MACK MRU, LEU Operator's Manual

Mack

Natural Gas

®

Mack® Natural Gas
(LEU / MRU)

Mack® Natural Gas
(LEU / MRU)

21607699

21607699 21607699

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

September 2010

Foreword

TheinformationinthismanualappliestovehiclesbuiltJanuary2010
andlater .Pleasekeepthismanualinthevehicleatalltimes.

ThisHandbookonlyappliestoLEUandMRUmodelsequippedwith
naturalgasengines.Formodelsequippedwithdieselengines,please
refertoMackT erraProSeriesOperator’sHandbook.

Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.

TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MACKTrucks,Inc.shouldbeinformedimmediatelyifyoubelieve
thatthevehiclehasadefectthatcouldcauseacrash,injuryordeath.

ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.

MackTrucks,Inc.

Greensboro,NCUSA

Ordernumber:PV776-21607699

©2010MackTrucks,Inc.,Greensboro,NCUSA

Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucks,Inc.

Contents

OPERATOR’SHANDBOOKCUMMINS-WESPORTISL-GNA TURALGAS

ENGINE.......................................................................................................................1

INTRODUCTION..........................................................................................................1

TOTHEOWNER........................................................................................................1

AboutThisHandbook..............................................................................................1

SafetyInformation.........................................................................................................2

INSTRUMENTSANDCONTROLS...........................................................................15

CABINTERIOR..........................................................................................................15

MethaneDetector/AlarmSystem.............................................................................19

OPERATION..................................................................................................................20

LIQUIDNATURALGASSYSTEM..........................................................................20

LNGTank................................................................................................................20

LNGFueling............................................................................................................23

COMPRESSEDNATURALGASSYSTEM..............................................................26

CNGFueling............................................................................................................26

MAINTENANCEANDLUBRICATION....................................................................27

MAINTENANCEINTRODUCTION.........................................................................27

DAILYLNG/CNGFUELSYSTEMCHECKS..........................................................27

BEFOREPERFORMINGMAINTENANCEONTHELNGORCNGTANKS

ORFUELSYSTEM....................................................................................................29

RemovingPressureBeforeWorkingontheEngineFuelSystem...........................29

RemovingPressureBeforeWorkingontheTanks..................................................30

MovingaV ehicleUsingAuxiliaryFuel..................................................................30

ENGINEMAINTENANCE........................................................................................32

AirFilter...................................................................................................................32

AirInletSystemDucts,HosesandClamps.............................................................34

Chassis-MountedChargeAirCooling(CMCAC).......................................................34

FuelSystem..............................................................................................................35

COOLINGSYSTEM...................................................................................................36

RadiatorPressureCap..............................................................................................37

Thermostat...............................................................................................................37

FederalEmissions..........................................................................................................39

FEDERALEMISSIONREQUIREMENTS................................................................39

TamperingwithGaseousEmissionControlSystemsProhibited............................39

GaseousEmissionControlSystemsW arranty.........................................................40

GASEOUSEMISSIONSCONTROLSYSTEMWARRANTYFEDERAL

EMISSIONREQUIREMENTS...................................................................................41

ItemsNotCoveredbytheEmissionControlSystemsWarranty.............................41

EmissionControlSystemsWarranty—California.................................................42

EMISSIONSCONTROLSYSTEMWARRANTY—CALIFORNIA......................44

ProceduresforHandlingEmissionsControlSystemWarranty...............................44

ELECTRICAL...............................................................................................................46

.....................................................................................................................................46

CircuitBreakerandRelayPanel..............................................................................46

INTRODUCTION1

TOTHEOWNER

AboutThisHandbook

ThishandbookisreferredtoastheCummins-WesportISL-G™NaturalGasEngine
Handbook.ItcoversallNaturalGasEnginemodels.Keepthishandbookwiththe
vehicleatalltimestoensurethateachownerand/oroperatorwillhaveaccesstoall
pertinentinformationrelatingtotheoperationandhandlingofthisvehicle.

Thissupplementwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthenaturalgasengine,itscharacteristicsanditspotentialhazardsifnot
maintainedproperly .Pleasereaditthoroughly;payparticularattentiontoadvisory
labelsthathavebeenincludedtodrawattentiontoimportantissuesofoperatorsafety
andoverallperformance.

Informationandillustrationsinthishandbookarebasedonthelatestproductionusage
atthetimeofprintingandaresubjecttochangewithoutpriornotice.

Refertoyourvehicle’sOperator’sHandbookforadditionalvehicleinformation.

2SafetyInformation

ImportantSafetyInformationforAll
OperatorsofNaturalGasV ehicles

Althoughformalcerticationisnotcurrentlyrequired-fromanoperational,safety
andliabilityperspective-itmaybedesirableforpersonnelhandlingLNG/CNG
equipmenttocarryawrittencerticateattestingtosuchtraining.Itistheresponsibility
oftheownerandoperatorofanyLNG/CNGfacilityorequipmenttohaveproper
safetytrainingbeforeoperatingLNG/CNGequipment.Informationconcerning
properLNG/CNGsafetytrainingisavailablethroughthemanufacturerofLNG/CNG
vehiclesandequipment.Ifyouareunsureaboutyourqualicationsforoperating,
refuelingorrecognizingandrespondingtopotentiallydangerousemergency
situationsthatcouldariserelatedtotheoperatingofanLNG/CNGvehicle,contact
yourimmediatesupervisororcallMACKOneCall™CustomerSupportSystem
at1-800-866-1177.

ThescopeofthishandbookisnottocoverallsituationsrelatedtoLNG/CNGsafety.
EffectivesafetytrainingprogramsarerequiredatallLNG/CNGvehiclefacilitiesto
ensurethesafetyofpersonnel,protectpropertyandmaintainfacilityperformance
requirements.FamiliarizingallpersonnelwithbasicLNG/CNGinformationwill
allowthemtomakewell-informedsafetyjudgments.Asafetyprogramatthefacility
shouldinclude:

1Scheduledequipmentinspections

2Operationalsafetyprocedures

3Personneltrainingandcertication

4Emergencyresponseproceduresandperiodicpracticedrills

5Emergencyresponsecommunityinteraction

DANGER

Donotoperate,occupyorrefuelan
LNG/CNGvehicleifyouareunsure
ofyourqualicationsforoperating,
refuelingorrecognizingandresponding
topotentiallydangerousemergency
situationsthatcouldariserelatedto
LNG/CNGvehiclesandequipment.

SafetyInformation3

Althoughthishandbookcontainssafetyinformationthatmaybeusedinconjunction
withasafetytrainingprogram,itisnottobeviewedasasafety-trainingmanual.The
safetyinformationcontainedinthismanualisforreferenceandrecallofinformation
alreadycoveredinanongoingsafetyprogram.Onlysafetytrainingandperiodic
practicedrillscanadequatelytrainoperatorsandlocalemergencypersonnel(suchas
redepartments,medicalemergencyunitsandpolicedepartments)forsafelyhandling
potentiallydangeroussituationsinthecommunityproximatetoLNG/CNGfacilities
andLNG/CNGvehicleoperation.

DANGER

Itisrecommendedthatpersonnelnever
enteravaporcloud.Ifthevaporignites,
theycouldbeseverelyburned.Inhaling
thevaporcancausebreathingproblems
orasphyxiation.

4SafetyInformation

PropertiesofLNG:

LiqueedNaturalGas/Methane(LNG)isacolorless,odorlessgasorliquid.
Atambienttemperatures,theproductisagas,butatcryogenic(super-cooled)
temperaturesitisaliquidorheavygasthatmaytravelalongtheground,riseasit
warmsandvaporizes,andbecometrappedunderanyclosed-inspace.

PropertiesofCNG:

CompressedNaturalGas/Methane(CNG)isacolorless,odorless(sulfur)gas.Itis
compressedat2400to3600poundspersquareinchandstored/usedinspecially
designedcylinders.

NormalMethaneVenting

Themethanefueltanksautomaticallyventtoreleasepressurewhenthevehicleis
parkedforsometime.Duringventingahissingsoundmaybeheard.Thefrequency
anddurationofthisventingwillvarydependingontankpressureandambient
temperature.Itwillcontinuetoventuntilthetruckisoperatedagain,therebydropping
thepressure,oruntilthetank(s)isempty .

PrimaryLNGTankVentPiping

Fromthefactory,theventpipingfromtheprimaryLNGtankventsisattachedtothe
intakestackbydisposableplasticstraps.Thepipingshouldberemovedfromthe
intakestackandplumbedupandoverthebodybythebodyinstallersasshownin
thefollowingillustration.Formoreinformation,seethesectiontitled"LNGT ank
PressureV ents"intheOPERATIONsectionofthismanual.

CAUTION

Itisimportanttokeeptheprimary
pressureventfreeofblockagedueto
ice,snowordebris.

SafetyInformation5

C0032249

6SafetyInformation

MethaneLeaks

Duringthedailywalkaround,inspecttheoutsideoftheLNGfueltankforfrost.
FrostedLNGtank(s),otherthanattheshroudarea*,indicatesthattheinnertank
isleakingintotheoutertank.Theappearanceofavaporcloudaccompaniedbya
hissingnoisemayalsoindicateamethaneleak.Aleakrequiresserviceonthetank(s)
beforethevehiclecanbeoperated.

