MACK PV776 MX, PV776 CMM, PV776 CLX, PV776 CSM, PV776 CXX Operator Manual

Mack

®

MAINTENANCE AND LUBRICATION

21636397

MAINTENANCE
AND LUBRICATION

© Mack Trucks, 2010

21636397

21636397

December 2010

MAINTENANCE
AND LUBRICATION

Contents

Operator’sManualVehicleMaintenanceCMM,CMH,CLX,CSM,andCXX.............1

Foreword......................................................................................................1

WarningLabelInformation................................................................................2

GeneralInformation........................................................................................4

InformationFortheOwner................................................................................4

NoiseEmissions.............................................................................................5

LabelInformation..........................................................................................10

SafetyInformation.........................................................................................12

ProperMaintenanceProcedure..........................................................................12

InjuryPrevention...........................................................................................15

EngineDamagePrevention...............................................................................23

ElectricSystemDamagePrevention....................................................................25

GeneralEngineInformation..............................................................................27

EngineOverview,MP8LeftSideView................................................................27

EngineOverview,MP8RightSideView..............................................................28

ElectricalSystem...........................................................................................29

Batteries......................................................................................................29

BatteryCondition...........................................................................................31

Charging......................................................................................................32

LoadTest.....................................................................................................33

ElectricalConnectionProtection........................................................................34

PrecautionsWhenInstallingElectricalEquipment..................................................37

EngineStorage..............................................................................................38

EngineStorage..............................................................................................38

MaintenanceandService.................................................................................39

MaintenanceHazards......................................................................................39

EngineComponents,ServiceSchedules...............................................................39

CoolingSystem.............................................................................................41

FuelSystem..................................................................................................46

EngineOil....................................................................................................58

EngineAirFilter............................................................................................65

ExhaustAfter-TreatmentSystem........................................................................68

DriveBeltReplacementIntervals.......................................................................78

AutomaticBeltTensionerMaintenance................................................................84

TurbochargerandChargeAirCooler...................................................................88

PreventiveMaintenanceAirSuspensions.............................................................91

SteeringandBrakesMaintenance.......................................................................92

Tires,WheelsandHubMaintenance...................................................................96

ChassisMaintenance.....................................................................................111

CabMaintenance.........................................................................................113

Lubrication.................................................................................................119

OilCapacityTablesandViscosityCharts...........................................................125

CUSTOMERSER VICE................................................................................136

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX1

Foreword

DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperationaland
safetyinformationthatisneededbyalldriversandownersofthisvehicle.

Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis
extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis
operated.Thismanualalsocontainsaconsiderableamountofinformationconcerningthe
vehicle,suchasvehicleidentication,PreventiveMaintenancerecommendationsandalog
foryourservicerecords.Pleasekeepthisinthevehicleatalltimes.Informationfromother
componentmanufacturersissuppliedinseparatemanualsintheOwnersPackage.

MACKTrucks

QLD, 4076

Ordernumber:PV776-21636397

Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinretrieval
system,ortransmittedinanyformsbyanymeans,electronic,mechanical,photocopying,
recordingorotherwise,withoutthepriorwrittenpermissionofMACKTrucks.

2Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

WarningLabelInformation

IMPORTANT:Beforedrivingthisvehicle,becertainthatyouhavereadandthat
youfullyunderstandeachandeverystepofthedrivingandhandlinginformationin
thisOperatorsManual.Becertainthatyoufullyunderstandandfollowallsafety
warnings.Itisextremelyimportantthatthisinformationisreadandunderstood
beforethevehicleisoperated.

ITISIMPOR T ANTTHA TTHEFOLLOWINGINFORMA TIONCONCERNINGLABELS
BEREAD,UNDERSTOODANDALW A YSFOLLOWED.

Thefollowingtypesoflabelsareusedthroughoutthismanual:

Note:Anotedenesanoperatingprocedure,practice,condition,etc.,whichisessentialto
properoperationofthevehicle.

DANGER

Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresultin
seriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablackbackground
withablackborder.

WARNING

Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresultin
personalinjuryorseveredamagetothevehicle.Thewarninglabelisinblacktypeon
agraybackgroundwithablackborder.

CAUTION

Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonalinjury
isnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblacktypeona
whitebackgroundwithablackborder .

