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.