Mack
®
MAINTENANCE AND LUBRICATION
21636397
MAINTENANCE
AND LUBRICATION
© Mack Trucks, 2010
21636397
21636397
December 2010
MAINTENANCE
AND LUBRICATION
https://www.truck-manuals.net/
https://www.truck-manuals.net/
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
https://www.truck-manuals.net/
https://www.truck-manuals.net/
Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX1
Foreword
DONOTRemovethismanualfromthevehicle.Itcontainsimportantoperationaland
safetyinformationthatisneededbyalldriversandownersofthisvehicle.
Thismanualcontainsinformationconcerningthesafeoperationofyourvehicle.Itis
extremelyimportantthatthisinformationisreadandunderstoodbeforethevehicleis
operated.Thismanualalsocontainsaconsiderableamountofinformationconcerningthe
vehicle,suchasvehicleidentication,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.
https://www.truck-manuals.net/
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:Anotedenesanoperatingprocedure,practice,condition,etc.,whichisessentialto
properoperationofthevehicle.
DANGER
Adangerlabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresultin
seriouspersonalinjuryordeath.Thedangerlabelisinwhitetypeonablackbackground
withablackborder.
WARNING
Awarninglabeldirectstheoperatorsattentiontounsafepracticeswhichcouldresultin
personalinjuryorseveredamagetothevehicle.Thewarninglabelisinblacktypeon
agraybackgroundwithablackborder.
CAUTION
Acautionlabeldirectstheoperatorsattentiontounsafepracticeswherepersonalinjury
isnotlikelybutpropertydamagecouldoccur.Thecautionlabelisinblacktypeona
whitebackgroundwithablackborder .
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX3
WarningandAdvisoryLabels
Advisory,Danger,WarningandCautionlabelsareplacedinvariouslocationsofthevehicle
toalertdriversandservicetechniciansaboutsituationsthatmayleadtopersonalinjury
orequipmentdamage.Intheeventthatalabelisdamagedormissingthelabelmustbe
replaced.ContactyourauthorizedMACKTruckdealerforassistanceregardingW arning
andAdvisorylabels.
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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.Forspecicmaintenance
informationonvendorcomponents,seetherespectivemanufacturersserviceand
maintenanceliterature.
Thismanual,togetherwithmanualsforspeciccomponentscontainimportantinformation
tobeabletooperatethisvehiclesafely.Theycontainadviceandinstructionswhichwill
enableyoutogettheoperatingeconomyandperformancethatyouexpectfromthisquality
vehicle.
Allinformation,illustrationsandspecicationscontainedinthismanualarebasedupon
thelatestproductinformationavailableatthetimeofpublication.Ifanyquestionsarise
concerningthecurrentstatusofFederalorstatelaws,theappropriateFederalorstateagency
shouldbecontacted.
https://www.truck-manuals.net/
Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX5
Note:Illustrationsareusedforreferenceonlyandmaydifferslightlyfromtheactualvehicle,
however,keycomponentsaddressedinthismanualarerepresentedasaccuratelyaspossible.
MACKreservestherighttomakechangesatanytimeortochangespecicationsordesign
withoutnoticeandwithoutincurringobligation.
NoiseEmissions
NoiseControlSystem,OperatorInspectionandMaintenance
Requirements
ANoiseControlSystemMaintenanceLogislocatedinthismanual.Thislogshouldbe
usedtodocumentallNoiseControlSystemrelatedmaintenance,whetherthemaintenance
resultsfromaspecicnoisecontrolsysteminspection,oradeciencyidentiedduring
anothergeneralmaintenanceevent.
Ifadditionallogspaceisneeded,furtherentriesmaybeaddedonaseparatesheetof
paper.Storetheseadditionswiththemainlogtopreserveacomprehensiverecord.Itis
recommendedthatcopiesofallnoiseemissionsrelatedmaintenanceinvoicesberetained.
ThefollowingNoiseControlSysteminspectionandmaintenanceinstructionscontain
suggestedmaintenanceintervals.Theseintervalsmayneedadjustmentinordertobest
accommodatethespecicvehicleusage.ThefollowinginstructionsonlyconcernNoise
Emissionsrelateditemsanddonotaddressormodifyanygeneralvehiclemaintenance
requirements.
