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.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX27

GeneralEngineInformation

EngineOverview,MP8LeftSideView

MP8EngineShown

1.BreatherTube10.Hand-PrimingPump

2.IntakeManifold11.FuelFilter

3.AirCompressor12.AirV alveEPG(ExhaustPressure
Governor)andW astegate

4.PowerSteeringPump13.CrankCaseV entilator

5.FuelPump

6.EngineControlModule(ECM)15.Alternator/ACCompressorBelt

7.AirV alveOn/OffSwitchingEPG

(ExhaustPressureGovernor)

8.FuelFilter17.Fan/CoolantPumpBelt

9.Fuel/WaterSeparator18.IntakeHousing

14.ACCompressor

16.Alternator

W2061649

28Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

EngineOverview,MP8RightSideView

W2061650

MP8EngineShown

1.ExhaustCounter-PressureSensor8.CoolantPipe

2.ExhaustManifold9.OilFilters

3.ValveCover10.Turbocharger

4.IntakeAirHeater(IAH)[optional]11.TurbochargerW astegateActuator

5.BeltTensioner

6.Thermostat13.ExhaustBrakeAcutator

7.CoolantPump

12.StarterMotor

ElectricalSystem

Batteries

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX29

WARNING

Batteryposts,terminalsandrelated
accessoriescontainleadandlead
compounds,chemicalsknowntocause
cancerandreproductiveharm.Washhands
afterhandling.

CAUTION

Disconnectingbatterycableswhenvehicle
isequippedwithpowerdoorlockswill
resultinautomaticlockingofdoors.

CAUTION

WARNING

Alwaysweareyeprotectionwhenworking
aroundbatteriestopreventtheriskof
injuryduetocontactwithsulfuricacidor
anexplosion.

Amaintenance-freebatterydoesnotrequiretheadditionofwaterforitsnormalexpected
life.Typicalfeaturesincludeheavy-dutyconstructionandawroughtlead-calciumgridto
resistvibration,shock,overcharge,heatandthermalrunaway.Nevertheless,thesebatteries
arevulnerabletotheravagesofcoldweatheroperationiftotallyignored.

Whenusingapressurewashertoclean
thevehicle,donotdirectthesprayat
electricalcomponentsintheengine
compartmentsuchasthealternator,starter
andcompressors.W atersprayfrom
pressurewasherscandamageelectrical
components.

W0054087

Battery

30Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

BesurethatthebatteriesusedinaparticularvehicleareratedforthespeciedCold
CrankingAmperes(CCAs)necessarytoensurereliablecoldweatherstarts.Thisis
important,sinceevenwell-maintainedbatterieschilledto18°C(0°F)maytemporarilybe
capableofprovidingonly40%oftheirratedcapacityat27°C(80°F).

Keeptheterminalscleantopreventformationofpower-robbingcorrosion.

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

Beforetheonsetofcoldweather,besuretoprotectthisvitalcomponentbymonitoringits
conditionaswellasinspectingthechargingandstartingsystems.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX31

BatteryCondition

Therstprocedurewhentestingabatteryistocheckforexternaldamagesuchasacracked
case,looseorcorrodedterminals,orsignsofexcessivegassingorovercharging.

Abatterymustbefullychargedbeforealoadtestisperformed.T estthebatterywitha
hydrometertodeterminethelevelofcharge.

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

W0054088

BatteryCondition

•GreendotvisibleAnygreenappearanceshouldbeinterpretedasagreendotandmeans

thatthebatteryisatorabovea65%stateofchargeandisreadyforuseortesting.This
doesnotautomaticallymeanthatthebatteryisingoodcondition.

•Darkgreendotnotvisible(blackdot)Thisindicatesthatthebatteryisbelowa65%

stateofchargeandmustbechargedbeforetesting.Ablackdotdoesnotmeanthat
thebatteryisautomaticallybad.

•ClearorlightyellowThismeansthattheelectrolytelevelisbelowthelevelofthe

built-inhydrometer,whichmayhavebeencausedbytippingofthebattery ,acracked
case,orovercharging.Thisbatteryshouldbereplaced.

32Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Charging

Chargingshouldbeconductedcarefullyundercontrolledconditions.Neverchargeafrozen
battery.Ifafrozenbatteryissuspected,thawitinawarmareaforseveralhoursbefore
charging.

Thefollowingchartshowsthenormalchargingtimesnecessarytoreachafullchargeat26
°C(80°F).Incoldertemperatures,thenecessarychargingtimemayincrease.

Open

Circuit

V oltage

12.61.265100%FullCharge

12.41.22575%15

12.21.19050%35

12.01.15525%50

11.81.1200%65

Battery

Specic

Gravity*

Stateof

Charge

*Correctfortemperature.

**Ifcolder,itwilltakelonger.

ChargingTimetoFullChargeat26°C(80°F)**

at60
amps

min.

min.

min.

min.

at50
amps

at40
amps

20

min.

45

min.

65

min.

85

min.

at30
amps

27

min.

min.

min.

min.

min.

55

min.

85

min.

110

min.

at20
amps

35

75

115

150

48

min.

95

min.

145

min.

195

min.

at10
amps

min.

180

min.

280

min.

370

min.

CompletelyDischargedBatteries

Extremelycoldorcompletelydischargedbatteriesmaynotinitiallyshowachargesince
theelectrolyteisnearlypurewaterand,therefore,apoorconductor.Astheacidlevelin
theelectrolyteincreasesduringcharging,thechargingcurrentwillalsoincrease.Usethe
followingprocedurewhenchargingacompletelydischargedbattery:

1Measurethevoltageatthebatteryterminals.Ifitisbelow10volts,currentwillbevery

lowandmaynotshowuponmanybatterychargerammeters.

2Setthechargeronthehighsetting.

3Somechargershaveapolarityprotectionfeaturewhichpreventsaccidentalreversalof

thechargerleads.Acompletelydischargedbatterywillnothaveenoughvoltageto
overridethisfeature,makingitappearthatthebatterywillnotacceptacharge.Checkthe
chargermanufacturersinstructionsonhowtobypassthisfeature.

4Oncethebatterystartstoacceptacharge,thechargingratewillriseveryrapidly.

Carefullymonitortheammetertopreventtoo-highachargingrate.

90

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX33

5Proceedtochargebatteryatone-tenthofitsratedcapacityforone-halfhour.

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

Note:Batterieswithverylowvoltage(below11.6volts)orthosethatdonotinitially
acceptachargearenotnecessarilydefective.Batteriesthathavebeendischargedforlong
periodsoftimemaybeheavilysulfatedorhydrated(containingleadshortsthatcausethe
batterytoself-discharge).Toacceptacharge,batterieswitheitheroftheseconditions
mayrequirealongerchargingtimeoraveryhighinitialcharge.

Usethefollowingcharttodeterminethetimerequiredforthebatterytobeginaccepting
ameasurablecharge.(Ifthebatteryhasnotstartedtoacceptachargeafterthespecied
time,itshouldbereplaced.)

ChargerV oltage

16.0ormoreUpto4

14.0to15.9Upto8

13.9orless

Hours

Upto16

LoadTest

Abatterymustbefullychargedbeforeperformingaloadtest.Toload-testabatterythatis
fullycharged,proceedasfollows:

1Connectaloadtesterandvoltmeteracrossthebatteryterminals.

2Applyaloadsothatagureof300ampsisobtainedfor15secondstoremovethe

batterysurfacecharge.

3Wait60secondstoletthebatteryrecoverandthenapplythepropertestloadtothebattery

todetermineitscondition.Togettheproperload,usehalfthecrankingperformance
rating.Readthevoltageafter15seconds.Rememberthattheminimumvoltagevaries
accordingtotemperature.Consultthefollowingchartfortheproperspecication.If
thebatteryvoltagedoesnotfallbelowtheminimumtestvoltageafter15seconds,the
batteryisacceptableforuse.

34Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

LoadT estTemperatureCorrection

MinimumV oltage

C

9.62170

9.51660

9.41050

9.3440

9.1130

8.9

8.71210

8.5180

7

Temperature

F

20

ElectricalConnectionProtection

Ifcorrosionisseenatanyexternalring-typeterminalconnections,suchasthoseusedatthe
starter,alternator,chassisand/orenginegrounds,etc.,LPSHardCoatCorrosionProtectant
mustbeappliedtotheconnectionafterdisconnecting,cleaningandreconnectingthering
terminal.Additionally,LPSHardCoatshouldbeappliedtoanyring-typeterminalconnector
followinganytypeofserviceprocedurewhichinvolveddisconnecting/reconnectingthering
terminals(suchascomponentreplacement,troubleshooting,serviceandrepair,etc.).

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX35

WiringHarness/CableandConnectorProtection

Tohelpprotectyourvehicle’sexternalhighamperageelectricalcablesandconnectionsfrom
corrosionduetotheeffectsofnewersalts(calciumchlorideandmagnesiumchloride)onthe
roadways,MACKisofferingacorrosioninhibitorforpurchasethroughthePDC.