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX3

WarningandAdvisoryLabels

Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsofthevehicle
toalertdriversandservicetechniciansaboutsituationsthatmayleadtopersonalinjury
orequipmentdamage.Intheeventthatalabelisdamagedormissingthelabelmustbe
replaced.ContactyourauthorizedMACKTruckdealerforassistanceregardingW arning
andAdvisorylabels.

4Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

GeneralInformation

InformationFortheOwner

Iftherearequestionsonthemaintenanceandperformanceofyourvehicle,pleasediscuss
themwithyourMACKTruckdealer .Y ourauthorizeddealerisrequiredtohavetrained
mechanics,specialtoolsandsparepartstofullyserviceyourvehicle.Ifnecessary,your
dealerwillcontactMACKorothermanufacturersforanyassistance.

InadditiontothisMaintenanceManual,theremaybeadditionalinstruction/operators
manualssuppliedbycomponentmanufacturers.ThesemanualsareplacedintheOwners
Packageandplacedinthecab.Besuretoreadallthemanualsthoroughlybeforeoperating
thevehicle.

Also,varioussafetylabelsmaybeplacedoncomponentsbythecomponentmanufacturer.
Besuretoreadandfollowtheselabelstopreventdamagetothevehicle,personalinjury
orevendeath.

InformationinthismanualreferstoMACKcomponentsandMACKdrivetrain.

EstablishaPreventiveMaintenanceProgramwiththehelpofyourlocalMACKTruck
dealer.APreventiveMaintenanceProgrammakesitpossibletomaximizetheamountof
timeyourvehicleisupandrunning,resultinginlongercomponentlife.Thismakesfora
safervehiclebyreducinganymechanicalfailuresduetopoormaintenancepractices.

Note:Federallawrequiresmanufacturerstonotifyownersofitsproductsintheeventof
aFederalMotorV ehicleSafetyStandardorifasafetyrelateddefectisdiscovered.Ifyou
arenottheoriginalownerofthisvehicle,pleasenotifyusaboutthechangeinownership
throughanauthorizedMACKTruckdealer .Thisistheonlywaywewillbeabletocontact
youifnecessary.

ThisMaintenanceManualcoversallMACKvehiclesmanufacturedbyMACK,including
thewholechassisandallMACKmanufacturedcomponents.Forspecicmaintenance
informationonvendorcomponents,seetherespectivemanufacturersserviceand
maintenanceliterature.

Thismanual,togetherwithmanualsforspeciccomponentscontainimportantinformation
tobeabletooperatethisvehiclesafely.Theycontainadviceandinstructionswhichwill
enableyoutogettheoperatingeconomyandperformancethatyouexpectfromthisquality
vehicle.

Allinformation,illustrationsandspecicationscontainedinthismanualarebasedupon
thelatestproductinformationavailableatthetimeofpublication.Ifanyquestionsarise
concerningthecurrentstatusofFederalorstatelaws,theappropriateFederalorstateagency
shouldbecontacted.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX5

Note:Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactualvehicle,
however,keycomponentsaddressedinthismanualarerepresentedasaccuratelyaspossible.

MACKreservestherighttomakechangesatanytimeortochangespecicationsordesign
withoutnoticeandwithoutincurringobligation.

NoiseEmissions

NoiseControlSystem,OperatorInspectionandMaintenance
Requirements

ANoiseControlSystemMaintenanceLogislocatedinthismanual.Thislogshouldbe
usedtodocumentallNoiseControlSystemrelatedmaintenance,whetherthemaintenance
resultsfromaspecicnoisecontrolsysteminspection,oradeciencyidentiedduring
anothergeneralmaintenanceevent.

Ifadditionallogspaceisneeded,furtherentriesmaybeaddedonaseparatesheetof
paper.Storetheseadditionswiththemainlogtopreserveacomprehensiverecord.Itis
recommendedthatcopiesofallnoiseemissionsrelatedmaintenanceinvoicesberetained.

ThefollowingNoiseControlSysteminspectionandmaintenanceinstructionscontain
suggestedmaintenanceintervals.Theseintervalsmayneedadjustmentinordertobest
accommodatethespecicvehicleusage.ThefollowinginstructionsonlyconcernNoise
Emissionsrelateditemsanddonotaddressormodifyanygeneralvehiclemaintenance
requirements.