ThefollowingelementsmakeuptheNoiseControlSystem:
•NoiseShieldingandInsulationDevices
•CoolingSystem
•ExhaustSystem
•AirIntake/AirInductionSystem
•EngineControlandFuelSystems
•SelectiveCatalyticReduction(SCR)
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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,includingmufers,
heavyordouble-wallexhausttubing,exibletubingorexhaustpipeclamping.
•Removal,orrenderinginoperative,ofthetemperature-modulatedcoolingfansystem.
•Removalofthecoolingfanshroud.
•Removal,orrenderinginoperative,oftheaircleanerorairintakein-linesilencer.
•Removalofthesounddeadeningmaterialfromthehoodorcabtunnel.
•Removal,orrenderinginoperative,oftheenginespeedgovernorsoastoallowengine
speedtoexceedthemanufacturersspecications.
•Removalofsplashshieldslocatedinsidethewheelhousings,iftted.
•Removalofengineblockshields,iftted.
•Removalofenginecrankcaseshieldsorinsulation,iftted.
•Removalofinsulatedrockerarmcovers.
•Removaloftransmissionnoiseshields,iftted.
NoiseShieldingandInsulationDevices
Maintenance
Ensuresoundshieldingandinsulatingdevicesareintact,iftted.Inspectcomponentsfor
damage.Primarysystemcomponentsrequiringnoiserelatedinspectionincludethehood,
enginecompartmentinsulatingmaterials(includinghoodinsulation,bulkheadinsulation,
doghouseinsulation,etc.)splashshields,cabskirts,fendershields,andbodypanels.Inspect
allrelatedfasteners,brackets,andclampsfordamageandtightness.
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX7
RegulatoryCompliance
ActsthatconstitutetamperingwiththeNoiseShieldingandInsulationDevices(whentted):
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.Conrm
operationoftemperaturemodulatedfanclutch.
RegulatoryCompliance
ActsthatconstitutetamperingwiththeCoolingSystem:
Removingorrenderinginoperativecoolingsystemcomponents(suchasthetemperature
modulatedfanclutch,fanshroud,fanring,recirculationshields,etc.).
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8Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX
ExhaustSystem
WARNING
Hotengine!Avoidallmovablepartsorhotengineparts,exhaustgases,and/oruids.A
hotengine,exhaust,and/oruidscancauseburns.
Maintenance
Makesuretheexhaustsystemisintact.Inspectfordamage,misalignmentand/orleakage.
Primarysystemcomponentsrequiringnoiserelatedinspectionincludeexhaustmanifold,
turbocharger,andallexhaustsystem(rigidandexible)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.
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX9
RegulatoryCompliance
ActsthatconstitutetamperingwiththeAirIntake/AirInductionSystem:
Removingorrenderinginoperativeairintake/inductionsystemcomponents(lter,lter
housings,ducts,etc.).
EngineControlandFuelSystems
ActsthatconstitutetamperingwithEngineControlandFuelSystems:
Removingrenderinginoperative,ormodifyingtheenginecontrolsystemsuchastheECU,
SCRandothersystemcomponents,orfuelsystemcomponents,inordertoallowtheengine
tooperateoutsideofthemanufacturersspecicationsisnotallowedandviolatesboth
warrantyandlegislation.
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10Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX
LabelInformation
VehicleIdenticationNumberLabel
Allmotorvehiclesarerequiredtobeidentiedbya17-digitV ehicleIdenticationNumber
(VIN).TheVINgivesspecicinformationaboutthevehicleasmanufacturedbyMACK.
TheVINcanbefoundatseveraldifferentlocationsonaMACKvehicle.Locations
includeastampingontheverticalfaceoftheright-handframerail(somewherebetween
thefrontspringhangerbrackets),aVINlabelinsidethecab(onthedooredge,thedoor
openingarea).Whenthevehicleisreceived,checktheVINateachlocationonthevehicle
andverifythattheyareidentical.Thevehicleidenticationnumbermustnotbechanged,
coveredorobliterated.
VINFrameStamping
W0031972
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX11
W0061426
VINLabelonInsideDriver’sDoor
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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/oranexplosionandre.
