhtsa.dot.gov.
MACKTrucks,Inc.
Greensboro,NCUSA
Ordernumber:PV776-21394653
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedin retrievalsystem,ortransmittedinanyformsbyanymeans,electronic,mechanical, photocopying,recordingorotherwise,withoutthepriorwrittenpermissionofMACK Inc.
WarningLabelInformation
IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadandthat youfullyunderstandeachandeverystepofthedrivingandhandlinginformation inthisOperatorsManual.Becertainthatyoufullyunderstandandfollowall safetywarnings.Itisextremelyimportantthatthisinformationisreadand understoodbeforethevehicleisoperated.
ITISIMPOR TANTTHA TTHEFOLLOWINGINFORMA TIONCONCERNING LABELSBEREAD,UNDERSTOODANDALW AYSFOLLOWED.
2Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
Thefollowingtypesoflabelsareusedthroughoutthismanual:
Note:Anotedenesanoperatingprocedure,practice,condition,etc.,whichis essentialtoproperoperationofthevehicle.
DANGER
Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresult inseriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablack backgroundwithablackborder.
WARNING
Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcould resultinpersonalinjuryorseveredamagetothevehicle.Thewarninglabelisin
blacktypeonagraybackgroundwithablackborder.
CAUTION
Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonal injuryisnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblack typeonawhitebackgroundwithablackborder.
WarningandAdvisoryLabels
Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsof thevehicletoalertdriversandservicetechniciansaboutsituationsthatmaylead topersonalinjuryorequipmentdamage.Intheeventthatalabelisdamagedor missingthelabelmustbereplaced.ContactyourauthorizedMACKTruckdealer forassistanceregardingWarningandAdvisorylabels.
Operator’sManualVehicleMaintenanceCXU,
CHU,GU,TD,MRUandLEU3
GeneralInformation
InformationFortheOwner
Iftherearequestionsonthemaintenanceandperformanceofyourvehicle,please discussthemwithyourMACKTruckdealer.Y ourauthorizeddealerisrequiredto havetrainedmechanics,specialtoolsandsparepartstofullyserviceyourvehicle. Ifnecessary,yourdealerwillcontactMACKInc.orothermanufacturersforany assistance.
InadditiontothisMaintenanceManual,theremaybeadditionalinstruction/operators manualssuppliedbycomponentmanufacturers.Thesemanualsareplacedinthe OwnersPackageandplacedinthecab.Besuretoreadallthemanualsthoroughly beforeoperatingthevehicle.
Also,varioussafetylabelsmaybeplacedoncomponentsbythecomponent manufacturer.Besuretoreadandfollowtheselabelstopreventdamagetothe vehicle,personalinjuryorevendeath.
InformationinthismanualreferstoMACKcomponentsandMACKdrivetrain.
EstablishaPreventiveMaintenanceProgramwiththehelpofyourlocalMACK Truckdealer.APreventiveMaintenanceProgrammakesitpossibletomaximize theamountoftimeyourvehicleisupandrunning,resultinginlongercomponent life.Thismakesforasafervehiclebyreducinganymechanicalfailuresduetopoor maintenancepractices.
Note:Federallawrequiresmanufacturerstonotifyownersofitsproductsintheevent ofaFederalMotorV ehicleSafetyStandardorifasafetyrelateddefectisdiscovered. Ifyouarenottheoriginalownerofthisvehicle,pleasenotifyusaboutthechangein ownershipattheaddressbeloworthroughanauthorizedMACKTruckdealer.Thisis theonlywaywewillbeabletocontactyouifnecessary.
MACKInc.
NortheastRegion
7900NationalServiceRoad,Mail:P .O.Box26259
Greensboro,NC27402
TEL:(336)291-9001
UnitedStatesofAmerica
ThisMaintenanceManualcoversallMACKvehiclesmanufacturedbyMACKInc., includingthewholechassisandallMACKmanufacturedcomponents.Forspecic maintenanceinformationonvendorcomponents,seetherespectivemanufacturers serviceandmaintenanceliterature.
Thismanual,togetherwithmanualsforspeciccomponentscontainimportant informationtobeabletooperatethisvehiclesafely.Theycontainadviceand
4Operator’sManualVehicleMaintenanceCXU, CHU,GU,TD,MRUandLEU
instructionswhichwillenableyoutogettheoperatingeconomyandperformance thatyouexpectfromthisqualityvehicle.
Allinformation,illustrationsandspecicationscontainedinthismanualarebased uponthelatestproductinformationavailableatthetimeofpublication.Ifany questionsariseconcerningthecurrentstatusofFederalorstatelaws,theappropriate Federalorstateagencyshouldbecontacted.
Note:Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactual vehicle,however,keycomponentsaddressedinthismanualarerepresentedas accuratelyaspossible.