ThefollowingelementsmakeuptheNoiseControlSystem:

•NoiseShieldingandInsulationDevices

•CoolingSystem

•ExhaustSystem

•AirIntake/AirInductionSystem

•EngineControlandFuelSystems

•SelectiveCatalyticReduction(SCR)

6Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

TamperingwithNoiseControlSystem

Federallawprohibitsthefollowingactsorthecausingthereof:

(1)Theremovalorrenderinginoperativebyanyperson,otherthanforpurposesof
maintenance,repair,orreplacement,ofanydeviceorelementofdesignincorporatedinto
anynewvehicleforthepurposeofnoisecontrolpriortoitssaleordeliverytotheultimate
purchaserorwhileitisinuse;

or

(2)theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremovedor
renderedinoperativebyanyperson.

Amongtheactsthatconstitutetamperingaretheactslistedbelow:

•Removal,orrenderinginoperative,ofanyexhaustcomponents,includingmufers,

heavyordouble-wallexhausttubing,exibletubingorexhaustpipeclamping.

•Removal,orrenderinginoperative,ofthetemperature-modulatedcoolingfansystem.

•Removalofthecoolingfanshroud.

•Removal,orrenderinginoperative,oftheaircleanerorairintakein-linesilencer.

•Removalofthesounddeadeningmaterialfromthehoodorcabtunnel.

•Removal,orrenderinginoperative,oftheenginespeedgovernorsoastoallowengine

speedtoexceedthemanufacturersspecications.

•Removalofsplashshieldslocatedinsidethewheelhousings,iftted.

•Removalofengineblockshields,iftted.

•Removalofenginecrankcaseshieldsorinsulation,iftted.

•Removalofinsulatedrockerarmcovers.

•Removaloftransmissionnoiseshields,iftted.

NoiseShieldingandInsulationDevices

Maintenance

Ensuresoundshieldingandinsulatingdevicesareintact,iftted.Inspectcomponentsfor
damage.Primarysystemcomponentsrequiringnoiserelatedinspectionincludethehood,
enginecompartmentinsulatingmaterials(includinghoodinsulation,bulkheadinsulation,
doghouseinsulation,etc.)splashshields,cabskirts,fendershields,andbodypanels.Inspect
allrelatedfasteners,brackets,andclampsfordamageandtightness.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX7

RegulatoryCompliance

ActsthatconstitutetamperingwiththeNoiseShieldingandInsulationDevices(whentted):

Removingorrenderinginoperativetheengineand/ortransmissionnoisedeadeningpanels,
shieldsorinsulatingmaterials.

Removingorrenderinginoperativethecab-tunnelorhoodnoiseinsulatingmaterials.

Removingorrenderinginoperativeanyvehiclebodymountedsoundinsulationcomponents
and/orshields(caborfendershields,skirts,wheelhousingsplashshields,airsystemexhaust
silencers,etc.).

CoolingSystem

WARNING

DONOTworknearthefanwiththeenginerunningortheignitionintheONposition.
Theenginefancanengageatanytimewithoutwarning.Anyonenearthefanwhenit
turnsoncouldbeseriouslyinjured.

Maintenance

Visuallyinspectcoolingsystemcomponentsfordamage,and/ormisalignment.

Primarysystemcomponentsrequiringnoiserelatedinspectionincludefanblades,fanclutch,
fanshroud,fanring,andrecirculationshields.Checkfanblades,fanring,fanshroud,belt
tensionerandrecirculationshieldsforanydamage.V erifythatfanbladesclearthefan
ring.Inspectallrelatedfasteners,brackets,andclampsfordamageandtightness.Conrm
operationoftemperaturemodulatedfanclutch.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeCoolingSystem:

Removingorrenderinginoperativecoolingsystemcomponents(suchasthetemperature
modulatedfanclutch,fanshroud,fanring,recirculationshields,etc.).

8Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

ExhaustSystem

WARNING

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

Maintenance

Makesuretheexhaustsystemisintact.Inspectfordamage,misalignmentand/orleakage.
Primarysystemcomponentsrequiringnoiserelatedinspectionincludeexhaustmanifold,
turbocharger,andallexhaustsystem(rigidandexible)piping.Closelycheckthesystem
forexhaustleaks.Specialattentionshouldbegiventoallwelds,seams,gaskets,support
points,clamps,couplingsandconnections.