Seriouspersonalinjuryordeathcouldoccur.
DANGER
Nevertrytooperateorworkonthisvehiclewhileundertheinuenceofalcohol.Y our
reexescanbeaffectedbyevenasmallamountofalcohol.Drinkingandoperatingthis
vehiclecanleadtoanaccident,causingseriouspersonalinjuryordeath.
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX13
WARNING
DONOTattempttorepairorservicethisvehiclewithouthavingsufcienttraining,
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.
•Neverputmaintenanceuidsintoglasscontainerssinceglasscontainerscanbreak.
•Reportallproblemsinatimelymannerbeforetheythreatenthesafetyofoperating
thevehicle.
•DONOTworkontheenginewhileitisrunning.
•Makesureprotectivelocksandcoversareintheirproperplace.
•DONOTusehighamperageelectronicstartingdevicesforjump-startingtheengine.
Relyonconventionalbatterychargingforchargingthebatteriesorjump-startwiththe
helpofastartbattery.
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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.Escapinguidunder
highpressure,evenapin-holesizedleak,canpenetratebodytissue,causingseriousinjury
ordeath.Ifuidisinjectedintoyourskin,immediatetreatmentmustbeadministeredby
adoctorfamiliarwiththistypeofinjury.
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX15
InjuryPrevention
BurnPrevention
EngineParts
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengineand/or
uidcancauseseriousburns.
WARNING
DONOTraisetheenginehoodifyouseeorhearsteamorcoolantescapingfromthe
enginecompartment.Waituntilsteamorcoolantcannotbeseenorheardanylonger
beforeraisingthehood.
DONOTremovethecoolantllcapifthecoolantinthesurgetankisboiling.Also,
donotremovethecapwhiletheengineandradiatorarestillhot.Scaldinguidand
steammaybeblownoutunderpressureifthecapistakenofftoosoon,whichcancause
personalinjuryanddamagetoenginecomponents.
W0001525
DONOTtouchanypartoftheenginewhileitishot.Allowtheenginetocoolbeforeany
repairormaintenanceisperformedontheengine.
Relieveallpressureinair,oil,fuelorcoolingsystemsbeforeanylines,ttingsorrelated
itemsaredisconnectedorremoved.
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16Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX
Coolant
WARNING
Coolantmaybecombustible.Coolantleakedorspilledontohotsurfacesorelectrical
componentscancauseare.Cleanupcoolantspillsimmediately.
W0001527
Topreventpersonalinjury ,donotclimbupontheenginetoremovethellercap.Usea
suitable,properlypositionedladdertoreachthecap.Atnormaloperatingtemperature,
theenginecoolantisveryhotandunderpressure.Ifpressureisrelievedrapidlyinahot
coolingsystem,thehotcoolantcanturnintosteam.Anycontactwithhotcoolantorsteam
cancausesevereburns.Theradiatorandallheatingsystemandradiatorlinesandhoses
containhotcoolant.
Verifycoolantlevelonlybythemarkingsontheexpansiontank.Openthellercaponly
aftertheengineisstoppedandcooleddown.Removethellercapslowlytorelievepressure.
Oils
WARNING
Hotengine.Keepyourselfclearofallhotenginepartsand/oruids.Ahotengineand/or
uidcancauseseriousburns.
Hotoilcancausesevereburns.DONOTallowhotoiltocontacttheskin.Whenchanging
oil,wearprotectivegloves.
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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.
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18Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX
FireorExplosionPrevention
DANGER
Thedieselenginewilloperateonanyfuelwhichentersthecylinder,whetheritisfrom
theinjectorsorfromtheairintakesystem.Therefore,ifanysolventisusedtoushout
theaircleanerelement,theenginemayoverspeedduringstart-up.Enginedamageand
severeinjuryand/ordeathfromburnsorexplosioncanoccur.
DANGER
Excessiveheatmaycausethepressurizedcomponentsoftheairconditionedsystem
toexplode.SomemixturesofR134arefrigerantcanbecomecombustibleatelevated
pressures.Neverweld,solder,steamcleanoruseagastorchnearanypartoftheair
conditioningsystem.Severeinjuryordeathmayoccurfromanexplosion.
