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PV776 MX
Operator Manual
142 pgs828.34 Kb0

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.
Note:Itisimportantthatthismanualstaywiththevehiclewhenitissold.Importantsafety informationmustbepassedontothenewcustomer.Theserviceinformationcontainedin thismanualgivestheownerimportantinformationaboutmaintainingthevehiclebutis notintendedasasubstituteforthePreventiveMaintenanceServiceManualandmustnot beregardedassuch.
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.
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