*Rearfueltankdoorandplumbingxtures.

WARNING

Donotoperateavehiclewhichhasa
methaneleak.

RapidPressureRise

TherearethreemaincausesofrapidpressureriseonLNGsystems;overlling,fuel
systemleaksormalfunctionsandlossofvacuum.Aproperlyfunctioning,properly
lledLNGfuelsystemshouldbuildlessthan15psig/day.Anysystembuildingmore
than40psig/dayneedstroubleshootingtondthecause.

VacuumLoss

TotalvacuumlossisanunusualeventforanLNGtank(resultinginfrostingtheentire
shell),howeverthevacuumwillslowlydecaywithtimeasgassesdiffuseoutof
thetankmaterials.Thiswillshowupovertimeasamorerapidpressurerisetime,
eventuallyexceeding40psig/day.Oncethevacuumhasdecayedtothispoint,the
tankwillneedtobere-evacuatedbyacompetentmaintenancefacility.

SafetyInformation7

METHANEDETECTOR/ALARMSYSTEM

Note:Thefollowinginformationappliestoequipmentlocatedonthevehicle
only.Separatemethanedetector/alarmsystemsshouldbeinstalledinfacilitiesthat
frequentlyhousenaturalgasvehicles.Inaddition,hand-heldmethanedetector/alarm
devicesshouldbeusedwhenworkingonnaturalgasvehicleswithnon-functioning
ordisconnectedmethanedetector/alarmsystemsandwherenoauxiliarymethane
detector/alarmsystemisinstalled.

Note:Consultyourlocalrecodeand/or
reinspectortomakesuethatadequate

Themethanevapordetectionsystemutilizestwosensorstoidentifymethanevapors;
onelocatedinthecabcompartmentandonelocatedintheenginecompartmentof
thevehicle.Thesystemoperateswithbothavisualandanaudiblealarmtowarn
theoperatorofpotentialdanger.Thealarmsaretriggeredattracelevels(20%LEL
[LowerExplosiveLimit])andatsignicantlevels(50%LEL)ofvaporconcentration.
Thesystemandsensoroperationisconstantlymonitored.Aninternalrelaycontrols
twoindicatorlamps(1greenand1red)thatcanbeseenthroughthewindshield.The
greenlampwillgooutandtheredlampwillilluminate15secondsafterasignicant
levelofmethanehasbeendetected.Themethanedetectoralsohasapassto-test
buttonthatcanbeusedtotesttheindicatorlampsandtheaudiblealarm.

detectionandpreventionmeasuresarein
place.

8SafetyInformation

BeforeEnteringtheVehicle

Greenandredmethanedetectorremoteindicatorlampsareeasilyviewedthrough
thewindshieldandshouldalwaysbecheckedbeforeenteringthevehicle.(See
illustration.)

W0059509

DANGER

WHENAPPROACHINGTHECAB
TOENTER:Donotopenthevehicle
doorsiftheREDLAMPISON!Donot
openthevehicledoorsiftheALARM
ISSOUNDING!Donotopenthe
vehicledoorsiftheGREENLAMP
isNOTON!Iftheindicatorlampis
red,ifthealarmissoundingorifthe
greenlampisNOTON,itisunsafeto
openthevehicledoorsbecauseeven
staticelectricitycanigniteconcentrated
methanefumesinanenclosedarea.
Immediatelyimplementthefollowing
procedure:*Removeallpersonnelfrom
thearea.Turnoffelectricalcircuitsand
sourcesofignitionintheimmediate
area.ManuallyturnofftheFuelShut­OffValveoneachfueltanktoprevent
furthergasleakage.Waituntilthegas
hasdissipatedandthealarmsituation
hascleared.Itisnowsafetoopenthe
vehicledoorsandwindowstoventthe
vehicle.Donotoperatethevehicleuntil
thesourceoftheleakhasbeenrepaired.

SafetyInformation9

Note:Whenthebatteryisdisconnected,themethanedetector/alarmsystemwillnot
operatesothegreenlightswillnotbeon.Themethanedetector/alarmsystemis
poweredbythebatteryandisactiveatalltimesunlessthebatteryisdisconnectedor
thefuseisblown.
Hand-heldmethanedetector/alarmdevicesshouldbeusedwhenworkingonnatural
gasvehicleswithanonfunctionalordisconnectedmethanedetector/alarmsystemand
wherenoauxiliarymethanedetector/alarmsystemisinstalled.

10SafetyInformation

DANGER

Intheeventofanalarmwhileoperating
thevehicle,immediatelyopenthe
cabwindows,safelystopthevehicle,
shutdowntheengineandturnoffthe
ignition.Exitthecabandleavethe
doorsandwindowsopentoventthe
vehicle.ManuallyturnofftheFuel
Shut-OffV alveoneachfueltankto
preventfurthergasleakage.Waituntil
thegashasdissipatedandthealarm
situationhascleared.Donotoperate
thevehicleuntilthesourceoftheleak
hasbeenrepaired.

Note:Foradditionalinformation,refertoandintheINSTRUMENTSAND
CONTROLSsectionofthishandbook.

CAUTION

AMGaDSIIIPlusisapropane,CNG
(CompressedNaturalGas)andLNG
(LiquidNaturalGas)detectoronly.
However,becausethesensorsdetect
allhydrocarbonvapors,analarmmay
betriggeredbytheuseofchemicals
suchascleaners,paint,polish,lacquer,
etc.Donotexposesensorstoliquids
orchemicalsunnecessarily.When
usingsuchsubstances,keepthevehicle
wellventilatedanddonotallowdirect
contactwiththesensors.Forcleaning
andmaintenanceoftheGasDetection
System,refertotheAMGaDSIIIPlus
Owner’sManualsuppliedwiththe
vehicle.

SafetyInformation11

PotentialHazardAssociateswithLNG/CNG:

Skin/Eyes

LNGisstoredatcryogenictemperatures(low-temperaturestate,startsatorbelow

-240°F(about-150°C)andCNGisstoredinspeciallydesignedtanksunder
extremelyhighpressure.Therefore,properlyinsulatedsafetyglovesandeye
protectionsuchasgogglesorafaceshieldshouldbewornwhenworkingwithor
aroundLNG/CNGaswhenrefueling.Ifsuper-cooledliquidorgascomesintocontact
withtheskinoreyes,seeaphysicianimmediately.

WARNING

COVEREYESANDEXPOSEDSKIN.Accidentalcontactoftheeyesorskin
withLNGmaycauseafreezinginjurysimilartoaburn.Protecttheeyesand
covertheskinwheneverthepossibilityofcontactwithsuper-coldmetals,liquids
orgasexists.

12SafetyInformation

Inhalation

LNG/CNGisnottoxic,butcancauseasphyxiationinconcentrationorinenclosed
areasbecauseitreducestheoxygenavailableforbreathing.Forthisreason,methane
detectorsarelocatedintheenginecompartmentandinsidethecab.Thesedetectors
willtriggeranalarminsidethecabifmethaneconcentrationgoesaboveasafelevel.
Thesedetectorsarealwaysactivewhetherthevehicleisonoroff,aslongasthebattery
isconnectedandthefuseisinplaceandnotblown.Ifovercomebyvapor,removethe
individualfromexposureandcallaphysicianimmediately.Ifbreathingisirregularor
hasstopped,startresuscitation(iftrainedinCPR)andadministeroxygenifavailable.

DANGER

KEEPTHEEQUIPMENTAREA
WELLVENTILATED.Although
LNG/CNGisnon-toxic,itcancause
asphyxiationinaconnedareawithout
ventilation.Anyatmospherethatdoes
notcontainenoughoxygenforbreathing
cancausedizziness,unconsciousness,
orevendeath.LNG,beingcolorless,
odorlessandtasteless,cannotbe
detectedbyhumansenses.Eventhough
CNGissulfurized,thesmellmay
gounnoticedonsomevehicles,such
asarefusetruck.Withoutadequate
ventilation,naturalgaswilldisplace
theoxygenandgivenowarningthat
anon-lifesupportingatmosphereis
present.StoreLNG/CNGinawell
ventilatedarea.

IfvehiclesequippedwithanLNGenginemustbeparkedorworkedonindoorsfor
shortperiodsoftime,pipingfromtheprimaryLNGtankventpipetotheoutsideof
thebuildingshouldbeprovided.See"PrimaryLNGT ankVentPiping"attheendof
theSAFETYsection.De-fuelingorremovaloftheLNGtank(s)isrecommendedfor
vehiclesstoredindoorsforlongperiodsoftime.

Separatemethanedetector/alarmsystemsshouldbeinstalledinfacilitiesthat
frequentlyhouseLNG/CNGvehicles,consultlocalcodesandordinancestoensure
compliance.Inaddition,handheldmethanedetector/alarmdevicesshouldbeused
whenworkingonLNG/CNGvehicleswithnon-functioningordisconnectedmethane
detector/alarmsystemandwherenoauxiliarymethanedetector/alarmsystemis
installed.

Note:DuetothecryogenicstateofLNGfuel,itcannotbeodorized,therefore,itwill
notsmelllikeCNGorpipelinegasinahome.