MACKrecommendscoatingallhighamperage(positiveandground)exposedelectrical
connectionsataminimumofevery6monthsor,whenevertheconnectorhasbeen
disassembled.Thefollowinglistcontainstherecommendedconnectionsthatshouldbe
liberallycoatedwiththecorrosioninhibitor;

•Batteryconnections

•Batterymainshutoffswitchconnections

•Maxiand/orMegafuseconnections

•Allgroundstudconnections

•Electricalpneumaticpass-thruconnections

•Allalternatorconnections

•Allstarterconnections

•Intakepreheaterandpreheaterrelayconnections

•Electricalpowerinverterconnections

Allconnectionsshouldbecleanedandfreeofpreviouslyappliedinhibitors,oil,dirt,dustor
othercontaminantspriortoapplication.Allowtimefortheproducttodrybeforeuse(drying
timemayvarydependingtemperature,humidity,etc.).

FormoreinformationregardingthiscorrosioninhibitorproducedbyLPSWorldwide,visit
theirwebsiteatwww.lpslabs.com.

36Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Lighting

WARNING

Usingincorrectbulbsorlampsmayresultinfailuresthatcouldleadtoareoravehicle
accidentcausedbyimproperlighting.

Checkalllightsonthevehicledailyforproperfunction.Replaceburnedoutinsertsand
bulbs.Replaceanybrokenorcrackedsideorrearreectors.Headlightsshouldbechecked
foraimatleastonceperyear.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX37

PrecautionsWhenInstallingElectricalEquipment

Connectingelectricallypoweredorelectricallycontrolledequipmenttoavehiclemaycause
interferencewithothervehicleelectricalorelectronicequipment(suchasABSsystems,
RolloverStabilitySystems,etc.).Theamountofinterferencedependsupontheoperating
frequencyofanynewsignalsandthedegreetowhichtransientsignalsarecoupledtothe
vehiclesystem.

Note:Whenevernewelectricalequipmentisinstalled,itistheobligationoftheinstaller
toensurethatthenewequipmentdoesnotinterferewiththeproperoperationofallother
electricalsystemsonthevehicle.

Ifnewelectricalequipmentisinstalled,avehiclecheckoutprocedureshouldbeperformed.

1Performthecheckoutprocedureunderthefollowingconditions:

•Enginerunning

•Brakesystemairpressureinoperatingrange

•Vehiclestationary

•Brakepedalfullydepressed

2Operatethenewequipmentunderallstarting,runningandshutdownconditions.

3ListenforsignsofairexhaustingfromtheABSmodulatorvalves(whichisanindication

ofaninterferencecondition).

4Correctallinterferenceconditionsbeforeoperatingthevehicle.

Note:Thecenterpinofthestandardseven-pintrailerelectricalconnectorhasbeen
standardizedasthededicatedconnectionforuninterruptedpowerfortrailerABS.Thispinis
alwayshotwhenthetractorignitionisturnedon.

DANGER

Sometrailersmanufacturedpriortothe
trailerABSregulationsmayusethecenter
pintopowercertaintrailerauxiliary
equipment.Thepossibilityexiststhatthis
auxiliaryequipmentmaybeunexpectedly
activatedbythetruckortractorelectrical
system,resultinginpersonalinjuryor
damagetoequipment.Cautionmustbe
usedwhenconnectingthetrailerelectrical
connectortoensurethatpowertothe
centerpinwillnotunintentionallyactivate
anytrailerauxiliaryequipment.

38Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

EngineStorage

EngineStorage

Ifthevehiclemustbeparkedforaperiod(morethan30days),protectitasfollows:

1Draintheengineoil.

2Filluptotheproperlevelwithoiloftherecommendedqualityandviscosity .

3Fillupthefueltankswiththerecommendedgradeoffuel.

4Runtheenginefortwominutesaround1000rpm.Shuttheenginedown.DONOT

draintheoilafterthisrun.

5CheckthecoolantforproperlevelsofVCScoolantprotection.Serviceasnecessary.

6Sealallengineopeningsusingprotectivecovers.

Toreturntoserviceanenginepreservedinthismanner,removepreviouslyinstalled
protectivecovers.Checkalluidlevelsandifnecessaryreplaceengineoilcontaminatedby
condensation.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX39

MaintenanceandService

MaintenanceHazards

DANGER

Beforeworkingonorinspectingavehicle,settheparkingbrakes,placethetransmission
inneutralandchockthewheels.Failuretodosocanresultinunexpectedvehicle
movementandcancauseseriouspersonalinjuryordeath.

DANGER

DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
correctserviceliteratureandthepropertools.Failuretofollowthiscouldleadtopersonal
injuryordeath,ormakingyourvehicleunsafe.

Note:Readallsafetyinformationbeforeworkingonthevehicle.

EngineComponents,ServiceSchedules

Component

FuelFilter
(MP8)

WaterSeparator
(MP8)

AirFilterEuro5ChangeEvery12months

Coolant
(MP8)

Valves/Injectors
(MP8)**

DriveBeltsEuro
5

Catalyzed
DPFFilter(If
equipped)

OperationKm(Miles)/MaximumMonths/Hours

ChangeEachoilchange*

FilterchangeEachoilchange*

Change500000(300,000)or48months,

Adjust

Change500000(300,000)or36months,

ChangeRefertotheappropriateCummins

whichevercomesrst

400000(250,000)or24months,
whichevercomesrst

whichevercomesrst

operator’smanualoracertied
Cumminsdealer.

40Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Component

Aftertreatment
Doser(If
equipped)

DieselExhaust
Fluid(DEF)
PumpFilter
(MP8)

DieselExhaust
Fluid(DEF)Tank
FillerNeckFilter
Cleaning
(MP8)

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

**Valvesmustbeadjustedwhenevertherockershafthasbeenremovedand
reinstalledforanyreason.

OperationKm(Miles)/MaximumMonths/Hours

CleanRefertotheappropriateCummins

operator’smanualoracertied
Cumminsdealer.

Change180000(112,000)or12months

Clean180000(112,000)or12months,

whichevercomesrst

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX41

CoolingSystem

GeneralCoolantInformation

DANGER

Coolantistoxic;riskofpoisoning.DONOTdrinkcoolant.Useproperhandprotection
whenhandling.Keepcoolantoutofreachofchildrenandanimals.Failuretofollowthese
precautionscancauseseriousillnessordeath.

WARNING

DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfromthe
enginecompartment.Waituntilsteamorcoolantcannotbeseenorheardbeforeraising
thehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.Also,
DONOTremovethecapwhiletheengineandradiatorarestillhot.Scaldinguidand
steammaybeblownoutunderpressureifthecapistakenofftoosoonandcancause
personalinjury.

WARNING

Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesorelectrical
componentscancauseare.Cleanupcoolantspillsimmediately.

CAUTION

MACKdoesnotrecommendusingplainwaterinthecoolingsystem.Wateralone
iscorrosiveatengineoperatingtemperaturesanddoesnotprovideadequateboiling
protection.Theenginemaydevelopcorrosionandcavitationproblemsintheengine
andradiator,andtheboilingpointofthecoolantisloweredcomparedtoaproper
antifreezeandwatermixture.FailuretofollowMACKcoolingsystemcare/maintenance
recommendationscanrenderthewarrantyinvalid.

42Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Thecoolingsystemplaysanimportantroleinoverallengineperformancebykeepingthe
enginewithinthenormaloperatingtemperaturerangehotenoughforefcientcombustion,
andcoolenoughtopreventenginedamagecausedbyoverheating.Goodpreventive
maintenancepractices,alongwithmonitoringcoolingsystemperformance,goalongwayin
preventingenginedamagethatcouldresultfromcoolingsystemproblems.Themaintenance
itemsandtestsoutlinedinthissectionshouldbeperformedattheintervalsspeciedto
ensureoptimumperformancefromthecoolingsystem.

SurgeTankCap

MACKconventionalmodelsutilizeacoolantsurgetankmountedontopoftheradiator.
Thesurgetankhasallcaplocatedonthetopright-handsideofthetank,andaonestage
pressurecapratedat120kPa(13PSI).Alsoincorporatedisanoverowtubelocatedon
theleft-handsideofthetank.Checkthecoolantlevelregularly ,makingsurethecoolant
levelisbetweentheCOLDMINandCOLDMAXlinesonthebackofthetank.Ateach
inspectioninterval,inspecttherubbergasketsoneachofthecaps.Replacethecap(s)ifthe
gasketsshowevidenceofdamagewhichcouldaffectsealing.

WARNING

DONOTremovethellcapwhilethecoolingsystemishot.Allowthesystemtocool
sufcientlybeforeremoving.Turnthellcapslowlycounterclockwiseandwaitfor
thepressureinthesystemtodissipate.Afterthepressurehasdissipated,completely
removethecap.

W0054042

SurgeTankConventionalModels

1.PressureCap

2.FillCap

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX43

Themainpurposeofcoolantistotransportheatfromthehotpartsoftheenginetothe
radiatorandtoprotectthecoolingsystemfromcorrosion.

Inadditiontothis,thecoolantmust:

•Protectagainstpittingandcavitationerosiondamageofthewaterpumpandcylinder

liners.

•Protectagainstfreezingandboiling.

•Preventformationofscale,sludgedepositsandclogging.

•Beharmlesstopolymermaterialsandsealsinthecoolingsystem.

•Maintainitsliquidpropertiesincoldclimates.

Manyenginefailurescanbetracedbacktoaprobleminthecoolingsystem.Ifthecoolant
levelisallowedtogobelowthebottomofthetank,thereistheriskoftheengineshutting
down.Seetheoperatorsmanualformoreinformationonthewarningfunctions.