Inspectallexhaustsystemfasteners,brackets,andclampsfordamageandtightness.

RegulatoryCompliance

ActsthatconstitutetamperingwiththeExhaustSystem:

Removingorrenderinginoperativeexhaustsystemcomponents(suchasthepipes,clamps,
etc.).

AirIntake/AirInductionSystem

Maintenance

Makesuretheairintakesystemisintact.Inspectcomponentsfordamage,misalignment
and/orleakage.Primarysystemcomponentsrequiringnoiserelatedinspectionincludethe
aircleanerhousing,aircleanerelement,turbocharger,chargeaircoolerandintakemanifold.

Alsoinspectallducts,pipes,hoses,tubingandelbowsusedtointerconnectthesystem.
Specialattentionshouldbegiventoallwelds,seams,gaskets,supportpoints,clamps,
couplingsandconnections.

Inspectallintakesystemfasteners,brackets,andclampsfordamageandtightness.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX9

RegulatoryCompliance

ActsthatconstitutetamperingwiththeAirIntake/AirInductionSystem:

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

EngineControlandFuelSystems

ActsthatconstitutetamperingwithEngineControlandFuelSystems:

Removingrenderinginoperative,ormodifyingtheenginecontrolsystemsuchastheECU,
SCRandothersystemcomponents,orfuelsystemcomponents,inordertoallowtheengine
tooperateoutsideofthemanufacturersspecicationsisnotallowedandviolatesboth
warrantyandlegislation.

10Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

LabelInformation

VehicleIdenticationNumberLabel

Allmotorvehiclesarerequiredtobeidentiedbya17-digitV ehicleIdenticationNumber
(VIN).TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK.

TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations
includeastampingontheverticalfaceoftheright-handframerail(somewherebetween
thefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge,thedoor
openingarea).Whenthevehicleisreceived,checktheVINateachlocationonthevehicle
andverifythattheyareidentical.Thevehicleidenticationnumbermustnotbechanged,
coveredorobliterated.

VINFrameStamping

W0031972

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX11

W0061426

VINLabelonInsideDriver’sDoor

12Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

SafetyInformation

ProperMaintenanceProcedure

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissioninneutral,
andchockthewheels.Failuretodosocanresultinunexpectedvehiclemovementand
cancauseseriouspersonalinjuryordeath.

DANGER

Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruseaproperly
ventedexhausthose.Prolongedorexcessiveexposuremaycauseseriousillnessordeath.

DANGER

Neveroperatetheengineinanareawherehydrocarbonvapors(gasoline,forexample)
arepresentoraresuspectedtobepresent.Hydrocarbonvaporscanentertheairintake
andoverspeedtheengine,causingsevereenginedamageand/oranexplosionandre.
Seriouspersonalinjuryordeathcouldoccur.

DANGER

Nevertrytooperateorworkonthisvehiclewhileundertheinuenceofalcohol.Y our
reexescanbeaffectedbyevenasmallamountofalcohol.Drinkingandoperatingthis
vehiclecanleadtoanaccident,causingseriouspersonalinjuryordeath.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX13

WARNING

DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadtopersonal
injuryormakingyourvehicleunsafe.

WARNING

DieselengineexhaustandsomeofitsconstituentsareknowntothestateofCaliforniato
causecancer,birthdefectsandotherreproductiveharm.

DuringMaintenance

Removekeyfromignitionwhileworkingonvehicleorengine.

DONOTallowunauthorizedpersonnelon,aroundorinthevehiclewhenmaintenance
orrepairisbeingperformed.

•Whenoperatingtheengineinanenclosedarea,venttheexhausttotheoutside.

•Beforeservicingyourvehicle,applytheparkingbrakesandadequatelychockthewheels

inordertopreventunintendedvehiclemovement.Iftheserviceprocedurerequiresthe
parkingbrakestobereleasedrechecktoensurethatthewheelsareadequatelychockedto
preventanyforwardand/orrearwardmovement.

•DONOTusecombustiblesubstancesinoraroundtheengineeitherduringrepairor

maintenanceorwhenrunningtheengine.