SafetyInformation13

Flammability

SinceLNGisextremelyammable,thetank(s)shouldbegroundedwhenfueling,to
avoidcreatingsparksfromstaticelectricity.Keepanysourceofignition,suchasalit
cigarette,farawayfromLNG/CNGtanksandfuelingareas.

WARNING

KEEPAWAYFROMFLAMEOR
SPARK.
Naturalgasisammable.Smoking,
openames,andgeneralpurpose
electricalequipmentshallbeprohibited
wherenaturalgasisstoredorhandled.

Pressure

TheLNG/CNGfuelsystemsarepressurizedsystems.Therefore,automaticand
manualsafetyvents,reliefvalvesandshutoffpointsareinstalledthroughoutthe
systemtopreventexcesspressurefrombuilding.

WARNING

REMOVEPRESSURE.Alwaysempty
theLNG/CNGfueltank(s)andremove
anypressureonthesystempriorto
removingpartsorcomponentsofthe
tankforrepair.

ReleasesorSpills

Duringareleaseorspill,shutoffandeliminateallignitionsources.Ifdesired,stop
thesourceofthereleaseorspill.Keeppeopleaway.Minimizebreathingvapors.
Absolutelyavoidskincontact.V entilateconnedspaces.Nodisposalmethodis
necessary,norshoulditbeattempted,becauseextremelyrapidevaporationofthe
naturalgaswilltakeplace.Ifaspillisindangerofigniting,useawaterspray(donot
usesolidstreamsofwater)todirectgas-airmixturesawayfromignitionsources

Ifaspillhasignited,usewatertokeepre-exposedcontainersandequipmentcool
andtoprotectpersonnelwhomayhavetostopthesourceoftheleak.Ifitisdesirable
toextinguishthere,usedrychemical,carbondioxideorhalogenatedextinguishing
agents.

14SafetyInformation

SPECIFICSAFETYINFORMATIONREGARDINGTHEINSTRUMENTS
ANDCONTROLS,THEOPERATION,ANDTHEMAINTENANCEOFTHE
CHASSISWILLBECOVEREDINYOUROPERA TOR’SHANDBOOK.

CabEntry/Exit

AsdescribedinyourOperator’sHandbook,followtheThree-LimbContactRule
toenterandexityourvehicle.

DANGER

Beforeopeningeithervehicledoor,
alwayslookthroughthedriverside
windowatthemethanealarmbox
locatedoninstrumentpanel(MRU
andLEU).DoNOTopenthedoorifa
redalarmlightisonorifyouhearthe
audiblealarmsounding.DoNOTopen
thedoorifthegreenlightisnotON.

INSTRUMENTSANDCONTROLS15

CABINTERIOR

Belowyouwillseehowthemethanedetector/alarmsystemisarrangedonatypical
LEUinstrumentpanel:(Theexactlayoutmaydifferfromyourtruck,butthegas
detectionsystemwilllookthesame.)

1.GasDetectionSystem—Seebelowfordetaileddisplayinformation

W0059510

16INSTRUMENTSANDCONTROLS

1.PowerOnIndicator(Green)6.RelayOn/OffIndicator

2.SignicantAlarmIndicators(Red)7.RelayResetButton

3.TraceSensorAlarmIndicators
(Amber)

4.AudibleAlarmSilenceButton9.SensorFaultIndicators

5.AlarmSilencedIndicator

8.SystemT estButton

C0032252

INSTRUMENTSANDCONTROLS17

1PowerOnIndicator(Green)—ThisgreenLEDshouldalwaysbeon.Nopower

on/offswitchisprovidedforthisunitasitshouldbeonatalltimes.

Note:Whenthebatteryisdisconnected,themethanedetector/alarmsystemwill
notoperatesothegreenlightwillnotbeon.Themethanedetector/alarmsystemis
poweredbythebatteryandisactiveatalltimesunlessthebatteryisdisconnected
orthefuseisblown.Hand-heldmethanedetector/alarmdevicesshouldbeused
whenworkingonnaturalgasvehicleswithanon-functioningordisconnected
methanedetector/alarmsystemandwherenoauxiliarymethanedector/alarm
systemisinstalled.

DANGER

WHENAPPROACHINGTHECABTOENTER:
DonotopenthevehicledoorsiftheREDLAMPISON!Donotopenthe
vehicledoorsiftheALARMISSOUNDING!Donotopenthevehicledoorsif
theGREENLAMPisNOTON!
IftheindicatorlampisRED,ifthealarmissoundingorifthegreenlampis
NOTON,itisunsafetoopenthevehicledoorsbecauseevenstaticelectricity
canigniteconcentratedmethanefumesinanenclosedarea.Immediately
implementthefollowingprocedure:*
Removeallpersonnelfromthearea.
Turnoffelectricalcircuitsandsourcesofignitionintheimmediatearea.
ManuallyturnofftheFuelShut-OffV alveoneachfueltanktopreventfurther
gasleakage.Waituntilthegashasdissipatedandthealarmsituationhas
cleared.Itisnowsafetoopenthevehicledoorsandwindowstoventthevehicle.
Donotoperatethevehicleuntilthesourceoftheleakhasbeenrepaired.

*Dependingonlocalordinancesorcompanypolicy,itmayberecommendedthat
emergencypersonnelbecontactedtoimplementtheseprocedures

DANGER

theeventofanalarmwhileoperatingthevehicle,immediatelyopenthecab
windows,safelystopthevehicle,shutdowntheengineandturnofftheignition.
Exitthecabandleavethedoorsandwindowsopentoventthevehicle.Manually
turnofftheFuelShut-OffValveoneachfueltanktopreventfurthergasleakage.
Waituntilthegashasdissipatedandthealarmsituationhascleared.Donot
operatethevehicleuntilthesourceoftheleakhasbeenrepaired.

2SignicantSensorAlarmIndicators(Red)—IlluminationoftheredLED

for"Zone1"(cabcompartment)or"Zone2"(enginecompartment)indicates
thesystemhasdetectedgasfumesinconcentrationsabove50%oftheLower
ExplosiveLimit(LEL)andanaudiblehornwillsound.

18INSTRUMENTSANDCONTROLS

3.T raceSensorAlarmIndicators(Amber)—IlluminationoftheamberLEDfor
"Zone1"(cabcompartment)or"Zone2"(enginecompartment)indicatesthesystem
hasdetectedagasconcentrationabove20%oftheLEL.Thisisacautionarysituation.
Correctivemeasuresshouldbetakenassoonaspossible—includingopeningthe
vehiclewindowsandreturningthevehicleforservice—toidentifyandcorrectthe
sourceofthemethaneleak.

4.AudibleAlarmSilenceButton—Presstosilencetheaudiblealarm.

5.AlarmSilencedIndicator—Illuminatestoindicatetheaudiblealarmhasbeen
silenced.

6.RelayOn/OffIndicator—IfthereisaSIGNIFICANTalarmdetectedfor15
seconds,the"RelayEngaged"LEDwillgoon.Theremotewindshield-visiblegreen
lampwillgooutandtheremotewindshield-visibleredlampwillilluminate.

7.Relay(Shutdown)ResetButton—Onlyafterthemethanegashasclearedand
thealarmsareoff,maytheinternalrelayberesetbypressingthe"ShutdownReset"
button.AfterpressingtheShutdownResetbutton,the"RelayEngaged"LEDgoesoff.

8.SystemT estButton—Pressingthebuttonwillcausethesystemtoperforma
self-testofallelectricalandsensorfunctionsandsimulateanalarmcondition.The
systemreturnstonormalwhenthetestbuttonisreleased.

9.SensorFaultIndicators—IfeitherSensorFaultlightremainsilluminated
orilluminatesintermittently ,adisconnectedorfaultysensorisindicatedinthe
correspondingzone.Zone1indicatesthecabcompartmentsensorandZone2
indicatestheenginecompartmentsensor.Donotoperatethevehicleuntilaqualied
personcorrectsthiscondition.

CAUTION

AMGaDSIIIPlusisapropane,CNG(CompressedNaturalGas)andLNG(Liquid
NaturalGas)detectoronly .However,becausethesensorsdetectallhydrocarbon
vapors,analarmmaybetriggeredbytheuseofchemicalssuchascleaners,paint,
polish,lacquer,etc.Donotexposesensorstoliquidsorchemicalsunnecessarily .
Whenusingsuchsubstances,keepthevehiclewellventilatedanddonotallow
directcontactwiththesensors.ForcleaningandmaintenanceoftheGasDetection
System,refertotheAMGaDSIIIPlusOwner’sManualsuppliedwiththevehicle.

INSTRUMENTSANDCONTROLS19

MethaneDetector/AlarmSystem

Inadditiontothemethanedetectorlocatedinthecab,thereisanothermethane
detectorlocatedinthe"doghouse"underthecabasshowninthefollowingillustration.

Themethanealarm/detectionsystemrunsoffthebatteryandisactiveatalltimes
unlessthebatteryisdisconnected.

C0032253

DANGER

Ifthebatteryisdisconnected,the
methanedetector/alarmsystemwillnot
operate.