Note:AlwaysdisposeofcoolantaccordingtoFederalorlocalregulations.Takeallused
coolanttoarecyclingorwastecollectioncenter.

CoolantSystemCapacities

CAUTION

Capacitiesmayvaryduetohosesandsize
ofradiator,aswellasaccessorycooling
equipment.Afterrunningtheengineuntil
normaloperatingtemperatureisreached,
checkthecoolantlevelandaddcoolantas
needed.

Chassis

Model

CMM
andCMH

CSM

CLXand
CXX

*Coolantcapacitieslistedareforchassisequippedwithmanualtransmissions.
Forautomatictransmissions,add16.5liters(17qts).

MP8*54(57)

CumminsISL32.5(34)

CumminsISX55.5(59)

EngineModelCoolantCapacityin

Liters(Quarts)

44Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

CoolantMixture

Thecoolantmixturemustbeproperlymaintainedtoprovidemaximumprotectionagainst
corrosion,cavitationerosionandpitting.Thefollowingcoolanttestsshouldbeperformedto
ensurethatthecoolantisprovidingmaximumprotection.

1Checkcoolantlevel.

Note:Forusedownto-25°C(-17°F),40%plus(+)orminus(-)2%ofBulldogVCS
coolant—Water.

2CheckandrecordtheconcentrationofVCScoolantwitharefractometer.Changethe

coolantevery4yearsor500000Km(310,000miles).

Note:DonotmixVCScoolantwithothercoolants.

UsearefractometertomeasureVCScoolantprotection.Arefractometerthatmeasures
VCScoolantconcentrationsisavailablefromSPXKent-Moore.

Thestandardfactory-llcoolantforallenginesisBulldogVCScoolant.Donotuseother

coolants.

Awellfunctioningandmaintainedcoolingsystemisasimportanttotheengineas
performingregularoilchangesorusinggoodfuel.Togetthebestresultusequalityproducts
andservicethesystematthecorrectintervals.Pleasereadthissectioncarefully .

Keeptheradiator(includingchargeaircooler)andthefrontalareafreefrombugs,dirt,
leaves,etc.(see“CleaningChargeAirCoolerandRadiatorPackage”,page89forcleaning
information).

Checkthecoolantlevelinthetankregularly .Fillthetankasnecessarywiththecorrect
coolant.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX45

Inspectionofthewholecoolingsystemisimportant.Checkforswollenordeteriorated
heaterandradiatorhoses,loosehoseclampsandconnections,andradiatorleaks.

DANGER

DONOTworknearthefanwiththeenginerunning.Theenginefancanengageatany
timewithoutwarning.Anyonenearthefanwhenitturnsoncouldbeseriouslyinjured.
Beforeturningontheignition,besurethatnooneisnearthefan.

CAUTION

Neveraddcoolanttoahotoroverheatedengine.Enginedamagecanresult.Allow
theenginetocoolrst.

46Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

FuelSystem

FuelSafetyReminders

DANGER

Adieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritisfromthe
injectorsorfromtheairintakesystem.Therefore,ifanysolventisusedtoushoutthe
aircleanerelement,theenginemayoverspeedduringstart-up.Enginedamage,severe
personalinjuryordeathfromburnsorexplosionmayoccur.

DANGER

DONOTmixgasolineoralcoholwithdieseloilfuel.Thismixturecancauseanexplosion
andresultinseverepersonalinjuryordeath.

DANGER

DONOTremovethefueltankcapnearanopename.Dieselfumesarecombustibleand
cancauseanexplosionorreresultinginseverepersonalinjuryordeath.

WARNING

Ifafuelleakisdetected,stoptheengineimmediately .Thevaporsfromhotfuelare
highlyammablewhichmayresultinare.

WARNING

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

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX47

DieselFuelSpecication

Quality

CAUTION

Dieselenginesfor2008andlatermodelyearvehiclesaredesignedtooperateonlywith
UltraLowSulfurDiesel(ULSD)fuel.UseoffuelotherthanULSDwillreducethe
efciencyanddurabilityoftheengine,permanentlydamagetheadvancedemission
controlsystems,reducefueleconomyandpossiblypreventtheenginefromrunningatall.
Manufacturerswarrantiesarelikelytoberenderedvoidbyusageofimproperorincorrect
fuel,andusageoffuelsotherthanULSDfuelindiesel-poweredvehiclesisillegaland
punishablewithcivilpenalties.Useoffueladditivestocompensateforthelowersulfur
contentisNOTrecommendedbyMACK

Thefuelsusedmustbeclean,completelydistilled,stableandnon-corrosive.Alwaystryto
keepthefueltankfull.DONOTputalcoholintothefueltank.Fillthetankaftercompleting
drivingfortheday.

FuelSulfurContent

ForMP8Euro5engines,toensurethattheemissionsrequirementsaremet,themaximum
sulfurcontentis50ppm.

CumminsISXenginesequippedwithaDPFmustrunonULSDfuelwithamaximumsulfur
contentof15ppm.Failuretodosowillresultindamagetotheaftertreatmentsystem.

ForCumminsISLenginesequippedwithSCR,themaximumsulfurcontentis50ppm.

Note:Theuseofultra-lowsulfurdieselfueldoesnotpermitextensionofengineoilchange
intervalsoroillterchanges.

Filtration

Fuelshouldbecleanandfreeofcontamination.Cleanfuelsshouldhavenomorethan

0.05%ofsedimentandwater.

48Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

FuelAdditives

Fueladditivesaregenerallynotrecommendedorneededforfuelslistedearlier.Cetane
improverscanbeusedasnecessary .Biocidesmaybeneededtoeliminatemicroorganism
growthinstoragetanks.Incoldconditions,treatmentforwaterinthevehicletanksmay
alsobenecessary.

Consultyourfuelsupplierabouttheuseofadditivestopreventincompatibilityamong
additivesalreadyinthefuelandtheadditivestobeused.

SupplementalFuelEnhancers

CAUTION

Supplementaladditivesarenotrecommendedbecauseofahighriskofinjectionsystem
problemsorenginedamage.

Therearemanyaftermarketproductsavailabletodaywhichareintendedtobeaddedbythe
customer.Theygenerallyincreaseoperatingcostwithoutprovidingbenets.Includedarea
varietyofindependentlymarketedproductswhichclaimtobe:

•Cetaneimprovers

•Emissioncontroladditives

•Detergents

•Combustionimprovers

•Smokesuppressants

•Coldweatherowimprovers

Note:Repairexpensesresultingfrommalfunctionsinthefuelsystemorwithengine
componentswhenfuelenhancershavebeenusedarenotcoveredunderwarranty.

Somefueladditivescanbeusedtoprovidetemporaryrelief,buttheydonotreplacegood
fuelhandlingpractices.Theseproductscanbeused:

•IsopropylAlcoholUse1/2literper450liters(1pintper125gallons)offuelforwinter

freeze-upprotection.

•BiocideFortreatmentofmicrobegrowthorblackslime.Followmanufacturers

instructionfortreatment.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX49

ProhibitedAdditives

WARNING

Theadditionofgasolinetodieselfuelwillcreateaseriousrehazard.Seriouspersonal
injurycanresult.

ThefollowingadditivesarespecicallyNOTallowedandmustNOTbemixedinwiththe
vehicledieselfuel:

•Gasoline:Addinggasolinetodieselfuelwillreducethecetanenumberandincrease

combustiontemperature.Ifatankcontainsadieselfuel/gasolinemixture,itshouldbe
drainedandcleanedassoonaspossible.

•Usedlubricatingoil:MACKdoesnotrecommendtheuseofanytypeofusedlubricating

oilasanextenderinthedieselfuel.Usedlubricationoilcontainssolidsandacidsfrom
thecombustionprocessthatcanseverelycorrodepartsoftheinjectionsystem,resulting
inreducedpowerandhighermaintenancecostovertime.

AlternativeFuels

Alternativefuelscanbeofseveraldifferenttypes.Therearevegetablebasedfuels,aviation
fuelandrecycledpetroleumbasedfuelsthatareusedincombustionengines.Thesearein
generalnotcompatiblewithmodernheavy-dutyover-the-roaddieselengines.

Theuseofunauthorizedfuelsmaycompromisethelevelsofpollutantsintheexhaustto
thepointwheretheenginedoesnotmeettheemissionrequirements.Thiswouldmakethe
vehicleillegaltodriveonpublicroads.DONOTuseanykindofalternativefuelunless
specicallyauthorizedbyMACK.

BioDiesel

TheonlyBioDieselFuelapprovedbyMACK.foruseinMACKEnginesisSoyMethyl
Ester(SMEorSOME)inblendsuptoB5Concentration(5%blend).

Note:Althoughhigherconcentrationsareavailable,concentrationuptoB5(maximum)are
theonlyblendscurrentlyapprovedbyMACK.

50Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

FuelStorage

Iffuelisstoredonsite:

•Keepstoragetankcoveredtopreventwaterentry.

•DONOTuseatankmadeofgalvanizedmetaloranygalvanizedpipingfordieseloil

storage.Dieselwillreactwiththezinc,formingsolidsthatcanclogfuelltersand
causeenginedamage.

•Fuelstoredforalongtimemayoxidizeandformsolids,causinglteringproblems.