MACKInc.reservestherighttomakechangesatanytimeortochangespecications ordesignwithoutnoticeandwithoutincurringobligation.
General
USA
TheFederalCleanAirAct,Section203(a)(3),statesthefollowingconcerningthe removalofairpollutioncontroldevicesormodicationofacertiedenginetoa non-certiedconguration: CAA,Section(a)(3)(A)prohibitsanypersonfromremovingorrenderinginoperative anyemissioncontroldeviceorelementofdesigninstalledonorinamotorvehicle ormotorvehicleengineincompliancewithfederalregulationsundertheCleanAir Actpriortothesaleanddeliveryofthevehicletotheultimatepurchaser.Thestatute alsoprohibitsanypersonfromknowinglyremovingorrenderinginoperativeany emissioncontroldeviceorelementofdesignaftersaleanddeliveryofavehicleor enginetotheultimatepurchaser.Anypersonwhoviolatestheseprovisionseither byremovingorrenderinginoperativeemissionscontroldevicespriortothesaleor deliveryofanengineorvehicletoanultimatepurchaser,orbyknowinglyremoving orrendinginoperativesuchdevicesafterthesaleanddeliveryofanengineorvehicle toanultimatepurchaser,canbesubjecttopenaltiesofupto$3,750perincident. Anydealerormanufacturerwhoviolatestheseprovisionscanbesubjecttopenalties ofupto$37,500perincident.
Canada
ThesameconditionsthatapplyintheUSAapplytoCanada,withoneexception. Afterthevehicleissoldtoaretailcustomer,thatis,theenduser,thejurisdiction controllingtheemissioncontroldevicesbecomestheprovinceinwhichthevehicleis licensed.Nochangesshouldbemadethatrenderanyorallofthedevicesinoperative.
Shouldtheowner/operatorwishtomakeanychangestotheemissioncontroldevices, checkwiththeprovincialauthoritybeforemakinganysuchchanges.
Operator’sManualVehicleMaintenanceCXU,
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, CHU,GU,TD,MRUandLEU
LabelInformation
VehicleIdenticationNumberLabel
Allmotorvehiclesarerequiredtobeidentiedbya17-digitVehicleIdentication Number(VIN).U.S.andCanadianregulationsdictatetheformatofthenumber. TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK, suchastypeofvehicle,model,typeofbrakesystem,grossvehicleweightrange andmodelyear.
TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations includeastampingontheverticalfaceoftheright-handframerail(somewhere betweenthefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge, thedooropeningareaortheseatriser)andonthevehiclesafetycerticationlabels andotherlabelsonthedooredgeordooropeningarea.Whenthevehicleisreceived, checktheVINateachlocationonthevehicleandverifythattheyareidentical.The vehicleidenticationnumbermustnotbechanged,coveredorobliterated.
VINFrameStamping
W0031972
Operator’sManualVehicleMaintenanceCXU,
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, CHU,GU,TD,MRUandLEU
WARNING
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining, correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadto personalinjuryormakingyourvehicleunsafe.
WARNING
Dieselengineexhaustandsomeofitsconstituentsareknowntothestateof Californiatocausecancer,birthdefectsandotherreproductiveharm.
DuringMaintenance
Removekeyfromignitionwhileworkingonvehicleorengine.
DONOTallowunauthorizedpersonnelon,aroundorinthevehiclewhen maintenanceorrepairisbeingperformed.
•Whenoperatingtheengineinanenclosedarea,venttheexhausttotheoutside.
•Beforeservicingyourvehicle,applytheparkingbrakesandadequatelychockthe
wheelsinordertopreventunintendedvehiclemovement.Iftheserviceprocedure requirestheparkingbrakestobereleasedrechecktoensurethatthewheelsare adequatelychockedtopreventanyforwardand/orrearwardmovement.
•DONOTusecombustiblesubstancesinoraroundtheengineeitherduringrepair
ormaintenanceorwhenrunningtheengine.
•DONOTwearlooseclothingorjewelrythatcancatchorgetsnaggedbypartsor
movingcomponentsontheengine.Alsowearallprotectiveequipmentrequiredby thejobconditions,suchasprotectiveglasses,hearingprotection,etc.
•Makecertainthatallprotectivecoversandguardsareinplaceandproperlysecured.
•Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.
•Reportallproblemsinatimelymannerbeforetheythreatenthesafetyofoperating
thevehicle.
•DONOTworkontheenginewhileitisrunning.
•Makesureprotectivelocksandcoversareintheirproperplace.
•DONOTusehighamperageelectronicstartingdevicesforjump-startingthe
engine.Relyonconventionalbatterychargingforchargingthebatteriesor jump-startwiththehelpofastartbattery.
Operator’sManualVehicleMaintenanceCXU,
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.
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