W0001526
DANGER
DONOTserviceanypartofthefuelsystemwhilesmokingorinthepresenceofames,
sparksorhotsurfaces.Failuretofollowtheseprecautionscanresultinre,whichcan
causeseriousinjuryordeath.
WARNING
DONOTstorefuelcontainersinthevehicle.Theymayleak,explodeandcauseorfeeda
re.Emptyorfull,theypresentahazardthatmayleadtoburnsintheeventofare.
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Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX19
W0001527
Theengineshouldnotbeoperatedinanareawherecombustiblegasesaresuspectedto
beintheair.Thesecouldbedrawnintotheenginethroughtheengineairintakesystem
andcouldcausetheenginetooverspeedwithpossibleseriousdamagetotheengineand
bodilyinjuryorpropertydamage.
Makeprovisionsforshuttingofftheengineintakeairorfuelsupplytostoptheengineif
thereisanoverspeedonstart-upafterperformingrepairormaintenanceonit.
ContactyournearestMACKTruckdealerforanynecessaryairconditioningtestingor
repairs.
Allfuels,mostlubricantsandsomecoolantmixturesareammable.Dieselfuelis
ammable.Gasolineisammable.Themixtureofdieselandgasolinefumesisextremely
explosive.DONOTsmokewhilerefuelingorwheninarefuelingarea.
Keepallfuelsandlubricantsstoredinproperlymarkedcontainersandawayfromall
unauthorizedpersonnel.Storeoilyragsorotherammablematerialinaprotective
container,inasafeplace.
Removeallammablematerialsuchasfuel,oilandothersubstancesbeforetheyaccumulate
ontheengine.
DONOTexposetheenginetoames,drivingoverburningground.
DONOTweldoramecutonoraroundpipesortubesthatcontainammableuids.
Exhaustheatshieldsmaybeinstalledtoprotectoilorfuelcarryinglinesandpipesfromhot
exhaustparts.Toprotectfrompipeorsealfailure,installheatshieldscorrectly.
Provideadequateandproperwasteoildisposal.Alwaysdisposeofwasteliquidsaccording
toFederalandlocalregulations.Oilandfuelltersshouldbeproperlyinstalledandhousing
coverstightenedtothepropertorquewhenbeingchanged.
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20Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX
StartingAids
DANGER
DONOTuseetherorothercombustiblestartingaidsonanyengineequippedwitha
preheater.Iftheengineisequippedwithapreheater,introductionofetherorsimilar
startingaidscouldcauseareorexplosionresultinginseverepropertydamage,serious
personalinjuryordeath.
DONOTuseetherorothercombustiblestartingaidsonenginesthathaveaheater
elementorotherheatingdevicesinstalledintheintakemanifoldforheatingtheintake
airduringcold-starts.
W0001484
FireExtinguisher
Anytimeworkisbeingdonetothefuelsystemoranyotherareawhereammablesubstances
arebeingused,haveareextinguisheravailableandknowhowtouseit.Inspectandhaveit
servicedasrecommendedonitsinstructionlabel.
https://www.truck-manuals.net/
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.
https://www.truck-manuals.net/
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
debriscanyoffobjectsthatarestruck.Makesurenoonecanbeinjuredbyyingdebris
beforestrikinganyobject.
W0001528
https://www.truck-manuals.net/
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.
https://www.truck-manuals.net/
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 .
https://www.truck-manuals.net/
Operator’sManualVehicleMaintenanceCMM,
CMH,CLX,CSM,andCXX25
ElectricSystemDamagePrevention
ElectricandElectronicSystems
WARNING
Alwaysweareyeprotectionwhenworkingaroundbatteriestopreventtheriskofinjury
duetocontactwithsulfuricacidoranexplosion.
W0001526
Neverdisconnectanychargingunitcircuitorbatterycircuitcablefromthebatterywhenthe
chargingunitisoperating.Asparkcancausetheammablevapormixtureofhydrogenand
oxygentoexplode.
Topreventpotentialsparksfromignitingcombustiblegasesproducedbysomebatteries,
attachthenegative(-)terminallastwhenhookingupandremovethenegativeterminalrst
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.
https://www.truck-manuals.net/
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.
https://www.truck-manuals.net/