•Keeptheareaaroundthellcapclean.Tiltthetankslightlytowardthedrainplugareaso

waterandsedimentcanbeeasilydrained.

Generally,fuelcontaminationoccursastheresultofimproperfuelhandling.Themost
commontypesofcontaminationarewater,dirtandmicrobialgrowth(blackslime).The
formationofvarnishesandgumsresultingfrompoorfuelstabilityorlongstorage(stalefuel)
alsoaffectsfuelquality.Thebesttreatmentforcontaminationispreventionbymaintaininga
cleanstoragesystemandchoosingareputablefuelsupplier.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX51

FuelFilters

Aprimaryfuelltercanbelocatedontheengineorremotemountedontheframerail.This
lterconsistsofaltercartridge,awaterseparationbowlandmayhaveafuelheaterbuiltin.

Thesecondaryfuellterislocatedonthelefthandside,belowtheengineelectroniccontrol
unit(EECU).Thelterisaspin-onlter.

MACKMPenginesutilizeaspin-onprimaryandsecondaryfuellters.Bothltersare
locatedontheright-handsideoftheengine.

W0054019

FuelFiltersMACKMPEngine

1.SecondaryFuelFilter2.PrimaryFuelFilter

TheprimaryfuellteronMACKMPenginesincorporatesaplasticwaterseparator
bowl.Additionally,theplasticbowlincludesawater-in-fuelsensor.Awarninglampon
theinstrumentpanelilluminateswhenwaterisdetectedinthefuel.RefertoFuel/Water
Separatorsection.

52Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

PrimaryFuelFilterReplacementProceduresMACK
MPEngines

Ateachspeciedoilandlterchangeinterval,changetheprimaryfuellterasfollows:

MACKMPPrimaryFuelFilter

1.PrimaryFilter

2.WaterSeparatorBowl

W0054023

3.Water-in-FuelSensorHarness

4.DrainAssembly

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX53

1Thoroughlywashtheareaaroundthefuellterandmountingadaptermatingareawitha

suitablesolventandblowdrywithcompressedair .

2Disconnectthewater-in-fuelsensorharnessconnectorfromtheplasticwaterseparator

bowl.

3UsingtoolJ24783,removetheprimarylter.

4Whileholdingthelteraboveasuitablecontainer,openthedrainvalveontheplastic

waterseparatorbowlandallowthefuelinthebowltodrain.Disposeofthedrained
fuelinanenvironmentallysafemanner .

5Unscrewtheplasticseparatorbowlfromthebottomofthespin-onprimaryltercartridge.

6ApplyathinlmofcleanengineoiltothewaterseparatorbowlO-ringonthebottomof

thenewprimaryltercartridge.

7Installtheplasticwaterseparatorbowltotheprimaryltercartridge,andtightenthe

bowlbyhand1/4to1/2turnafterthebowlcontactstheO-ring.

8Applyathinlmofcleanengineoiltothesealinggasketofthenewltercartridge.

9Installthenewlterandtightenanadditional1/2to3/4turnbyhandafterthegasket

contactsthebase.

10Reconnectthewater-in-fuelsensorharnessconnector .

11Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel

SystemMACKMPEngines”,page55).

12Starttheengineandcheckforleaks.

54Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

SecondaryFuelFilterReplacementProcedures

Ateachspeciedoilandlterchangeinterval,changethesecondaryfuellterasfollows:

Note:Becauseoficebuildupinthefuelsystemorfuelwaxingwhichcanclogfuellters,it
maybenecessarytoreducethetimeormileageintervalbetweenfuellterchangesduring
extremelycoldweather.

Toinstallanewlter:

1Thoroughlywashtheareaaroundthefuellterandmountingadaptormatingareawitha

suitablesolventandblowdrywithcompressedair .

2UsingtoolJ24783,removetheoldlters.

3Applyathinlmofcleanengineoiltothesealinggasketofthenewlters.

4Installthenewltersandtightenanadditional3/4to1turnbyhandafterthegasket

contactsthebase.

5Primetheengineasrequiredpriortostartingtheengine(referto“PrimingtheFuel

SystemMACKMPEngines”,page55).

6Starttheengineandcheckforleaks.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX55

PrimingtheFuelSystemMACKMPEngines

OnMACKMPengines,theprimingpumpislocatedontheprimaryfuelltermounting
adapter.Primethefuelsystemasfollows:

DANGER

Beforeworkingonorinspectinga
vehicle,applytheparkingbrakes,place
thetransmissioninneutralandblock
thewheelstopreventthevehiclefrom
moving.Failuretodosocanresultin
unexpectedvehiclemovementandcause
severepersonalinjuryordeath.

WARNING

DONOTworknearthefanwhilethe
engineisrunning.Theenginefancan
engageatanytimewithoutwarning,
resultinginseriousinjury.Beforeturning
theignitionon,makesurethatnooneis
nearthefan.

DANGER

Toavoidpotentialrehazard,donot
serviceanypartofthefuelsystemwhile
smoking,orinthepresenceofames,
sparksorhotsurfaces.Donotservicethe
fuelsystemwhiletheengineisrunning.
Failuretofollowtheseprecautionscan
resultinare.T oguardagainstburns
fromdirectcontactwithhotfuel,wear
adequateprotectiveclothing(faceshield,
heavygloves,apron,etc.)whenworking
onahotengine.

Note:ThereareNObleednipplesthatmustbeopenedinordertoprimethefuelsystem.

56Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

1Unlocktheprimerpumphandlebypushingthehandledownwardandthenturningit

counterclockwise.

W0054026

UnlockingFuelSystemPrimerPumpHandle

2Operatethepumphandleuntilpumpingeffortincreases.

W0054027

PumpingHandPrimerPump

Note:Withafuelsystemthatiscompletelyempty ,200ormorestrokesofthepumpmay
benecessarytoproperlyprimethesystem.

3Whenthefuelsystemisprimed,locktheprimerpumphandlebypushingitfullyintothe

housingandturningitclockwise.

4Starttheengineandrunitat1000rpmforapproximately5minutestopurgeany

remainingairfromthesystem.

Note:Iftheenginedoesnotstartafterperformingtheaboveprimingprocedure,contact
yourlocalMACKdealerforassistance.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX57

Fuel/WaterSeparatorMACKMPEngines

TheprimaryfuellteronMACKMPenginesincludesaplasticwaterseparatorbowlwith
anintegralwater-in-fuelsensorandadrainassembly.Awarninglampontheinstrument
panelilluminateswhenwaterisdetectedinthefuel.Whenthelampilluminates,drainthe
waterfromtheseparatorbyopeningthedrainvalveandallowingthewatertodrainfrom
thebowlintoasuitablecontainer.Whenfuelbeginstodrain,closethevalveandtightento

0.655Nm(5lb-in).Disposeofthedrainedwater/fuelinanenvironmentallysafemanner.

W0054022

WaterSeparatorDrainV alveMACKMP

Engines

Note:DONOTdrainthewaterseparatorbowlwhiletheengineisrunning.

58Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

EngineOil

General

Keeptheengineoilattheproperlevelandchangeitattherecommendedintervals.Always
replacetheoilltersatthesametimeaswhentheoilischanged.

OilQuality

MACKrecognizesengineoilsthatmeetorexceedthestandardsgivenbyAmerican
PetroleumInstitute(API)fortheoilclassicationslistedinthismanual.Onlyoilslicensed
tocarrytheAPIsymbolshouldbeused.LubricantsmeetingAPIstandardshaveprovided
maximumenginelifewhenusedtogetherwiththerecommendedoilandoillterchange
intervals.

EO-NPremiumPlus(orVDS-3)dieselengineoilistheminimumrequirementforEuro
5ADR80/03.

CAUTION

DONOTaddextraoiladditives.Additivessuchasbreak-inoils,topoils,graphitizers,
andfriction-reducingliquidsarenotnecessaryandcanharmtheengine.

OilChangeIntervals

Thelengthoftimeanenginecanoperatebeforeanoilchangedependsonthequalityoil
used,thetypeoffuelused,engineoilconsumption,vehicleapplication,levelofdustin
theair,andfuelconsumption.Thechangeintervalsgiveninthismanualarem a x i m u m
intervals.Ifthevehicleisoperatinginheavy-dutyoperation,dustyoroff-roadconditions,
etc.,reducetheintervalsformorefrequentoilchanges.Forthecorrectoilchangeinterval,
see“OilCapacityTablesandViscosityCharts”,page125.

Foradditionalinformationaboutoilchangeintervals,seeyourMACKTruckdealer .

Note:Oilltersshouldalwaysbechangedwhenchangingoil.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX59

OilFilters

Therearethreeltersontheengine,oneofwhichisabypasslter.Thisshouldbechanged
atthesametimeasthefull-owlter(s).

CAUTION

MACKbrandedoilltersaredesignedtoprovidetheproperlevelofltrationand
protectionforMACKengines.Filtersthatdonotmeetthesamestringentrequirements
mayvoidenginewarranty.

Spin-OnOilFilters

1.Spin-OnOilFilters

W0054029

60Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

SyntheticLubrication

Syntheticoilsareofferedbysomeoilsuppliersasanalternativetothetraditional,petroleum
basedoilsforengines.TheseoilsmaybeusedinMACKengines,providedtheymeetthe
qualitylevelsspeciedintheprevioussectionsofthismanual.