FrostedLNGtank(s),otherthanaroundtheareaoftherearfueltankdoorand
plumbingxtures,indicatesthattheinnertankisleakingintotheoutertank.The
appearanceofavaporcloudaccompaniedbyahissingnoisemayalsoindicatea
methaneleak.Aleakingconditionrequiresserviceonthetank(s)beforethevehicle
canbeoperated.

DANGER

Intheeventthemethanealarmred
lightcomesonandthealarmsounds,
thecabwindowsshouldimmediately
beopened,thevehicleshouldbesafely
stoppedandturnedoff,andpersonnel
shouldexitthecab.Followsafety
precautionsintheSAFETYsectionof
thismanual.

WARNING

DoNOToperateavehiclewhichhasa
methaneleak.

20OPERATION

LIQUIDNATURALGASSYSTEM

LNGTank

ThereareoneortwoLNGtanks.Theyaremountedononeorbothsidesofthetruck
withtheplumbingcomponentsaccessibleinsidetherearofeachtank.TheLNGfuel
tankis,forsimplicityofexplanation,designedlikeavacuum(Thermos™)bottle
whichcanwithstandpressuresupto230psi,orwhatevermaximumpressureisposted
onthemanufacturer’slabel(seeillustration).

1.RearofTank(Shroud)withDoor
Closed

2.Maximum-PressureLabelinPounds
perSquareInch(psi)

3.Manufacturer’sLabel6.LiqueedNaturalGasSymbol

4.FuelT ankFillFitting

5.TankSafetyLabel

C0032254

1.FillConnectiontoSecondFuelTank6.FuelShut-OffValve

2.ManualVent7.ExcessFlowValve

3.FuelTankPressureGauge8.FuelT ankFillFitting

4.TankManufacturer’sManual(Inside

9.FuelGaugeSendingUnit

BottomhalfofTankDoor)

5.EvacuationPlug(DoNotRemove)10.FuelTankLevelProbe

OPERATION21

C0032255

22OPERATION

1FillConnectiontoSecondFuelTank—Whenfueling,LNGwillenterthe

secondvesselthroughthisconnectingpipe.

2ManualV ent—ThisvalveisclearlymarkedwithOPENandCLOSEdirectional

arrows.Itisnormallykeptclosed,butmaybeopenedtobleedthetankorincertain
fuelingsituationswhicharedescribedinthesection"LNGFueling."

Note:Thereisnormallynoneedtomanuallyventthetank.Thevesselisprotected
fromover-pressurizationbyseveralautomaticsafetyreliefvalves.

3FuelT ankPressureGauge—Eachtankhasaseparatepressuregauge.The

normaloperatingpressureofthetanksisapproximately120psiorhigher.Normal
procedureistorefuelonadailybasisoreachtimethevehicleistakenintoactive
service.

4TankManufacturer’sManual—Locatedinsidethebottomhalfofthetankdoor.

Asthelabelindicates,thismanualshouldbereadentirelybeforeoperatingthetank.

5EvacuationPlug(DoNotRemove)—TheLNGfueltankisequippedwithan

outerjacketevacuationplugthatwillpopopenifthereisalossofvacuum.The
lossoftheevacuationplugindicatesaninnervesselleak.Theevacuationplugis
protectedfromtheenvironmentandtamperingbyaplasticcap.Donotremovethe
plasticcaporevacuationplug.

6FuelShut-OffValve—ThisvalveisclearlymarkedwithOPENandCLOSE

directionalarrows.Duringnormaloperation,thevalveshouldremainfullyopento
allowfueltoreachtheengine.Closethisvalvetoshutofffueltotheengine.

Note:Ifthereismorethanonetank,bothtankvalvesmustbeturnedofftoshut
offfueltotheengine.

7ExcessiveFlowValve—Restrictsexcessfuelowintheeventofafuelline

breakage.

8FuelT ankFillFitting—FillingtheLNGvehiclefueltanksisdonethrougha

singlehoseconnectedtothelltting.Instructionsonllingthefueltanksare
underthesection"LNGFueling."

9FuelGaugeSendingUnit—Receivessignalsfromthetankprobeandconverts

themintovaluescompatiblewiththefuelgauge.Thesendingunitissealedand
non-adjustable.

10FuelTankLevelProbe—Sensesthefuellevelinthetank.

Duringthedailywalkaroundinspection,ifyouseeanysignsofamethaneleaksas
previouslymentionedintheSAFETYsectionofthishandbook,openthetankdoor.If
theEvacuationPlughaspoppedout,thetankmustbeservicedbeforeoperating.

OPERATION23

LNGT ankPressureReliefV alves

Periodicallypressurewillbeharmlesslyreleasedthroughtheprimaryreliefvalveas
thefuelheatsupandexpandsduetoambientoutsidetemperature.LiquidLNGin
thetankscanbeaslowas-260°F(-177°C).BecausesmallamountsofLNGare
convertedintolargeamountsofnaturalgas,pressuresmayrapidlyincreaseifameans
ofreliefisnotprovided.

Theprimaryandsecondarypressureventsarelocatedinsidethefueltankdoor.The
primaryventisconnectedtopipingwhichshouldbeattachedtothebodyofthe
truckfacingtowardtherearofthevehicle,awayfromthepassengercompartment.
Onlytheprimaryreliefvalveispipedaway.Thesecondaryreliefvalveshouldbe
leftwiththefactoryinstalledplasticcapinplace.Refertothetankmanufacturer’s
manualformoredetails.

Fromthefactory,theventpipingfromtheprimaryLNGtankventisattachedtothe
intakestackbydisposableplasticstraps.Thepipingshouldberemovedfromthe
intakestackandplumbedupandoverthebodybythebodyinstallersasshowninthe
illustrationattheendoftheSAFETYsectioninthishandbook.

CAUTION

Itisimportanttokeeptheprimarypressureventfreeofblockageduetoice,snow
ordebris.

LNGFueling

Normalprocedureistorefuelthetanksonadailybasisoreachtimethevehicleis
takenintoactiveservice.Thenormaloperatingpressureineachtankisapproximately
120psiorhigher.Ifthepressureislow,say90psi,thevehicleisprobablylowon
fuel.Asaresult,itwillbelowinpowerandmayeventuallyrunoutoffuel.

Note:CompleteandsafeinstructionsonLNGfuelingshouldbeobtainedfromthe
tankmanufacturer’smanualandfromtheassistanceofpersonnelwhoareexperienced
inLNGfueling.

WARNING

COVEREYESANDEXPOSEDSKIN.
Accidentalcontactwiththeeyesorskin
maycauseafreezinginjurysimilarto
aburn.Protecttheeyesandcoverthe
skinwheneverpossiblecontactwith
supercooledmetals,liquidsorgases
exists.

24OPERATION

DANGER

KEEPTHEEQUIPMENTAREA
WELLVENTILATED.Although
LNG/CNGisnon-toxic,itcancause
asphyxiationinaconnedareawithout
ventilation.Anyatmospherethat
doesnotcontainenoughoxygen
forbreathingcancausedizziness,
unconsciousness,orevendeath.LNG,
beingcolorless,odorlessandtasteless,
cannotbedetectedbyhumansenses.
Withoutadequateventilation,natural
gaswilldisplacetheoxygenandgive
nowarningthatanon-lifesupporting
atmosphereispresent.StoreLNGina
wellventilatedarea.

GroundT ankandOpenFuelTank
FillFitting

DANGER

KEEPAWAYFROMFLAMEOR
SPARK.Naturalgasisammable.
Beforefueling,connectthefueltankto
thegroundcableatthefuelingstation.
Smoking,openames,andgeneral
purposeelectricalequipmentshallbe
prohibitedwhereliqueednaturalgas
isstoredorhandled.

C0032256

ConnectFillHose

DANGER

Fuelingstationsandfuelingsituations
differ.DonotllanLNGtankwithout
rstgoingthroughtheprocedureswith
theassistanceofexperiencedpersonnel.

OPERATION25

C0032257

NormalFilling

FillingtheinnervesseloftheLNGvehiclefueltankisdonethroughasinglehose.
Whenthellhoseisconnectedtothefueltanklltting,LNGissuppliedata
pressurehigherthanthevehicletankpressure.Thellisautomaticallyterminated
whenthepressurereachesapresetvalueatthefuelingstation.Removethelling
hosefromthetting.

WarmTankFilling

TheLNGvehiclefueltankisconsideredtohaveawarminnervesseleitherpriorto
initialllingofthetank,orafterthetankhasbeenoutofserviceformorethantwo
weeks.Therecommendedprocedureforawarmtankllistollthevehicletank
withapproximately95liters(25gallons)ofLNGandallowittobuildpressure.This
willbegintocooltheinnervesselandbuildenoughpressuretoallowaleaktesttobe
performed.Thepressuremaynowbemanuallyventeddownandanormalfueling
sequencemaybedone.

26OPERATION

COMPRESSEDNATURALGASSYSTEM

CNGFueling

RefertoFuelSystemInstallerforfueling/defuelingrequirements.

WARNING

COVEREYESANDEXPOSEDSKIN.
Accidentalcontactwiththeeyesorskin
maycauseafreezinginjurysimilarto
aburn.Protecttheeyesandcoverthe
skinwheneverpossiblecontactwith
supercooledmetalsorgasesexists.