•DONOTwearlooseclothingorjewelrythatcancatchorgetsnaggedbypartsormoving

componentsontheengine.Alsowearallprotectiveequipmentrequiredbythejob
conditions,suchasprotectiveglasses,hearingprotection,etc.

•Makecertainthatallprotectivecoversandguardsareinplaceandproperlysecured.

•Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.

•Reportallproblemsinatimelymannerbeforetheythreatenthesafetyofoperating

thevehicle.

•DONOTworkontheenginewhileitisrunning.

•Makesureprotectivelocksandcoversareintheirproperplace.

•DONOTusehighamperageelectronicstartingdevicesforjump-startingtheengine.

Relyonconventionalbatterychargingforchargingthebatteriesorjump-startwiththe
helpofastartbattery.

14Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

•DONOTattemptrepairsyoudonotunderstand.Ifyoudonothavetheproper

tools/knowledgetoperformtherepairscorrectly,MACKrecommendscontactingyour
nearestMACKTruckdealerforallnecessaryrepairs.

•Whenstartinganengineafterrepairshavebeenmadetothefuelorinjectionsystem,

prepareequipmentforshuttingofftheengineintakeairand/orfuelsupply(tostopthe
engine),incasethereisanoverspeedonstart-up.

•Starttheengineonlyfromthedriverseat.Neveroperatethestartermotoracrossthe

starterterminalsorthebatteriesasthiscouldbypasstheengineneutral-startsystemas
wellascausingdamagetotheelectricalorelectronicsystems.

CompressedAirandWater

DANGER

Compressedaircancauseseriouspersonalinjury.Whenusingcompressedairfor
cleaning,wearaprotectivefaceshield,protectiveclothingandprotectiveshoes.
Pressurizedwatercouldcauseparticlesand/orhotwatertobesprayedinyourdirection
andcausepersonalinjury.Themaximumairpressuremustbebelow30psi(200kPa)for
cleaningpurposes.

AsbestosInformation

Note:TheMACKengineandreplacementpartsforitshippedfromthefactoryareasbestos
free.MACKrecommendstheuseofonlygenuineMACKspareparts.
Neveruseanypartsthatcontainorarethoughttocontainasbestos.Exposuretoasbestos
berscancreateserioushealthrisks,includingdeath.

FluidPenetration

DANGER

Alwaysuseapieceofpaperorcardboardwhencheckingforaleak.Escapinguidunder
highpressure,evenapin-holesizedleak,canpenetratebodytissue,causingseriousinjury
ordeath.Ifuidisinjectedintoyourskin,immediatetreatmentmustbeadministeredby
adoctorfamiliarwiththistypeofinjury.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX15

InjuryPrevention

BurnPrevention

EngineParts

WARNING

Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengineand/or
uidcancauseseriousburns.

WARNING

DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfromthe
enginecompartment.Waituntilsteamorcoolantcannotbeseenorheardanylonger
beforeraisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.Also,
donotremovethecapwhiletheengineandradiatorarestillhot.Scaldinguidand
steammaybeblownoutunderpressureifthecapistakenofftoosoon,whichcancause
personalinjuryanddamagetoenginecomponents.

W0001525

DONOTtouchanypartoftheenginewhileitishot.Allowtheenginetocoolbeforeany
repairormaintenanceisperformedontheengine.

Relieveallpressureinair,oil,fuelorcoolingsystemsbeforeanylines,ttingsorrelated
itemsaredisconnectedorremoved.

16Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Coolant

WARNING

Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesorelectrical
componentscancauseare.Cleanupcoolantspillsimmediately.

W0001527

Topreventpersonalinjury ,donotclimbupontheenginetoremovethellercap.Usea
suitable,properlypositionedladdertoreachthecap.Atnormaloperatingtemperature,
theenginecoolantisveryhotandunderpressure.Ifpressureisrelievedrapidlyinahot
coolingsystem,thehotcoolantcanturnintosteam.Anycontactwithhotcoolantorsteam
cancausesevereburns.Theradiatorandallheatingsystemandradiatorlinesandhoses
containhotcoolant.

Verifycoolantlevelonlybythemarkingsontheexpansiontank.Openthellercaponly
aftertheengineisstoppedandcooleddown.Removethellercapslowlytorelievepressure.