Theuseofsyntheticoilsdoesnotpermittheextensionoftherecommendedoilchange
intervals.Itisthecontaminationrate,i.e.,soot,andthedepletionofadditives,rather
thanbaseoilqualitythatdeterminestheusefulengineoillifeandthereforetheoil
changeintervals.

OilViscosity

Theviscositygradedenesthethicknessoftheoil.Theoilmustbethinenoughatlow
temperaturesforeasycoldstartsandthickenoughtoprotectathightemperatures.Anoilis
notfullydeneduntilboththeAPIqualityclassicationa n d theviscositygradearespecied.

Choosetheviscositygradeforthetypicalambienttemperaturefortheapplication.
Multigradeoilshaveabroadrangethatsuitoperationinchangingtemperature.Thestandard
oilweightforMACKenginesis10W/30.

MACKrecommendstheviscositiesshownintheviscosity/temperaturetableforMACK
engines.

W1000144

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX61

OilAdditives

CAUTION

Extraoiladditivesmustneverbeaddedtoanyengineoilused.Additivessuchasbreak-in
oils,topoils,graphitizers,andfrictionreducingliquidsarenotnecessaryandmayeven
harmtheengine.

Usingoilstothequalitystandardsrecommendedinthismanualmakestheuseofextraoil
additivesunnecessary,astheseoilsalreadycontainabalancedtreatmentofadditives.

OilConsumption

Oncetheengineisstopped,checktheoilleveldaily .Iftheenginehasjustbeenstopped
anditiswarm,waitapproximatelyveminutestoallowtheoiltodrainbacktotheoil
panbeforechecking.Addoilasnecessary .

Note:DONOToverllenginewithoil.

Alldieselenginesaredesignedtoconsumesomeoil,soitisnormaltoaddoilperiodically.
Anengineusedinheavy-dutyoperationwillconsumemoreoilthanoneinnormaloperation.

62Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

OilChange

WARNING

Ahotengineorengineoilcanbedangerous.Seriousburnscanresultfromcontactwitha
hotengineoroil.T akeprecautionswhendrainingtheoil.Wearglovesorlettheengine
cooldownbeforedraining.

WARNING

Whendrainingtheoil,usethepropertoolsandkeepawayasfaraspossible.Raise
theelbowsotheforearmisparalleltothegroundtopreventoilrunningdownthearm,
causingburns.

CAUTION

Alwaysdisposeofalllubricants(motoroil,coolant,gearboxoils,etc.)andlters
accordingtoFederalorlocalregulations.Usedoildisposedofinnatureorwaterways
contaminatesourdrinkingwaterandkillswildlife.

CAUTION

Prolongedcontactwithusedengineoilmaybeharmful.Userubbergloveswhenhandling
usedoil.W ashskinthoroughlyifitcomesincontactwithusedoil.

Forinformationonthetypeofoilrecommendedforyourengine,see“OilQuality”,page58
and“OilCapacityTablesandViscosityCharts”,page125forquantitiesandviscosities,or
refertotheenginemanufacturersoperatorsmanual.

Itisimportanttodrainasmuchoilaspossible.Trytochangeoilimmediatelyafterdriving,
whentheoiliswarm.Alwaysreplacetheoillterswhenchangingoil.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX63

OilFiltersChange

WARNING

Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.Whenchanging
oil,wearprotectivegloves.

CAUTION

MACK-brandedoilltersaredesignedtoprovidetheproperlevelofltrationand
protectionforMACKengines.Filtersthatdonotmeetthesamestringentrequirements
maycauseunsatisfactoryresults.

1Coattheltergasketwithoil.

2Installthelterandturnitbyhanduntilthegasketmakescontactwiththesealingsurface.

3Manuallyturnthelteranadditional3/4toonefullturn.

64Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

CheckingOilLevel

CAUTION

DONOTlettheoillevelfallbelowthemarkingonthedipstick.DONOToverllso
thelevelisabovetheuppermarkingonthedipstick.Thiscouldleadtoexcessiveoil
temperatureand/orpoorcrankcasebreatherperformance.

Ensurethatthevehicleisparkedonlevelgroundbeforecheckingtheoillevel.W aitve
minutesaftershuttingofftheengine,thenproceedwithcheckingoil.

W2056443

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX65

EngineAirFilter

Theaircleanerpreventsdust,dirtandotherharmfulcontaminantsfromenteringthe
enginethroughtheairintakesystem.Maximumengineprotectioncanonlybeachieved
throughregularlyscheduledmaintenancepracticesthatincludeperiodicairintakesystem
inspectionsandairlterelementchanges.

Themostefcientmethodofdeterminingairlterelementchangeintervalsisbyregularly
checkingtheairlterrestrictiongauge,whichmayeitherbemounteddirectlytotheair
cleanercanister,ontheaircleaneroutlettubeorinsidethecab.Therestrictiongauge
measurestheamountofrestrictionintheairlterelement.Somechassismayhavea
dash-mounteddial-typerestrictiongaugewhichmeasureslterrestrictioninmm/inchesof
water.

Changetheairlterelementinaccordancewiththeproceduresasoutlined,whenthe
restrictiongaugeredsignallocksinfullview,orthedash-mountedgaugeindicatesinlet
restrictionasfollows:

MountedGaugeInletRestrictionIndication

EngineMillimeters(Inches)Water/kPa

MP8

Cummins635mm(25)/5kPa

510mm(20)/5kPa

AirFilterRestrictionGauge

W0054007

66Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Damagetotheairlterelement,suchasholesintheltermedium,willgiveaninaccurate
restrictionreading.Therefore,evenifmaximumrestrictionisnotindicated,theairlter
elementshouldbechangedeverytwelve(12)months.

Whenreplacingtheairlterelement,orwhenevertheairinletsystemhasbeen
disassembled,inspecttheinletairductsbetweentheaircleanercanisteroutletandthe
turbochargerinletasfollows:

•Inspecttherubberelbowsforcracks,splittingand/orholes.Rubbercomponentsmustbe

exiblesothattheyconformtotheplasticductsandensureatightseal.

•Inspectplasticductsforcracksand/orholes.

•Ensurethatallhoseclampsareproperlyinstalledandtightenedtospecications.

•Makesuretheplasticductsdonotrubagainstanycomponentssuchasairconditioning

hoses,wireharnesses,etc.

Toproperlyinstallanewlterelement:

1Wipetheaircleanerhousingclean.

2Removethelterelement(s).

3Inspectsealingareasfordirttrackswhichwouldindicatethatdusthasleakedpastthe

seal.Ifdirttracksarefound,thecausemustbedeterminedandcorrected.

4Thoroughlycleantheinsideoftheaircleanercanisterwithadampclothorvacuum

cleaner.

5Ifequippedwithametalcanister,inspectinsidethecanisterforrust.Ifrustispresent:

1Removetheaircleanercanisterfromthechassis.

2RemovealllooserustwithawirebrushoracoarseScotchBritepad.

3Sandwith180/240gritwetordrysandpaper .

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

andgreaseremoverandwipedry .

5PrimeimmediatelywithPPGDEP-351epoxyprimer .

6Reinstalltheaircleanercanister.

6Inspectthesealingareasofthehousingfordamage.Repairorreplaceasnecessary .

7UseMACK-approvedreplacementelementsandgaskets.Makesurethenewelements

andgasketsarenotdamaged.Besuretousenewgasketseachtimetheelementis
changed.Installthecoverand,dependinguponcoverconguration,tightenasfollows:

•Aircleanerwithlargewingnutincenterofcoverhand-tightenwingnut.

•Aircleanerwiththreethumbscrewsaroundouteredgeofcoverhand-tightenthumb

screws.

•Aircleanerwithretainingnutsaroundouteredgeofcovertightenretainingnuts

between11–14Nm(8–10lb-ft).

Note:DONOTattempttocleantheairlterelementwithcompressedair,asthiscould
damagetheltermediumandpossiblyresultinsevereenginedamage.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX67

W0053982

ReplacementPartsandFilters

68Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

ExhaustAfter-TreatmentSystem

AftertreatmentDieselParticulateFilter(DPF)

W4061331

Operator’sManualVehicleMaintenanceCMM,

StandardSystemView

CMH,CLX,CSM,andCXX69

1.SelectiveCatalyticReduction(SCR)

Catalyst

2.AftertreatmentDEFTank

3.AftertreatmentDEFDosingUnit

4.PumpUnitUreaDosingSystem

W2061423

DANGER

TheSCR/DPFshieldshouldnotbe
removedwhilethevehicleisinuse.
Also,onlyremovetheshield,oncethe
vehicleisoutofuseandtheSCR/DPFis
sufcientlycooled.Failuretofollowthese
instructionscanresultinre,whichcan
causecomponentdamage,personalinjury
ordeath.

70Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

CAUTION

TheDieselparticulateltersandtheir
components,cannotbemovedoraltered
fromtheOEMinstallationinanyfashion.
Anyalterationsmaycausecomponent
damageandisprohibitedbythelaw .

CheckifthevehicleisequippedwithaDieselParticulateFilter(DPF)orSelectiveCatalytic
Reductionunit(SCR).Thesecomponentsarepartoftheoverallvehicleemissionscontrol
system.Innormaloperation,thesecomponentscanexperiencesurfacetemperaturesas
highas350°C(662°F).Itisimportanttoverifythetemperatureatwhichthematerial
orsubstancein,orassociatedwith,thebodycanignite.Ifitispossibleforthematerial
orsubstancetofallorleakfromthebody,takestepstopreventthemfromcontactingor
collectingontheDPForSCR.Failuretodosomayresultinre.