DANGER

KEEPTHEEQUIPMENTAREA
WELLVENTILA TED.AlthoughCNG
isnon-toxic,itcancauseasphyxiation
inaconnedareawithoutventilation.
Anyatmospherethatdoesnotcontain
enoughoxygenforbreathingcan
causedizziness,unconsciousness,or
evendeath.EventhoughCNGis
odorized,undercertaincircumstances,
inarefusevehicleforexample,it
maynotbedetectedbyhumansenses.
Withoutadequateventilation,natural
gaswilldisplacetheoxygenandgive
nowarningthatanon-lifesupporting
atmosphereispresent.StoreCNGina
wellventilatedarea.

DANGER

KEEPAWAYFROMFLAMEOR
SPARK.Naturalgasisammable.
Beforefueling,connectthefueltankto
thegroundcableatthefuelingstation.
Smoking,openames,andgeneral
purposeelectricalequipmentshallbe
prohibitedwherecompressednatural
gasisstoredorhandled.

DANGER

Fuelingstationsandfuelingsituations
differ.DonotllaCNGtankwithout
rstgoingthroughtheprocedureswith
theassistanceofexperiencedpersonnel.

DANGER

Failureorimproperselectionor
improperuseofthisproductcancause
death,personalinjuryandproperty
damage,including,butnotlimited
toelectrocution,uidinjectionor
lossoflimbcausedbyhighpressure
leak,dangerouslywhippinghose,re
explosionorcontactwithsuddenly
movingorfallingobjects.

MAINTENANCEANDLUBRICATION27

MAINTENANCEINTRODUCTION

ThishandbookcontainsmaintenanceinformationspecictotheNaturalGasV ehicle
andEngine.Forrecommendedlubricationchangeintervalsandproceduresfor
gearoils(transmission,rearaxlecarrier[s],frontdriveaxlecarrier,transfercase
andywheelPTO)orothermaintenanceschedulesorproceduresnotincludedin
thisportionofthehandbook,refertotheMaintenanceandLubricationManual
(21394653)oryourvehiclemodel’sOperatorHandbook.

DAILYLNG/CNGFUELSYSTEMCHECKS

CheckforMethaneLeaksorLossofVacuum

TheLNGandCNGfuelsystemsarepressurizedsystems.Anydamagetothefuel
deliverysystemmayresultinleaks.Allthetubingcarryingliquidorgasfuelfrom
thefueltankstothevaporizerarestainlesssteel.Thetubingfromthevaporizer
throughouttheremainderofthefueldeliverysystemisspecializedhighpressure
tubing.Anydamagetothissystemshouldberepairedassoonaspossible.

Duringthedailywalkaround,checkforanyleaksordamagetothefuelsystem.The
appearanceofavaporcloudaccompaniedbyahissingnoisemayindicateamethane
leak.Inspecttheoutsideofthefueltankforfrost(LNGonly).Afrostedtankindicates
thattheinnertankisleakingintotheoutertankortherehasbeenalossofvacuum.
Openthetankdoor;iftheEvacuationPlughaspoppedout,thetankmustbeserviced.
Aleakingconditionrequiresservicebeforethevehicleisoperated.

WARNING

Donotoperateavehiclewhichhasa
methaneleak.

Note:Somefrostingandsweatingisnormalaroundtheplumbingttingsinthe
shroudedendofthetank.

28MAINTENANCEANDLUBRICATION

PrimaryLNGTankVentPiping

Fromthefactory,theventpipingfromtheprimaryLNGtankventsisattachedtothe
intakestackbydisposableplasticstraps.Thepipingshouldberemovedfromthe
intakestackandplumbedupandoverthebodybythebodyinstallers.

CAUTION

Itisimportanttokeeptheprimary
pressureventfreeofblockagedueto
ice,snowordebris.

CAUTION

IfLNGvehiclesmustbeparkedor
workedonindoorsforshortperiodsof
time,pipingfromtheprimaryLNGtank
ventpipetotheoutsideofthebuilding
shouldbeprovided.De-fuelingor
removaloftheLNG/CNGtanksis
recommendedforvehiclesstored
indoorsforlongperiodsoftime.

MAINTENANCEANDLUBRICATION29

BEFOREPERFORMINGMAINTENANCEONTHE
LNGORCNGTANKSORFUELSYSTEM

Note:Separatemethanedetector/alarmsystemsshouldbeinstalledinfacilitiesthat
frequentlyhouseLNG/CNGvehicles.Inaddition,hand-heldmethanedetector/alarm
devicesshouldbeusedwhenworkingonLNG/CNGvehicleswithanon-functioning
ordisconnectedmethanedetector/alarmsystemandwherenoauxiliarymethane
detector/alarmsystemisinstalled.

CAUTION

Beforeperforminganymaintenanceon
theLNG/CNGtanksystem,refertothe
tankmanufacturer’soperationmanual.

WARNING

REMOVEPRESSURE.Before
workingontheLNG/CNGfuelsystem,
closethefuelvalvesoneachtankand
relievethepressureinthefuellineby
openingthedrainonthefuellterorby
runningtheengineuntilitstops.
TheLNG/CNGfuelsystemsare
pressurizedsystems.LNGwillboiland
causepressuretobuildinthesystem.
DoNOTallowLNGtobecometrapped
inpiping,asbetweentwoclosedvalves.
Itwillvaporizeandrapidlyincrease
pressure,burstingthepipe.

RemovingPressureBeforeWorkingontheEngine
FuelSystem

BeforeservicingtheLNG/CNGenginefuelsystem,removepressurefromthefuel
linesbyturningthevalvesoneachtanktotheOFFposition.Thiswillstopmorefuel
fromenteringthelinestotheengine.Allowtheenginetorununtilit"dies."

30MAINTENANCEANDLUBRICATION

RemovingPressureBeforeWorkingontheTanks

Ifthefuellinesbetweenthetanksorthetanksthemselvesmustbeworkedon,the
systemmustbetotally"bled"offuel,includingthetanks.Withaminimumamount
offuelinthetanks,openthemanualventvalvesonthetanksuntilthetankpressure
gaugesreadzero.

Note:Ifpossible,trytoservicethetanksafterthevehiclehasusedmostofits
on-boardfuel.

WARNING

Neverbleedthetanksinanenclosed
area.Besuretherearenosourcesof
ignitioninthearea.

MovingaVehicleUsingAuxiliaryFuel

WhenLNGtanksarenotfueledorhavebeenremoved,thevehiclemaybemovedby
connectinganauxiliaryCNG(compressednaturalgas)tanktotheconnectionlocated
ontheleftsideframerailbehindthefrontinsideofthefueltankonthedriverside.

CAUTION

UseaCNGtankwithitsownpressure
regulator.Pressuremustnotexceed120
psigatauxiliarytankconnectionvalve
(seeillustration).

MAINTENANCEANDLUBRICATION31

Turnthethree-wayvalvetoAUXtooperatethevehiclefromanauxiliarytank.

TurnthevalvetoONtooperatefromthemaintank(s)and,besuretoturnthevalveto
OFFwhenparkingthevehicle.

C0032260

1.Three-WayFuelValve3.FrontEdgeofFuelTank,DriverSide

2.AuxiliaryTankConnectionValve­120psigmaximum

C0032261

32MAINTENANCEANDLUBRICATION

ENGINEMAINTENANCE

AirFilter

ChecktheFilterMinderGaugedaily.TheFilterMinderGaugeistypicallymounted
directlyontheaircleanercanisterbehindthecab(MRUandLEU)asshowninthe
illustrationfollowing.Changethelterwhenthegaugeshows300mm(12in)of
waterortherestrictiongaugeredsignallocksinfullview.Regardlessofthegauge
reading,changetheelementatleastonceyearly.

Note:Asdamageorholesintheltermediumwillgiveaninaccuraterestriction
reading,changetheelementatleastonceyearlytopreventdust,dirtandotherharmful
contaminantsfromenteringtheengine.

CAUTION

Donotattempttocleantheairlter
elementwithcompressedairasthis
coulddamagetheltermediumand
possiblyresultinsevereenginedamage.

C0032262

MAINTENANCEANDLUBRICATION33

Toproperlyinstallanewlterelement:

1Wipetheaircleanerhousingclean.

2Loosenthecoverretainingnutsandremovethelterelement.

3Inspectsealingareasfor"dirttracks"whichwouldindicatethatdusthasleaked

pasttheseal.Ifdirttracksarefound,thecausemustbedeterminedandcorrected.

4Thoroughlycleantheinsideoftheaircleanercanisterwithadampclothor

vacuumcleaner.

5Inspecttheinsideofthecanisterforrust.Ifrustispresent:

•Removetheaircleanercanisterfromthechassis.

•RemovealllooserustwithawirebrushorcoarseScotchBrite®pad.

•ThoroughlywashtheareawithPPGDX-440®,orequivalentwaxandgrease

remover.

•EtchandpreparewithPPGMetalPrep79(DX-579®),orequivalent.

•Rinsewithwateranddrythoroughly.

•TreattheareawithundilutedGalvaprepSGDX-520®,orequivalent.