Oils

WARNING

Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengineand/or
uidcancauseseriousburns.

Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.Whenchanging
oil,wearprotectivegloves.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX17

Batteries

WARNING

Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskofinjury
duetocontactwithsulfuricacidoranexplosion.

WARNING

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCaliforniatocausecancerandreproductiveharm.Wash
handsafterhandling.

Batteryelectrolytecontainsacidandcancauseinjury .Avoidcontactwiththeskinandeyes.
Washhandsaftertouchingbatteriesandconnectors.Useofglovesisrecommended.Always
wearprotectiveglasseswhenworkingwithbatteries.

SpeedRestrictiveTires

DANGER

Operatingavehicleequippedwithspeedrestrictivetiresinexcessoftheirstatedrating
mayresultintreadseparationand/orblowoutresultinginthelossofsteeringcontroland
possiblecollision.Seriouspersonalinjuryordeathcouldoccur.Alwaysmaintainproper
airpressureandneverexceedthetireratings.

Whenavehicleisequippedwithspeedrestrictivetires,DONOToperatethevehicle
inexcessoftheindicatedspeeds.Ifyourvehicleisequippedwithsuchtires,thespeed
restrictionswillbestatedonthesidewallofthetires.Theoperatorofthisvehicleisurgedto
checkthetiresofthevehicletodetermineifthereareanylimitations.

18Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

FireorExplosionPrevention

DANGER

Thedieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritisfrom
theinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedtoushout
theaircleanerelement,theenginemayoverspeedduringstart-up.Enginedamageand
severeinjuryand/ordeathfromburnsorexplosioncanoccur.

DANGER

Excessiveheatmaycausethepressurizedcomponentsoftheairconditionedsystem
toexplode.SomemixturesofR134arefrigerantcanbecomecombustibleatelevated
pressures.Neverweld,solder,steamcleanoruseagastorchnearanypartoftheair
conditioningsystem.Severeinjuryordeathmayoccurfromanexplosion.

W0001526

DANGER

DONOTserviceanypartofthefuelsystemwhilesmokingorinthepresenceofames,
sparksorhotsurfaces.Failuretofollowtheseprecautionscanresultinre,whichcan
causeseriousinjuryordeath.

WARNING

DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcauseorfeeda
re.Emptyorfull,theypresentahazardthatmayleadtoburnsintheeventofare.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX19

W0001527

Theengineshouldnotbeoperatedinanareawherecombustiblegasesaresuspectedto
beintheair.Thesecouldbedrawnintotheenginethroughtheengineairintakesystem
andcouldcausetheenginetooverspeedwithpossibleseriousdamagetotheengineand
bodilyinjuryorpropertydamage.

Makeprovisionsforshuttingofftheengineintakeairorfuelsupplytostoptheengineif
thereisanoverspeedonstart-upafterperformingrepairormaintenanceonit.

ContactyournearestMACKTruckdealerforanynecessaryairconditioningtestingor
repairs.

Allfuels,mostlubricantsandsomecoolantmixturesareammable.Dieselfuelis
ammable.Gasolineisammable.Themixtureofdieselandgasolinefumesisextremely
explosive.DONOTsmokewhilerefuelingorwheninarefuelingarea.

Keepallfuelsandlubricantsstoredinproperlymarkedcontainersandawayfromall
unauthorizedpersonnel.Storeoilyragsorotherammablematerialinaprotective
container,inasafeplace.

Removeallammablematerialsuchasfuel,oilandothersubstancesbeforetheyaccumulate
ontheengine.

DONOTexposetheenginetoames,drivingoverburningground.

DONOTweldoramecutonoraroundpipesortubesthatcontainammableuids.

Exhaustheatshieldsmaybeinstalledtoprotectoilorfuelcarryinglinesandpipesfromhot
exhaustparts.Toprotectfrompipeorsealfailure,installheatshieldscorrectly.

Provideadequateandproperwasteoildisposal.Alwaysdisposeofwasteliquidsaccording
toFederalandlocalregulations.Oilandfuelltersshouldbeproperlyinstalledandhousing
coverstightenedtothepropertorquewhenbeingchanged.

20Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

StartingAids

DANGER

DONOTuseetherorothercombustiblestartingaidsonanyengineequippedwitha
preheater.Iftheengineisequippedwithapreheater,introductionofetherorsimilar
startingaidscouldcauseareorexplosionresultinginseverepropertydamage,serious
personalinjuryordeath.

DONOTuseetherorothercombustiblestartingaidsonenginesthathaveaheater
elementorotherheatingdevicesinstalledintheintakemanifoldforheatingtheintake
airduringcold-starts.

W0001484

FireExtinguisher

Anytimeworkisbeingdonetothefuelsystemoranyotherareawhereammablesubstances
arebeingused,haveareextinguisheravailableandknowhowtouseit.Inspectandhaveit
servicedasrecommendedonitsinstructionlabel.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX21

RespiratoryHazardPrevention

DANGER

Exhaustgasescontaincarbonmonoxide.Alwaysruntheengineoutdoorsoruseaproperly
ventedexhausthose.Prolongedorexcessiveexposuremaycauseseriousillnessordeath.

WARNING

DieselengineexhaustandsomeofitsconstituentsareknowntothestateofCaliforniato
causecancer,birthdefectsandotherreproductiveharm.

W0001523

Alwaysworkinawellventilatedspaceiftheengineneedstoberunninganduseahoseto
routetheexhausttotheoutside.

PoisonousSubstances

DANGER

Coolantistoxic;riskofpoisoning.
DONOTdrinkcoolant.Useproperhandprotectionwhenhandling.Keepcoolantout
ofreachofchildrenandanimals.Failuretofollowtheseprecautionscancauseserious
illnessordeath.

Coolingsystemsupplementaladditivecontainsalkali.T opreventpersonalinjury,avoid
contactwiththeskinandeyes.

DONOTdrinkcoolantofanyconcentration.

22Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

CrushingorCuttingPrevention

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissioninneutral
andchockthewheels.Failuretodosocanresultinunexpectedvehiclemovementand
cancauseseriouspersonalinjuryordeath.

WARNING

DONOTworknearthefanwiththeenginerunningortheignitionintheONposition.
Theenginefancanengageatanytimewithoutwarning.Anyonenearthefanwhenit
turnsoncouldbeseriouslyinjured.

W0001524

Neverattemptadjustmentsorrepairswhiletheengineisrunning,seeyourauthorized
MACKTruckdealer.

Inspectthefanbladeassemblybeforeserviceforcracksorloosemountingbeforestarting
theengine.Neverstandalongsidearotatingfanassembly,particularlyathighfanspeeds.

Wearprotectiveglasseswhenstrikingobjectstoavoidinjurytoyoureyes.Chipsorother
debriscanyoffobjectsthatarestruck.Makesurenoonecanbeinjuredbyyingdebris
beforestrikinganyobject.

W0001528

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX23

ClimbingUpandDown

DANGER

Alwayshavethreelimbs(onefootandtwohandsortwofeetandonehand)incontact
withthevehicleatalltimeswhenenteringorexitingthecabortheareabehindthecab.
Failuretofollowthiswarningcanresultinseriouspersonalinjuryordeath.

DONOTclimbuponorjumpofffromtheengineorstandoncomponentsthatcannot
supportyourweight.Useanadequateladderorscaffolding,suitablysituated.

DONOTusetopofengineorcowlingledgeasfootholdwhenreachingontopofcab.Clean
steps,handholdsandareasofthevehicleonwhichyouwillbeworkingorarearound.Refer
totheOperatorsManualforproperentryandexitprocedures.

Alwaysuseathree-pointstance(twohandsandonefootoronehandandtwofeet)
wheneverclimbingupordown.

EngineDamagePrevention

BeforeStartingtheEngine

DANGER

Beforeworkingonavehicle,settheparkingbrakes,placethetransmissioninneutral
andchockthewheels.Failuretodosocanresultinunexpectedvehiclemovementand
cancauseseriouspersonalinjuryordeath.

Inspectengineforpotentialhazards.Makesureallprotectiveguardsandcoversareproperly
installedifanengineneedstobestartedtomakeadjustmentsorchecks.Tohelpprevent
anaccidentbymovingparts,workcarefullyaroundthem.

DONOTdisableorbypassautomaticalarm/shutoffcircuits.Theyareprovidedtoprevent
personalinjuryandenginedamage.