Itisimportanttonotethatadditionalshieldingmay,dependinguponconditionsandthe
materialorsubstance,trapammablesubstancesbetweentheadditionalshieldandthe
DPF/SCR.Ifthisconditioncandevelop,advisetheuserofthevehicletoperiodicallycheck
toensuretherearenotrappedsubstances.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX71

ExhaustEmissions(CumminsISX)

NewstringentstandardsforexhaustemissioncontrolbeginwiththeADR80/03
introduction.TheDieselParticulateFilter(DPF)systemhasbeendevelopedtoactin
combinationwithUltraLowSulphurDiesel(ULSD)fueltoreduceparticulateemissions
tomeettherequirement.TheExhaustAfter-TreatmentSystem(EATS)includesallthe
engineandexhaustemissionscontrolcomponentsthatarerequiredtomeetthestringent
ADR80/03standard.

ParticulatematterconsistsofsootandashintheexhaustthatCumminsengineswithanEGR
systemalone,arenotequippedtohandle.Theparticulatematterisconsideredacontaminant
thatcontainsundesirableelements.TheDPFsystemreducestheunwantedelementstoa
moreacceptableleveldenedintheregulations.

Theparticulatematterremovedfromtheexhaustcollectsontheltersurfaces.T oavoid
eventualblockage,whichwouldincreaseexhaustbackpressureandaffectpowerandfuel
economy,theltermustbecleaned.TheDPFiscleanedautomatically.Thesootbreaks
downtosafersubstancesbeforebeingreleasedtotheatmosphere.Someoftheashremains,
buttakesalongtimetoreachthepointwhereashclogsthelter.

Cleaningaltersoitcancontinuetofunctioniscalled“regeneration.”Eithersystemuses
highheattobreakdownthechemicalproperties.Dependingonvehicleusage,theengine
isequippedwithapassiveoractiveregenerationsystem.

Passiveregenerationnaturallyoccursatexhausttemperaturesof260°C(500°F)or
greater.Ifpassiveregenerationisnotsufcienttoeliminatethecollectedsoot,theactive
regenerationprocesswilloccurwhenengineconditionspermit.

Duringtheactiveregenerationprocess,fuelisinjectedintotheexhauststreamandpasses
throughanoxidationcatalysttoincreasethetemperatureinsidetheparticulatelter .Typical
exhausttemperaturesduringtheactiveregenerationprocessare500-625°C(932-1157°F).

WARNING

Priortoeverworkingontheexhaust,allow
timefortheentireexhaustsystemtocool.
Failuretodosomayresultinpersonal
injury.Severeburnscanoccur .

72Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

SelectiveCatalyticReduction(SCR)

SelectiveCatalyticReduction(SCR)isanemissions-reductiontechnologywiththeability
todeliverreducedemissionsofnitrogenoxides(NOx),asmog-causingpollutantand
greenhousegas.SCR’sperformancehasbeenprovedinmillionsofkilometers(Km)of
real-worldtruckoperationsinothercountries,aswellasinlong-termeldtestsintheU.S.
SCRreducesNOxemissionstoverylowlevels,whileatthesametimedeliveringexcellent
fueleconomyandreliability .Thesystemdoesn’tchangethedesignoroperationofthebasic
engine.Rather,SCRisanaftertreatmentsystemwhichconvertsNOxintheexhauststream
intoharmlessgases.Moderndieselsalreadyuseexhaustaftertreatmentsystems,called
dieselparticulatelters,tocontrolemissionsofanotherpollutant,soot(alsoknownas
particulatematterorPM).
SCRworksbyinjectingDieselExhaustFluid(DEF)intotheexhauststeam.DEFisasafe,
simplesolutionofwaterandurea.DEFworkswiththeheatoftheexhaustandacatalystto
convertNOxintonitrogenandwatervapor-twoharmlessandnaturalcomponentsoftheair
webreathe.Theendresultiscleanerair,excellentfuelefciencyandareliableemissions
controlsystemfortoday’smoderndieselengine.

1.DieselEngine

2.AftertreatmentDEFTank

3.AftertreatmentDEFPump

4.AftertreatmentDEFDosingUnit

5.SelectiveCatalyticReduction(SCR)Catalyst

6.AftertreatmentDEFTankGauge

W2061387

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX73

CAUTION

DonotputdieselfuelintheAftertreatment
DEFtank.Dieselfuel,ifsprayedintothe
hotexhaustalongwiththeDEF,could
igniteexplosivelycausingareresulting
inpersonalinjuryordamagetotheexhaust
system.

TheSCRsystemissimpleandeffective,withfewcomponents.Itconsistsofa
AftertreatmentDEFtankpositionednearthestandarddieseltank,plusaAftertreatmentDEF
pump,AftertreatmentDEFDosingunitandSCRcatalyst.TheadvantageofusingDEFis
thatitenablestheenginetousenoEGR.ByusingDEF ,weavoidthedisadvantagesofthe
EGR.Thisresultsinbetterfueleconomyfromyourengine.

74Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

DieselExhaustFluid(DEF)

DieselExhaustFluid(DEF)isareactantthat’ skeytotheSCRprocess.It’sanontoxic,
aqueoussolutionofureaandwater.Ureaisacompoundofnitrogenthatturnstoammonia
whenheated.Itisusedinavarietyofindustries,perhapsmostcommonlyasafertilizer
inagriculture.Theuidisnotammable,norisitdangerouswhenhandlednormally .
However,itishighlycorrosivetometal,particularlycopperandaluminium.Readthe
separatesectionconcerningthehandlingofDEFsolution.OnlyuseapprovedDEFuid.

DescriptionMin./Max.

UreaContent

Density20°C(68°F)1.08701.0930g/cm

RefractingIndexat20°C(68°F)1.38141.3843

Alkalinity

Biuret

Aldehyde5mg/kg

Insolubles20mg/kg

Phosphate(PO4)0.5mg/kg

Calcium0.5mg/kg

Iron

Copper

Zinc0.2mg/kg

Chromium0.2mg/kg

Nickel0.2mg/kg

Aluminium0.5mg/kg

Magnesium0.5mg/kg

Sodium0.5mg/kg

Potassium0.5mg/kg

31.8to33.2%byweight

3

asNH3:0.2%

0.3%

0.5mg/kg

0.2mg/kg

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX75

W3036787

Note:CommonNamesandReferencesfor
DieselExhaustFluid(DEF):AdBlue™,
Urea,NOxReductionAdditiveandAir1™

76Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

DieselExhaustFluid(DEF)Handling

WhenhandlingDEFsolution,itisimportantthatelectricalconnectorstobeconnectedor
wellencapsulated.OtherwisethereisariskthattheDEFwillcauseoxidationthatcannot
beremoved.W aterorcompressedairdonothelp,sinceDEFquicklyoxidizesmetal.Ifa
connectorcomesintocontactwiththeDEFsolutionitmustbereplacedimmediatelyto
preventtheDEFsolutionfromcreepingfurtherintothecopperwiring,whichtakesplaceat
aspeedofabout60cm(2.4in)perhour.

CAUTION

Whendetachinghosesandcomponents,do
notspillDEFondisconnectedconnectors.
IfDEFisspilledonaconnector,the
connectormustbereplacedimmediately

ThingstoknowaboutspilledDieselExhaustFluid(DEF)

Ifureasolutioncomesintocontactwiththeskin,rinsewithplentyofwaterandremove
contaminatedclothing.

Ifureasolutioncomesintocontactwiththeeyesrinseforseveralminutesandcallfor
medicalhelpifnecessary.

Ifinhaledbreathefreshairandcallformedicalhelpifnecessary .

DonotallowtheDEFsolutiontocomeintocontactwithotherchemicals.

TheDEFsolutionisnotammable.IftheDEFsolutionisexposedtohightemperatures,it
breaksdownintoammoniaandcarbondioxide.

TheDEFsolutionishighlycorrosivetocertainmetals,includingcopperandaluminium.

IftheDEFsolutionisspilledontothevehicle,wipeofftheexcessandrinsewithwater.
SpilledDEFsolutioncanformconcentratedwhitecrystalsonthevehicle.Rinseoffthese
crystalswithwater.

Note:DonotushDEFspillsintothenormaldrainsystem.

WARNING

DEFspiltontohotcomponentswill
quicklyvaporize.Turnyourfaceaway!

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX77

DieselExhaustFluid(DEF)Consumption

DEFconsumptionisrelatedtofuelconsumption.Agaugemuchlikeafuelgaugewill
indicatethelevelofDEFinthetank.ADEFlow-levelwarningwillactivatewhenDEFis
low.IfadriverrunsoutofDEFcompletely,vehiclepowerwillbereducedtoderatemode.
WhentheDEFtankisrelled,theenginewillresumenormalpower.

DieselExhaustFluid(DEF)Availability

ContactyourlocalMackdealerforDEFavailability .

78Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

DriveBeltReplacementIntervals

Ifbeltssqueakorsqueal,cleanwithhydraulicbrakeuidoranapprovedcleaninguid.
Replacebeltsthatareseverelywornorfrayed.