•Rinsewithwateranddrythoroughly.

•PaintwithPPGDP40/401®,orequivalent.

•Reinstalltheaircleanercanisteronthechassis.

6Inspectthesealingareasofthehousingfordamage.Repairorreplaceasnecessary.

7UseMACKTrucks,Inc.,approvedreplacementelementsandgaskets.Makesure

thenewelementsandgasketsarenotdamaged.Besuretousenewgasketseach
timetheelementischanged.

8Reinstallthecoverandtorquetheretainingnutsevenlyat11N.m(8-10lb-ft).

9ResettheFilterMinderbypushinginthebutton.

34MAINTENANCEANDLUBRICATION

AirInletSystemDucts,HosesandClamps

Every45daysor150hours,whicheveroccursrst,inspectallductsandhosesfor
signsofleakageorchang.Replacehoseandrepairorreplaceductswithholes.
Tightenclamps.

Chassis-MountedChargeAirCooling(CMCAC)

VehiclesequippedwithCMCACrequirethefollowingpreventivemaintenance:

•Daily—Removeallinsects,leavesandotherforeigndebrisfromthefrontalarea

byusingarmbristlebrushandsoapywater.

CAUTION

DonotuseacausticsolutiontocleanCMCAC.

•Every45daysofusageor150hours*—Checkallairductingandgasket

connections.Properhoseclamptorquingprocedureistotightenhoseclampnuts
untilspringisfullycompressed3.9to4.5N.m(35–40lb-in).

•Every180daysofusageor600hours*—Checkforcracks.Checkthemounting

bracketsforsecurityandcondition.Torquethemountsto41N.m(30lb-ft).Check
corensforexternaldamage,debrisorsaltcorrosion.Usearm,bristledbrushto
removedsaltcorrosion.Useairpressuretocleancoreblockageduetodebris.

*Whicheveroccursrst.

MAINTENANCEANDLUBRICATION35

FuelSystem

WARNING

BeforeservicingtheLNG/CNGengine
fuelsystem,removepressurefromthe
fuellinesbyturningthevalvesoneach
tanktotheOFFposition.Thiswillstop
morefuelfromenteringthelinestothe
engine.Allowtheenginetorununtil
it"dies."

1.Engine-MountedFilterAdapter(For
clarity,thelterassemblyisshown
removedfromtheengine.)

2.FilterDrain6.ThreadedFilterRod

3.FilterCanister7.O-Ring

4.FilterRetainer

5.FilterElement

C0032264

36MAINTENANCEANDLUBRICATION

•Afterallfuelhasbeenremovedfromthefuelsystem,opentheltercanister

drain[2]atthebottomofthelterunit.Allowanyaccumulatedwaterandany
remainingfueltodrain.

•Rotatetheltercanister[3]counterclockwisetoreleaseitfromthemounted

lteradapter[1].

•Removetheretainer[4]fromthebottomofthethreadedrod[6]thatholdsthelter

element.Pullstraightdownonthelterelementtoremoveitfromtherod.

•ReplacethecanisterbowlO-ring[7]ifthereareanysignsofdamageor

deterioration.Cleananylterdebrisfromtheadapter,canisterandretainer.

•LubricatetheO-ringverylightlywithcleanengineoilandreinstallitintheadapter

groove.Installthenewlterelementontotherodandhand-tightentheretainer
ontotherodtoholdthelterinplace.

•Reinstallandhand-tightenthecanisteroverthelterelement.

•Closethelterdrain.

•Openthevalvesoneachtanktoallowfueltore-enterthesystem.

•Starttheengineandcheckforleaks.

Note:Avaporcloudorhissingsoundnearthelterindicatesaleak.

CAUTION

UseofanythingotherthangenuineMACK/Cumminsltersmaycausedamage
andvoidtheenginewarranty.

COOLINGSYSTEM

Thecoolingsystemplaysanimportantroleinoverallengineperformanceby
keepingtheenginewithinthenormaloperatingtemperaturerange-hotenoughfor
efcientcombustion,andcoolenoughtopreventenginedamagefromoverheating.
Goodpreventivemaintenancepractices,alongwithmonitoringcoolingsystem
performance,goalongwayinpreventingenginedamagethatcouldresultfrom
coolingsystemproblems.Themaintenanceitemsandtestsoutlinedinthissection
shouldbeperformedattheintervalsspeciedtoensureoptimumperformancefrom
thecoolingsystem.

MAINTENANCEANDLUBRICATION37

RadiatorPressureCap

AteveryCandDinspection,checktheconditionoftheradiatorcapgasket.Also,
pressuretestthecapusingasuitablecoolingsystemandradiatorcaptester.A16-psi
pressurecapiscurrentlyusedonallMACKTrucks,Inc.,modelchassis.

Thermostat

Checkthermostatoperation,particularlyduringcoldweather,tomakesurethe
thermostatclosesfully,doesnotallowanyleakageanddoesnotopentoosoon.Also,
thethermostatsealshouldbecheckedforleakage.Coolantleakingpastthethermostat
cancauseovercoolingandmayresultininsufcientcabheat.

38MAINTENANCEANDLUBRICATION

FederalEmissions39

FEDERALEMISSIONREQUIREMENTS

ThissectioncoverstherequirementoftheUnitedStatesCleanAirActwhichstates:

"Themanufacturershallfurnishwitheachnewmotorvehicleormotorvehicleengine
suchwritteninstructionsforthemaintenanceanduseofthevehicleorengineby
theultimatepurchaserasmaybereasonableandnecessarytoassuretheproper
functioningofemissioncontroldevicesandsystems."

Thissectionalsocoverstherequirementsoftheemissionsregulationspromulgated
undertheMotorV ehicleSafetyActinCanada.

TamperingwithGaseousEmissionControl
SystemsProhibited

TheFederalCleanAirActprohibitstheremovalorrenderinginoperativeofany
deviceorelementofdesigninstalledonorinamotorvehicleormotorvehicleengine
incompliancewithFederalEmissionRegulationsby:

1Anypersonpriortoitssaleanddeliverytotheultimatepurchaser,or

2Anymanufacturerordistributorafteritssaleanddeliverytotheultimatepurchaser,

or

3Anypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or

tradingmotorvehiclesormotorvehicleenginesfollowingitssaleanddelivery
totheultimatepurchaser,or

4Anypersonwhooperatesaeetofmotorvehiclesfollowingitssaleanddelivery

totheultimatepurchaser.

40FederalEmissions

GaseousEmissionControlSystemsWarranty

(SupplementtoStandardV ehicleWarranty)

MACKTrucks,Inc.warrantstotheoriginalandeachsubsequentpurchaserofa
MACKTrucks,Inc.,motorvehicleorCummins-WesportISL_Genginethatsuch
vehicleorengineisdesigned,builtandequippedsoastoconformatthetimeofsale
withallsuchUnitedStatesandCanadaFederalemissionsregulationsapplicableatthe
timeofmanufacture,andthatitisfreefromdefectsinmaterialsandworkmanship
whichwouldcauseittofailtomeetsuchregulationswithinaperiodofveyearsafter
deliveryofsuchvehicleorenginetotheoriginalpurchaseror,subjecttotheexclusions
setforthbelowforcomponentsnotmanufacturedbyMACKTrucks,Inc.,beforesuch
vehicleorthevehicleinwhichsuchenginehasbeeninstalled,hasbeenoperated480
000km(300,000miles)or10,800hoursofengineoperation,whicheverrstoccurs.

Equipmentsuchasturbochargers,injectionequipment,andchargeaircoolersnot
manufacturedbyMACKTrucks,Inc.areexcludedfromtheabovewarranty,butare
coveredbytheapplicablewarrantyoftherespectivemanufacturerineffectatthe
timeofdelivery;provided,however,thatinnocasewillanysuchcomponentbe
warrantedforlessthanveyearsafterdeliveryofthevehicleorenginetotheoriginal
purchaseror160000km(100,000miles)ofoperationofsuchvehicleorofthe
vehicleinwhichsuchenginehasbeeninstalled,or3,000hoursofengineoperation,
whicheverrstoccurs.

Themanufacturer’sobligationunderthiswarrantyislimitedtotherepairor
replacement,ashereinprovided,atitsoptionofanypartorpartsoftheemission
controlsystemofsuchvehicleorenginefoundtotheManufacturer’ssatisfactionto
bedefectiveuponexaminationbyit,providedthatsuchpartorpartsshallbereturned
totheManufacturer’sfactoryortoitsnearestauthorizedDistributororSubsidiary.

FederalEmissions41

GASEOUSEMISSIONSCONTROLSYSTEM
WARRANTYFEDERALEMISSIONREQUIREMENTS

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheFederalemissionsregulations.

ItemsNotCoveredbytheEmissionControl
SystemsWarranty

•Malfunctionscausedbymisuse,improperadjustments,modication,alteration,

tampering,disconnection,improperorinadequatemaintenance.

•Damageresultingfromaccident,actsofnatureorothereventsbeyondthecontrol

ofMACKTrucks,Inc.

•Inconvenience,lossofuseofthevehicle,orcommercialloss.

•Anyvehicleonwhichtheodometerhasbeenchangedsothatmileagecannot

bereadilydetermined.