OnlyproperlytrainedandauthorizedMACKServiceTechniciansmayattemptrepairs
onthisvehicle.

24Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

EngineStarting

DONOTstarttheengineormoveanyofthecontrolsordisengagetheparkingbrakeifthe
warningtagDONOTOPERATEisattachedtotheignitionkeyorlocatedonthedash.
Checkwiththepersonwhoattachedthetagbeforestarting.

Makesurenooneisworkingonorclosetotheengineorcomponentsdrivenbytheengine
beforestartingit.Alwaysmakeaninspectionoftheenginebeforeandafterstarting.

Dieselengineexhaustcontainsproductsofcombustionwhichmaybeharmfultoyour
health.Alwaysstartandoperatetheengineinawell-ventilatedarea,andifinanenclosed
area,venttheexhausttotheoutside.

Starttheengineonlyfromthedriverseatinthecab.Neverstarttheenginebyshorting
acrossthestartermotorterminalsorbatteriestostarttheengineasthiscouldbypassthe
engineneutral-startsystemaswellasdamagetheelectricalandelectronicsystem.Always
starttheengineaccordingtotherequiredenginestartingproceduredescribedinthis
operatorsmanualtopreventmajorenginecomponentdamageandpersonalinjury .

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX25

ElectricSystemDamagePrevention

ElectricandElectronicSystems

WARNING

Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskofinjury
duetocontactwithsulfuricacidoranexplosion.

W0001526

Neverdisconnectanychargingunitcircuitorbatterycircuitcablefromthebatterywhenthe
chargingunitisoperating.Asparkcancausetheammablevapormixtureofhydrogenand
oxygentoexplode.

Topreventpotentialsparksfromignitingcombustiblegasesproducedbysomebatteries,
attachthenegative(-)terminallastwhenhookingupandremovethenegativeterminalrst
aftertheenginehasstarted.Checkregularlyaroundtheengineandenginecompartment
forlooseorfrayedwires.Havealllooseorfrayedelectricalwirestightened,repairedor
replacedbeforeoperatingthevehicle.

GroundingPractices

Propergroundingforvehicleandengineelectricalandelectronicsystemsisnecessaryfor
propervehicleandengineperformanceandreliability.Impropergroundingwillresultin
uncontrolledandunreliableelectricalpaths.

Uncontrolledengineelectricalcircuitpathscanresultindamagetomainbearings,crankshaft
journalssurfacesandaluminumcomponents.Uncontrolledelectricalcircuitpathscanalso
causeelectricalnoisewhichmaydegradevehicleandradioperformance.

Operatingengineswithouttheengine-to-framegroundstrapinstalledcancausedamage
totheengine.Topreventelectricaldischargedamage,checktomakesuretheengines
electricalsystemhasanengine-to-framegroundstrap.Allgroundconnectionsshouldbe
tightandfreeofcorrosion.

26Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

ElectronicEngineControlSystem

DANGER

Theengineuseshighvoltagetotheelectronicunitinjectors.
DONOTcomeincontactwiththeunitinjectorterminalswhiletheengineisrunning.An
electricshockcancauseaninvoluntarymusclespasmandcauselossofbalanceandfalls
leadingtoseverepersonalinjuryordeath.

W0001522

Tamperingwiththeelectronicsysteminstallationcanbedangerousandcouldresult
inpersonalinjuryordeathand/orenginedamage.Itisveryimportanttotakethe
properprecautionswiththeelectricalandelectronicsystemwhenchargingthebatteries,
jump-startingorperformingelectricweldingonthevehicle.SeethevehicleOperators
Manualforcorrectprocedures.

Thisengineisequippedwithmonitoringfeaturesthatmaycausereducedpowerorshutdown
undercertainconditions.Thepoweroutput,monitoringandidlingfeaturescanonlybe
programmedand/orchangedwithelectronicservicetoolsandpasswords.

Certainfeatures,suchaslowoilpressure,highcoolanttemperatureorlowcoolantlevel
couldcausetheenginepowerand/orvehiclespeedtobelimitedandtheenginemayalso
shutdown.Theshutdownwilltakeapproximately30secondsfromthetimethewarning
featureisactivated.SeethevehicleOperatorsManualformoreinformation.