RibCracking

Anin-servicepolyV-beltwillgothroughseveralphasesofcrackingduringitslife.Afteran
extendedtimeinservice,minorribcracksmayappear,usuallyoneortwocracksperinch.
Thiscrackingisnormal.

BeltwithMinorRibCracks

W0054003

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX79

Beltsshouldnotbereplacedunlesstheribsexhibitseveremultiplecrackingasshownbelow.
Multiplecrackingwillleadtoribchunking.

W0054004

BeltwithMultipleCracking

BeltwithSevereCrackingandRibChunking

W0054005

80Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

RibSidewallGlazing

Whenthebeltribsappeartohaveashinysurfacethatishardandbrittle,itisusually
anindicationofbeltslippage.Thisisattributedtoinadequatetensionand/orextreme
temperature.Boththeseconditionswillleadtoseverecrackingandbeltfailure,oftenwith
littleadvancewarning.Ifthisoccurs,locatethecauseandcorrectbeforeinstallinganew
belt.

BeltWear

Acceleratedwearonanypartofthebelt(fabricbacking,tensilecordorribrubber)isa
concernandshouldbeinvestigatedforcause,andcorrectedbeforeinstallinganewbelt.

PossibleCausesofAcceleratedBeltWear

•DriveMisalignmentBeltperformancewillbeadverselyaffectedwhenmisalignment

exceeds1/16inchforevery12inchesofbeltspan.

•BeltLengthMustbecorrect.

•EnvironmentalConditionsTemperature,exposuretoengineuids,etc.

•AbrasiveMaterialsSmallstones,metalshavings,etc.

W0054006

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX81

ForeignObjects

Anyobjectprotrudinginthepathofthebeltdriveandcontactingthebeltwillcausedamage
andeventualfailure.Locatetheobjectbeforeinstallinganewbelt.(See)

W0054011

DamagefromObjectProtrudinginBeltPath

Noise,VibrationandHarshness(NVH)

PolyV-beltdrivesystemsweredesignedtopreventNoise,VibrationandHarshness(NVH)
problems.Fieldproblems,however,whichmayberelatedtoNVHcausesoccasionally
occur.

82Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

PossibleCauses

Insufcientbelttensionmaycreateahigh-pitchedhowl(squeal)orraspingsoundduring
engineaccelerationordeceleration.

Misalignmentmaycauseachirpingnoise,especiallyat,ornear,idlespeed.Rigidbracketing
ofaccessoriesisamustforreasonablyvibration-freebeltspans.Somespanvibrationisto
beexpectedduringtherangeofenginespeedandaccessoryloading.

WARNING

Failuretofollowrecommendedapplication
informationandrecommendedprocedures
forinstallation,caremaintenanceand
storageofbeltsmayresultinfailureto
performproperlyandmayresultindamage
topropertyandseriousbodilyinjury.Make
surethebeltselectedforanyapplicationis
recommendedforthatservice.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX83

DriveBeltInstallation

ToinstallapolyV-belt,swingtheautomatictensionertothefullsprungposition(fully
towardtheinstallstop),thenplacethebeltoverthepulleys.Slowlyreturntheautomatic
tensionerbacktoitsoriginalposition.Donotallowthetensionertosnapagainstthestops.
Forproperbeltrouting,refertothefollowingbeltroutingdiagrams.Beforeinstallingthe
newbelt,ensurethatthepulleygroovesarecleanandfreeofdebris.

DriveBeltRoutingMACKMP8engines,allmodels.

DriveBeltRoutingMP8Engines

1.CrankshaftPulley

2.AutomaticTensioner

3.IdlerPulley

4.WaterPump

5.MainDriveBelt

6.FanDrive

W0054017

7.IdlerPulley(whenapplicable)

8.AccessoryDriveBelt

9.AutomaticTensioner

10.Alternator

11.AirConditionerCompressor(if
equipped)

84Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

AutomaticBeltTensionerMaintenance

Theautomaticbelttensionerisdesignedtomaintainproperbelttensionthroughoutthelife
ofthetensioner.Thebelttensionercannotbeadjustedorrepaired,ateachinspectioninterval
oronceperyear,whicheveroccursrst,checkthefollowing:

•Withthebeltonthedrive,checkthefollowing:

Checktoseeifthetensionerisrestingagainsttheinstallstoporthefree-armstop.Ifthe
tensionerisrestingagainsteitherstop,thetensionermustbereplaced.

W0054013

TensionerInstallStopandFree-ArmStop(MainDriveBeltT ensionerShown)

1.InstallStop

Onmaindrivebelttensioners,checkbelttracking.Ifthebeltistrackingallthewayto
onesideofthetensionerpulley(eitherthefront-orback-side),replacethetensioner.Belt
trackingcanbedeterminedbylookingatthewitnessmark(theshinyareaonthepulley
wherethebeltrides).Thewitnessmarkshouldbeapproximatelythesamewidthofthe
belt.

2.Free-ArmStop

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX85

W0054014

MainDriveBeltTensionerBeltTrackingWitnessMark

1.Acceptable(WitnessMark
ApproximatelySameWidthasBelt)

2.NotAcceptable(WitnessMark
TrackingOffEdgeofPulley)

•Removethebeltbyusinga3/8inchbreakerbartopullthetensionerbacktotheinstall

stop.Slowlyreturnthetensionertothefree-armstop.

•Withthebeltremoved,usethebreakerbartoslowlypullthetensionerfromthefree-arm

stoptotheinstallstopandthenslowlyreleasingitbacktothefree-armstop.Any
excessiveroughnessorhesitancynoticedwhileperformingthischeckindicatesthat
thetensionermustbereplaced.

•Checkformetal-to-metalcontactasfollows:

Checkforcontactbetweenthearmandthespringcase.Replaceifmetal-to-metalcontact
isseen.

86Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

CheckingforContactBetweenArmandSpringCase

W0054015

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX87

Checkformetal-to-metalcontactbetweenthearmandtheendcap.Replaceifcontactis
seen.

W0054016

CheckingforContactBetweenArmandEndCap

Checkforcracksinthetensionerbodyorforbrokenstopsonthespringcase.Ifeitheris
seen,replacethetensioner.

ReinstallthebeltmakingsurethatthebeltisproperlyseatedinthegroovesofALLpulleys.

CAUTION

Ifanautomaticbelttensionermustbe
replaced,makesurethattheproper
tensionerisused.T ensionerspringtension
variesbyengineandchassismodel.Do
notsubstituteonetensionerpartnumber
foranother,asdrivebeltfailurecanresult.

88Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

TurbochargerandChargeAirCooler

DANGER

Ifoilleaksinternallyfromtheturbocharger
totheengineintake,theoilactsasafuel.
Watchforexcessiveexhaustsmoke.DO
NOToperateengineuntilproblemis
corrected.Thereisnowaytoregulatethe
enginespeedifitrunsonoilanditmay
overspeed.Lossofcontrolofvehiclemay
leadtoanaccidentcausingseverepersonal
injuryordeath.

Visuallyinspectturbomountings,intakeandexhaustductingandconnectionsforleaksona
dailybasis.Checkoilinletandoutletforleaksorsignsofrestrictionstooilow.Checkfor
unusualnoiseorvibration.Ifanyfaultsaredetected,donotoperatetheengineuntilthe
causeisdeterminedandrepaired.

WARNING

DONOTremove,attach,ortighten
turbochargerairintakeductingwhilethe
engineisoperating,oroperatetheengine
whiletheductingisremoved.Working
aroundtheturbochargerwiththeducting
removedmaycauseseverepersonalinjury .

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX89

CleaningChargeAirCoolerandRadiatorPackage

WARNING

Alwaysweareyeprotectionwhencleaning
radiator,charge-aircoolerandcondenser.
Failuretofollowthisrecommendationmay
resultineyeinjury.

Periodicallyinspectthefrontoftheradiator/charge-air-coolerpackageforbuildupofdirt,
mud,insects,etc.Overtime,theremaybeabuild-upofdirt,mud,insects,etc.,between
theradiatorandchargeaircooler.Inspectforbuild-upandcontactyourauthorizedMACK
Truckdealer,ifnecessary.

Overtime,dirtandinsectswillaccumulatebetweenthensoftheradiator,airconditioning
condenserandcharge-air-cooler .Thereducedairowreducestheheattransferfromthe
componentstotheair.Thisincreasestheloadonthefanandairconditioningcompressor
andcanresultinengineoverheatingandotherperformancerelatedproblems,suchashigh
fuelconsumption,etc.

CAUTION

Whenusingapressurewashertoclean
thevehicle,donotdirectthesprayat
electricalcomponentsintheengine
compartmentsuchasthealternator,starter
andcompressors.W atersprayfrom
pressurewasherscandamageelectrical
components.

90Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Thesimplestmethodtocleanthepackageistouseairpressureorawaterstream.This
shouldbedonefromthebackofthecore.Airpressureshouldnotexceed30psi(200kPa)
forradiatorandchargeaircoolercores.Theuseofancombisalsoagoodtooltoloosen
bugsanddirtfromthens.Ifdirtcannotbecleanedoffwiththisprocedure,consultyour
MACKTruckdealer.