Therepairorreplacementofdefectivepartsunderthiswarrantywillbemadewithout
chargeforpartsand,ifmadeatthemanufacturer’sfactory,Subsidiary,orauthorized
Distributor’splaceofbusiness,withoutchargeforlabor.

THISW ARRANTYISMADEEXPRESSL YINLIEUOFANYOTHER
WARRANTIES,EXPRESSEDORIMPLIED,INCLUDINGANYIMPLIED
WARRANTYOFMERCHANTABILITYORFITNESSFORAP ARTICULAR
PURPOSE,ANDOFANYOTHEROBLIGA TIONONTHEPARTOF
THEMANUFACTURER,INCLUDING,WITHOUTLIMITA TIONOFTHE
FOREGOING,CONSEQUENTIALANDINCIDENT ALDAMAGE.

42FederalEmissions

EmissionControlSystemsWarranty—California

TheCaliforniaAirResourcesBoardandMackT rucks,Inc.arepleasedto
explaintheCaliforniaemissioncontrolsystemwarrantyonyournewmotorvehicle

engine.InCalifornia,newmotorvehicleenginesmustbedesigned,builtandequipped
tomeettheState’sstringentanti-smogstandards.MackTrucks,Inc.mustwarrantthe
emissioncontrolsystemonyourenginefortheperiodoftimelistedbelow;provided
therehasbeennoabuse,neglect,orimpropermaintenanceofyourengine.

Youremissioncontrolsystemmayincludepartssuchasthefuelcontrolsystem,
turbochargerassembly,electroniccontrolmoduleandotheremission-related
assemblies.

Whereawarrantableconditionexists,MackTrucks,Inc.willrepairyourengineatno
costtoyouincludingdiagnosis,parts,andlabor.

Manufacturer’sWarrantyCoverage

Ifanemission-relatedpartofyourengineisdefective,thepartwillbe
repairedorreplacedbyMackTrucks,Inc.Thisisyouremissioncontrol
systemDEFECTSWARRANTY.

Owner’sW arrantyResponsibilities

Asthemotorvehicleengineowner,youareresponsiblefortheperformanceofthe
requiredmaintenancelistedinthismanual.MackTrucks,Inc.recommendsthat
youretainallreceiptscoveringmaintenanceofyourvehicle,butMACKTrucks,
Inc.cannotdenywarrantysolelyforthelackofreceiptsorforyourfailuretoensure
theperformanceofallscheduledmaintenancelistedinothermanualswhichwere
suppliedwithyourvehicle(s).

YouareresponsibleforpresentingyourmotorvehicleenginetoaMACKTrucks,Inc.
dealerassoonasaproblemexists.Thewarrantyrepairsshouldbecompletedina
reasonableamountoftime,nottoexceed30days.

Asthemotorvehicleengineowner,youshouldalsobeawarethatMackTrucks,Inc.
maydenyyouwarrantycoverageifyourvehicleoraparthasfailedduetoabuse,
neglect,impropermaintenance,orunapprovedmodications.

Ifyouhaveanyquestionsregardingyourwarrantyrightsandresponsibilities,you
shouldcontacttheMackTrucks,Inc.WarrantyDepartmentatP.O.Box1801,
Allentown,P A18105,ortheCaliforniaAirResourcesBoardat9480TelstarAvenue,
ElMonte,California91731.

FederalEmissions43

(SupplementtoStandardV ehicleWarranty)

(Applicableonlytovehiclesand/orenginescertiedforsaleandregisteredin
theStateofCalifornia)

MackTrucks,Inc.warrantstotheoriginalandeachsubsequentpurchaserofaMACK
TrucksInc.motorvehicleorCummins-W esportISL_Genginethatsuchvehicle
orengineisdesigned,builtandequippedsoastoconformatthetimeofsalewith
allStateofCaliforniaemissionsstandardsapplicableatthetimeofmanufacture,
andthatitisfreefromdefectsinmaterialsandworkmanshipwhichwouldcauseit
tofailtomeetsuchstandardswithinaperiodofveyearsafterdeliveryofsuch
vehicleorenginetotheoriginalpurchaser,orsubjecttotheexclusionssetforthbelow
forcomponentsnotmanufacturedbyMACKTrucks,Inc.,beforesuchvehicleor
thevehicleinwhichsuchenginehasbeeninstalled,hasbeenoperated480000km
(300,000miles)or10,800hoursofengineoperation,whicheverrstoccurs.

Equipmentsuchasturbochargers,injectionequipment,andchargeaircoolersnot
manufacturedbyMACKTrucks,Inc.areexcludedfromtheabovewarranty,butare
coveredbytheapplicablewarrantyoftherespectivemanufacturerineffectatthe
timeofdelivery;provided,however,thatinnocasewillanysuchcomponentbe
warrantedforlessthanveyearsafterdeliveryofthevehicleorenginetotheoriginal
purchaseror160000km(100,000miles)ofoperationofsuchvehicleorofthe
vehicleinwhichsuchenginehasbeeninstalled,or3,000hoursofengineoperation,
whicheverrstoccurs.

MACKTrucks,Inc.’sobligationunderthiswarrantyislimitedtotherepairor
replacement,ashereinprovided,atitsoptionofanypartorpartsoftheemissions
controlsystemofsuchvehicleorenginefoundtotheManufacturer’ssatisfactionto
bedefectiveuponexaminationbyit,providedthatsuchpartorpartsshallbereturned
totheManufacturer’sfactoryortoitsnearestauthorizeddealer .

Thiswarrantyshallnotapplytoanydefectswhicharisesolelyasaresultofaccident
orownerabuseorlackofrequiredmaintenance.

Therepairorreplacementofdefectivepartsunderthiswarrantywillbemadewithout
chargeforpartsand,ifmadeatMACKTrucks,Inc.’sfactoryorauthorizeddealer’s
placeofbusiness,orauthorizedrepairfacility,withoutchargefordiagnosisorlabor.

THISW ARRANTYISMADEEXPRESSL YINLIEUOFANYOTHER
WARRANTIES,EXPRESSEDORIMPLIED,INCLUDINGANYIMPLIED
WARRANTYOFMERCHANTABILITYORFITNESSFORAP ARTICULAR
PURPOSE,ANDOFANYOTHEROBLIGATIONORLIABILITYONTHEPAR T
OFMACKTRUCKS,INC.INCLUDING,WITHOUTLIMITATIONOFTHE
FOREGOING,CONSEQUENTIALANDINCIDENT ALDAMAGESSUCHAS
INCONVENIENCE,LOSSOFUSEOFTHEVEHICLE,COMMERCIALLOSS,
ETC.

44FederalEmissions

EMISSIONSCONTROLSYSTEMWARRANTY—
CALIFORNIA

ProceduresforHandlingEmissionsControl
SystemWarranty

Thefollowingenginecomponentsarecoveredbythesupplementalemissionscontrol
systemwarrantypolicyasrequiredbytheCaliforniaCodeofRegulations.

1RepairsbyMACKTrucks,Inc.Dealers,Sub-DealersandServiceDealers

RepairscoveredbytheCaliforniaEmissionControlSystemsWarrantywillbe
performedbyanauthorizedMACKTrucks,Inc.repairfacilityathisplaceof
businesswithnochargeforpartsandlabor(includingdiagnosis),usingMACK
Trucks,Inc.partsforanypartoftheemissioncontrolsystemscoveredbythis
warrantyandfounddefective.

2InanEmergency

Inanemergency,whereanauthorizedMACKTrucks,Inc.facilityisnotavailable,
repairsmaybeperformedatanyavailableserviceestablishment,orbytheowner,
usinganyreplacementpart,withinthelimitationsofparagraphs4and5inthis
section.Anemergencyconditionexistsunderthissectionif,after30days,repairs
havenotbeencompletedorpartsarenotyetavailable.MACKTrucks,Inc.
willreimbursetheownerforsuchrepairsthatarecoveredunderthiswarranty,
includingdiagnosis,nottoexceedMACKTrucks,Inc.suggestedretailpricefor
partsreplacedandlaborchargesbasedonMACKTrucks,Inc.recommendedtime
allowanceandgeographicallyappropriatehourlylaborrate.Replacedpartsand
paidinvoicesmustbepresentedataMACKTrucks,Inc.facilityasaconditionof
reimbursementforemergencyrepairsperformedelsewhere.

3RepairsbyNon-MACKTrucks,Inc.Facilities

Ownersmayelecttohavemaintenance,replacement,orrepairofemissioncontrol
systemsperformedbyanyrepairfacility,andmayelecttousepartsotherthan
MACKTrucks,Inc.partswithoutinvalidatingthewarrantyonothercomponents,
butthecostofsuchserviceorpartswillnotbecoveredbyMACKTrucks,Inc.
underitswarranty .

4UseofNon-MACKTrucks,Inc.Parts

UseofreplacementpartswhicharenottheequivalentofMACKTrucks,Inc.
partsmayimpairtheeffectivenessofemissioncontrolsystems.Ifotherthan
MACKTrucks,Inc.partsareused,theownershouldobtainassurancesthatsuch
partsarewarrantedbytheirmanufacturertobetheequivalentofMACKpartsin
performanceanddurability.MACKTrucks,Inc.assumesnoliabilityunderthis
warrantywithrespecttopartsotherthanMACKTrucks,Inc.parts;however,the
useofnon-MACKTrucks,Inc.partsdoesnotinvalidatethewarrantyonother
componentsunlessnon-MACKTrucks,Inc.partscausedamagetowarrantedparts.