W2001496

CleaningChargeAirCoolerandRadiator

(typicalradiatorshown)

Inspectthechargeaircoolerforcracksateveryinspection.DONOToperatethevehicle
withadamagedorbrokenchargeaircooler .Todosowouldvoidthewarrantyandthe
enginewillnotmeetemissionregulationrequirements.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX91

PreventiveMaintenanceAirSuspensions

Note:Thefollowingmaintenanceitemsshouldbeperformedonallairsuspensions
(includingMACKAL,ALII,AL-401LH,MAXAIR40/40A,MAXLITE2040,MAXLITE
2040EZandHendricksonPRIMAAX)ateachinspectioninterval,orevery40200Km
(25,000miles)orsixmonths,whichevercomesrst.

•VisualInspection:Inspectallsuspensioncomponents,checkingforsignsofwear,

damageorunwantedmovement.Lookforbentorcrackedparts.Replaceallwornor
damagedcomponentsasrequired.

•AirSpring:Inspectforchangoranysignsofspringorcomponentsdamage.Ensure

thattheupperbeadplateistightagainsttheundersideoftheframe.Checkforlateral
slippageatthelowerairspringbracket.Slippageof3.3mm(1/8inch)ineitherdirection
isacceptable.Replacewornordamagedcomponentsasrequired.

•SupportBeamAssembly:Inspecttheoverallconditionofthesupportbeamfordents,

dingsorotherdamage.OnHendricksonPRIMAAXsuspensions,checktheD-pin
bushingsfortearingorextremebulging.Checkformetal-to-metalcontactinthebushed
joints.Replacewornordamagedcomponentsasrequired.

•FrameHangerBracket:Inspectforanysignsoflooseningordamage.OnHendrickson

PRIMAAXsuspension,checkforlooseningordamageattheQUIK-ALIGNconnections
orlongitudinaltorquerodconnections.Replacewornordamagedcomponentsas
required.

•CrossBeam:Inspectforcracks,damage,metalshavingsorloosenessatthebeam

connections.Replacewornordamagedcomponentsasrequired.

•TransverseTorqueRods:Inspectforsignsofloosenessatthetransversetorquerod

connections.Checkbushingsfortearingorexcessivebulging.Checkthetransverse
torquerodfordentsorbending.Replacewornordamagedcomponentsasrequired.

•ShockAbsorbers:Inspectforsignsofdentsorleaking(oilmistingisnotconsidered

leakage).Replacewornordamagedshocksasrequired.

•TireWear:Inspecttiresforwearpatternsthatmightindicatesuspensiondamageor

misalignment.Replacewornordamagedcomponentsasrequired.

•HeightControlValveandAirLines:Checkforloose,bentordamagedparts.Check

airlinesforchangoranyunwantedcontactwithmovingcomponents.Checkheight
controlvalveandairlinesforleakage.Replacewornordamagedcomponentsasrequired.

92Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

SteeringandBrakesMaintenance

SteeringSystem

Excessiveplayinthesteeringsystemischeckedbyturningthesteeringwheelwhilethe
engineisstopped.Withthefrontwheelspointingstraightahead,turnthesteeringwheel
untilthefrontwheelstartsmoving.Then,turnthesteeringwheeltheotherwayuntilthe
frontwheelmoves.Playshouldnotbemorethan25mm(1in)attherimofthesteering
wheel.Ifthesteeringplayisexcessive,checkthesteeringlinkageforlooseness,wear,etc.
Makenecessaryrepairsbeforedrivingthevehicle.

PowerSteeringFluidReservoir

ThepowersteeringuidreservoirislledwithAutomaticTransmissionFluid(A TF)Dexron
IIIforthepowersteeringsystem.Iftheuidhasdarkened,itindicatesthatthepower
steeringsystemisrunninghotterthannormalandtheuidisoverheating.T akethevehicle
toaMACKTruckdealerfortroubleshootingtheoverheatingandtohavetheuidchanged.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX93

BrakeSystem

DANGER

DONOTusereplacementpartsanywhereinthebrakesystemunlessitconformsexactly
tooriginalspecications.Anonconformingpartinyourvehiclesbrakesystemcould
causeamalfunction,leadingtolossofcontrolofthevehicleresultinginseverepersonal
injuryordeath.

DANGER

DONOTreleasetheparkingbrakeorattempttomovethevehicleuntilbrakeairpressure
inbothcircuitsisatleast100psi(690kPa).Failuretofollowthisproceduremayleadto
uncontrolledvehiclemovementandcauseseverepersonalinjuryordeath.

DANGER

AutomaticslackadjustersMUSTNOTbemanuallyadjustedinanefforttocorrect
excessivepushrodstroke,asthisconditionindicatesthataproblemexistswiththe
automaticadjuster,installationoftheautomaticslackadjusterorproblemsrelatedto
componentsofthefoundationbrakes.Theseconditionswillnotbecorrectedbymanually
adjustingtheautomaticslackadjusters.
Manualadjustmentofautomaticslackadjustersisadangerouspracticethatcould
resultinseriousconsequences.Thispracticegivesthevehicleoperatorafalsesenseof
securityabouttheeffectivenessofthebrakes,andthebrakeswilllikelysoonbeoutof
adjustmentagain.

Note:Thebrakesystemisacriticalvehiclesafetysystem.Foryoursafetyandforthose
aroundyou,followtherecommendedpreventivemaintenancechecks.Ifanyproblems
occur,havetheminvestigatedimmediatelybyanauthorizedservicefacility.

ThefollowingDualCircuitBrakeSystemFunctionTestshouldbeperformedateach
inspectioninterval,orafteranyairsystemserviceproceduresthatinvolvedisconnectingand
reconnectingairlineswhereincorrectreconnection,suchasthetreadlevalve,isapossibility.

1Blockthewheelstopreventthevehiclefrommoving.

2Starttheengineandbuildairsystempressuretogovernorcutout.

3Stoptheengine.

4Completelydrainoneairreservoir.

5Releasetheparkingbrakes.

6Applyandholdthetreadlevalve.

94Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

7Haveanassistantcheckforproperresultsbyobservingthemovementoftheslack

adjustersasindicatedbelow:
TRUCK:

•Thebrakesonthereardriveaxle(s)shouldalwaysapplyasindicatedbymovementof

theslackadjuster.

•Thelow-airwarningbuzzerandwarninglampshouldactivateforatleasttwoofthe

tests.
TRACTOR:

•Thebrakesoneitherthesteeringaxleorthereardriveaxle(s)shouldalwaysapplyas

indicatedbymovementoftheslackadjuster.

•Thelow-airwarningbuzzerandwarninglampshouldactivateforatleasttwoof

thetests.

8Repeattheaboveproceduresfortheremainingairreservoirs.

AirTanks

DANGER

Draintheairsystemtanksattherecommendedintervals.Ifcondensationaccumulates,
moisturecanenterthebrakesystemairvalves,causingcorrosionorclogging.The
safetyofthebrakesystemcouldbecompromised,leadingtoanaccidentcausingsevere
personalinjuryordeath.

WARNING

Whendrainingtheairtanks,DONOTlookintotheareaofthedrainingair.Dirtorsludge
particlesmaybeintheairstreamthatcouldcauseeyeinjury .

Airtanksshouldbedraineddaily.Makesurethedraincockscloseproperlyafterdraining.
Emptymoisturefromairtanksbypullingthedrainvalvelanyardorpullcord.Thetanks
shouldbecheckedforcondensationuid,evenifanautomaticdrainvalveisinstalled.

Itisveryimportantthattheairsystemiskeptclean.Ifsludgeoroilisfoundinthedrainage
oranexcessiveamountofuidisdrainedoutofthetanksseeyourauthorizedMACK
Truckdealer.

Operator’sManualVehicleMaintenanceCMM,

CMH,CLX,CSM,andCXX95

AirDryers

AllMACKchassisareequippedwithairdryerswhichutilizeanoilcoalescingdesiccant
cartridgewhichremovesatomizedoilandotherparticulatematterfromtheairsystem.The
oilcoalescingdesiccantcartridgemustbechangedyearly.Refertothespecicairdryer
serviceliteraturefordetailedinformation.

96Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX

Tires,WheelsandHubMaintenance

WheelSafetyInformation

DANGER

DONOTattempttorepairwheelsortiresunlessyouaretrainedandequippedtodoso.
Wheelandtireassembliescannotbeworkedonwithoutpropertoolsandequipment.
Failuretofollowthismayleadtoseriouspersonalinjuryordeath.

DANGER

Failuretoproperlytorque-tightenthewheelnutscanresultinthebreakageofwheelstuds
andthesubsequentlossofwheels.Lossofvehiclecontrolandseriouspersonalinjury
ordeathcanoccur.

DANGER

DONOTuseoilorgreaseonstudsornuts.Thetighteningtorqueisaffectedandcan
leadtoincorrectclampingloadsbetweentherimandhub.Thiscouldleadtoalossofthe
wheel.Lossofvehiclecontrolandseriouspersonalinjuryordeathcanoccur.

DANGER

DONOTinstallregrooved,retreadedorrepairedtiresonthesteeringaxle(s).They
couldfailunexpectedlyandcausethelossofvehiclecontrol,leadingtoseriouspersonal
injuryordeath.

DANGER

DONOTusemismatchedwheelcomponents.Iftheydonotexactlymatchtheoriginal
designspecications,theymaycausefailureorseparationleadingtoblowoutandan
accidentandpersonalinjuryordeath.