5MaintenanceandMaintenanceRecords

Thevehicleownerisresponsiblefortheperformanceofallrequiredmaintenance
speciedinthishandbook.MACKTrucks,Inc.willnotdenyawarrantyclaim
solelybecausethereisnorecordofmaintenance;however,MACKTrucks,Inc.
maydenyawarrantyclaimiffailuretoperformrequiredmaintenanceresultsinthe
failureofawarrantedpart.Receiptsorotherrecordscoveringtheperformance

FederalEmissions45

ofscheduledmaintenanceshouldberetainedtoanswerquestionsthatmayarise
concerningmaintenance.Maintenancerecordsshouldbetransferredtosubsequent
ownersifthevehicleissold.

6ItemsNotCoveredbytheEmissionControlSystemsWarranty

•Malfunctionscausedbymisuse,improperadjustments,modication,alteration,

tampering,disconnection,improperorinadequatemaintenance.

•Damageresultingfromaccident,actsofnatureorothereventsbeyondthe

controlofMACKTrucks,Inc..

•Inconvenience,lossofuseofthevehicle,orcommercialloss.

•Anyvehicleonwhichtheodometerhasbeenchangedsothatmileagecannot

bereadilydetermined.

CAUTION

Intheeventthatdamageresultsfromunauthorizedadjustmentsasevidencedby
settingsotherthanasspecied,orbrokenfastenerseals,thecostofrepairingsuch
damageWILLNOTBECOVEREDunderwarranty.

CAUTION

Anyunauthorizedadjustmentscancauseseveredamagetotheengine.Intheevent
thatdamageresultsfromunauthorizedadjustments,asevidencedbysettingsother
thanspecied,orbrokenfastenerseals,thecostofrepairingsuchdamageWILL
NOTBECOVERED.

7CustomerAssistance

MACKTrucks,Inc.wishestoensurethattheCaliforniaEmissionControlSystem
Warrantyisproperlyadministered.Intheeventthatownersdonotreceivethe
warrantyservicetowhichtheybelievetheyareentitledundertheCalifornia
EmissionControlSystemsWarranty,theyshouldcontactthenearestMACK
Trucks,Inc.RegionalOfceforassistance.Theaddressandtelephonenumber
foreachRegionalOfceisintheMACKTrucks,Inc.DirectoryofSales,Parts
andServiceCenters.Ownersinneedofadditionalassistanceorinformation
concerningtheCaliforniaEmissionControlSystemsWarrantymayalsocontact:

MackTrucks,Inc.

WarrantyActivities

P.O.Box26259

Greensboro,NC27402–6115

46ELECTRICAL

CircuitBreakerandRelayPanel

LEUSerieswithCNGEngine

C0032284

LEUSerieswithLNGEngine

ELECTRICAL47

C0032285

48ELECTRICAL

LEUSerieswithCNGEngine

CabCircuitProtection

#1—5A#2—20A#3—15A#4—25A

RearHazard
Lamps

#5—10A#6—10A#7—15A#8—20A

ParkBrake,
EmergencyStop
Lamps

#9-20A#10-15A#11-20A#12-10A

CBPosts

#13-10A#14-10A#15-5A#16-10A

Anti-LockBrake
System

#17-10A#18-5A#19-15A#20-15A

KysorControlAnti-LockBrake

#21-20A#22-20A#23-10A#24-10A

LHWiperMotorRHWiperMotorWiperControl,

#25-30A#26-15A#27-10A#28-15A

Heater

#29-10A#30-#31-#32-15A

HydraulicPump
ProtectionCircuit

#33-20A#34-#35-20A#36-

StopLamps

Headlamps(T ypeI
Breaker)

DomeLamps

Communication
Connector

Anti-LockBrake
System

System

PlowUp-Down
Solenoids

NoCircuitNoCircuitRearFloodLamp

NoCircuitClearanceLampsNoCircuit

MarkerLamps,
CabIDLamps,
Park&TailLamps

IgnitionSwitchCigarLighter,Horn

Spare

Spare

Gauges,Indicator
Lamp

WasherMotor

RearHopper
Lamps

DirectionalLamps,
Flasher

ParkBrakeApply
Solenoid

BodyBuzzer

WoodwardEngine
ECU

MasterLH-RH
Switch

AllisonHD
InterfaceCircuits

ELECTRICAL49

CabCircuitProtection

#37-20A#38-#39-20A#40-15A

TailLampsNoCircuitBody,Ignition

Power

#41-15A#42-20A#43-#44-20A

HydraulicPump
Solenoid

#45-#46-15A#47-20A#48-10A

Spare

ReverseLamps,
BackUpAlarm

SynchroStart

NoCircuitAirDryer,Drain

Spare

ReserveFuelTank

Valve

AllisonHDControl
Unit

50ELECTRICAL

LEUSerieswithLNGEngine

CabCircuitProtection

#1-15A#2-20A#3-15A#4-20A

Lighter,Horn

#5-20A#6-20A#7-20A#8-10A

Stop,ParkLampsHeadlampDRL

#9-20A#10-20A#11-10A#12-10A

ClearanceLampBatteryPowerFeed

#13-15A#14-10A#15-15A#16-20A

GaugePanelKysorW arningMirrorHeatAirDryer

#17-20A#18-10A#19-30A#20-20A

IgnitionPower
Feed

#21-20A#22-10A#23-10A#24-15A

LHWiperLH/RHControlMunciePTOMirrorMotor

#25-15A#26-#27-5A#28-15A

CNGEngine
Interface

#29-20A#30-15A#31-10A#32-

Power,Indicator
Lamps

#33-#34-30A#35-#36-

NoCircuitNeutral/Reverse

CBPost

(TypeIBreaker)

EngineBrake

NoCircuitABS,Ignition

J1708Diagnostic
Connection

Power

Radio,IgnitionDirectionalSignal

MarkerLamps

SpareSparePower,

Heater

Power

Spare,IgnitionNoCircuit

NoCircuitNoCircuit

Lamps

DomeLamps

IndicatorLamps

RHWiper

Automatic
Transmission

ELECTRICAL51

CabCircuitProtection

#37-15A#38-#39-#40-

2-WayRadioNoCircuitD-Full,ABS,

Battery

#41-#42-#43-#44-15A

NoCircuitNoCircuitNoCircuitD-Basic,ABS,

#45-#46-20A#47-#48-10A

NoCircuit

BeaconLamps

NoCircuitAutomatic

NoCircuit

Battery

TransmissionECU

52ELECTRICAL

MRUSeries

C0032286

ELECTRICAL53

CabCircuitProtection

#1-5A#2-20A#3-15A#4-25A

AccessoryRelayHeadlampsMarkerLams,ID

Lamps

#5-10A#6-10A#7-10A#8-20A

StopLamps

#9-20A#10-15A#11-15A#12-

CB,RadioCommunication

#13-10,15,20A#14-10A#15-15A#16-

ABSABSSpareOpen

#17-10A#18-15A#19-10A#20-20A

KysorShutdownNGWoodward

#21-20A#22-20A#23-20A#24-10A

LHWiperRHWiper

#25-30A#26-10A#27-5A#28-15A

Heater,A/C

#29-15A#30-#31-10A#32-15A

IgnitionStud

#33-20A#34-30A#35-30A#37-20A

TrailerStopLampsReverse/Neutral

#38-20A#39-20A#40-#41-10A

BatteryStudTrailerABSPower

#42-15A#43-20A#44-20A#45-30A

Back-UpLamps

#46-20A#47-

Strobe

DomeLamps

Connection

ECU

SpareABS

Open

Power

BatteryBox,
IgnitionStud

Open

IgnitionSwitchHorn,CigarLighter

BatteryStud

Gauges

BatteryBox,
IgnitionStud

Automatic
Transmission

Cab&Trailer
ClearanceLamps

Open

AirDryerFuelHeater

DirectionalSignal
Flasher

Spare

MirrorHeat

Spare

HDAutomatic
Transmission

Spare

TrailerTailLamps

PTO,FanClutch

54ELECTRICAL

1F1-5A—MPHSensor,TransmissionModulatorRelay,FuelGauge,PowerStud,

ElectronicMalfunctionIndicator,PowersFuse8

2F2-15A—CamSensor,Relay#1

3F3-35A—ManifoldAbsolutePressure,NaturalGasT emperature,EngineCoolant

Temperature,Pre-TurbinePressure,NGTP/TKTemperatureReturn,ExhaustBack
Pressure,Relay#2

4F4-15A—UEGOConnectionOxygenSensor,LowPressureLockoffSolenoid,

HighPressureLockoffSolenoid

5F5-15A—Governor,Wastegate

6F6-10A—IgnitionModule

7F7-3A—MethaneWarningDetector

8F8-1A—PoweredbyFuse1,FuelTankSendingUnit(LNGOnly)