® Mack MAINTENANCE AND LUBRICATION MAINTENANCE AND LUBRICATION MP7, MP8, and MP10 Engines © Mack Trucks, Inc. 2010 Printed in U.S.A.
Contents Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU ... 1 Foreword .............................................................................................. 1 Warning Label Information........................................................................ 1 General Information ................................................................................ 3 Information For the Owner ........................................................................
Preventive Maintenance......................................................................... 146 Service Charts..................................................................................... 150 Scheduled Services............................................................................... 150 Tire Record ........................................................................................ 154 Fuel and Oil Record..............................................................................
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 1 Foreword DO NOT Remove this manual from the vehicle. It contains important operational and safety information that is needed by all drivers and owners of this vehicle. This manual contains information concerning the safe operation of your vehicle. It is extremely important that this information is read and understood before the vehicle is operated.
2 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU The following types of labels are used throughout this manual: Note: A note defines an operating procedure, practice, condition, etc., which is essential to proper operation of the vehicle. DANGER A danger label directs the operators attention to unsafe practices which could result in serious personal injury or death. The danger label is in white type on a black background with a black border.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 3 General Information Information For the Owner If there are questions on the maintenance and performance of your vehicle, please discuss them with your MACK Truck dealer. Your authorized dealer is required to have trained mechanics, special tools and spare parts to fully service your vehicle. If necessary, your dealer will contact MACK Inc. or other manufacturers for any assistance.
4 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU instructions which will enable you to get the operating economy and performance that you expect from this quality vehicle. All information, illustrations and specifications contained in this manual are based upon the latest product information available at the time of publication. If any questions arise concerning the current status of Federal or state laws, the appropriate Federal or state agency should be contacted.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 5 Mexico The same conditions that apply in the USA apply to Mexico. Refer to the Mexican Federal Law for Emission Control which adheres to EPA regulations. No changes should be made that render any or all of the emissions control devices inoperative. Should the owner/operator wish to make any changes to the emission control devices, check with the state authority before making any such changes.
6 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Tampering with Gaseous Emission Control Systems Prohibited The Federal Clean Air Act prohibits the removal or rendering inoperative of any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with Federal Emission Regulations by: 1 Any person prior to its sale and delivery to the ultimate purchaser, or 2 Any manufacturer or distributor after its sale and delivery to the ultimate purchaser,
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 7 Noise Control System, Operator Inspection and Maintenance Requirements A Noise Control System Maintenance Log is located in this manual. This log should be used to document all Noise Control System related maintenance, whether the maintenance results from a specific noise control system inspection, or a deficiency identified during another general maintenance event.
8 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU • Removal, or rendering inoperative, of the temperature-modulated cooling fan system. • • • • Removal of the cooling fan shroud. • • • • • Removal, or rendering inoperative, of the air cleaner or air intake in-line silencer. Removal of the sound deadening material from the hood or cab tunnel. Removal, or rendering inoperative, of the engine speed governor so as to allow engine speed to exceed the manufacturers specifications.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 9 Cooling System WARNING DO NOT work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured. Maintenance Visually inspect cooling system components for damage, and/or misalignment.
10 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Maintenance Make sure the exhaust system is intact. Inspect for damage, misalignment and/or leakage. Primary system components requiring noise related inspection include exhaust manifold, turbocharger, and all exhaust system (rigid and flexible) piping. Closely check the system for exhaust leaks. Special attention should be given to all welds, seams, gaskets, support points, clamps, couplings and connections.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 11 Engine Control, EGR and Fuel Systems Acts that constitute tampering with Engine Control, EGR and Fuel Systems: Removing rendering inoperative, or modifying the engine control system such as the ECU, EGR system components, or fuel system components, in order to allow the engine to operate outside of the manufacturers specifications is not allowed and violates both warranty and legislation.
12 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Label Information Vehicle Identification Number Label All motor vehicles are required to be identified by a 17-digit Vehicle Identification Number (VIN). U.S. and Canadian regulations dictate the format of the number. The VIN gives specific information about the vehicle as manufactured by MACK, such as type of vehicle, model, type of brake system, gross vehicle weight range and model year.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 13 W0031973 VIN Label on Drivers Seat Riser
14 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Regulatory Labels In addition to, or in place of the previously mentioned labels, MACK Trucks, Inc. may affix one or more of the following labels to the cab. Heater/Defroster Omission Label A windshield defroster, as required by FMVSS 103, Windshield Defrosting and Defogging, is not required for vehicles destined for sale in the State of Hawaii, Puerto Rico, the Northern Mariana Islands, Guam, the Virgin Islands and American Samoa.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 15 Export Label In order to comply with U.S. regulations, all MACK vehicles intended for export from the United States (including export to Canada) will have an Export Label, similar to the label shown below, affixed to the inside of the windshield.
16 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Export/Special Application Label Export (excluding export to Canada) or special application vehicles supplied from the assembly plant are not necessarily designed to conform to applicable Federal and Canadian motor vehicle safety standards. On these vehicles, an Export/Special Application Label, similar to the label shown in the illustration below, is affixed to the cab.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 17 Export vehicles (other than those intended for sale in Canada) also have an Export Label, similar to the label shown below, affixed to the door area.
18 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Off-Highway Identification Label In addition to the Export/Special Application Label, vehicles designed strictly for off-highway operations will have an Off-Highway Identification Label, similar to the label shown in the illustration below, affixed to the cab.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 19 Safety Information Proper Maintenance Procedure DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral, and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. DANGER Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose.
20 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU WARNING DO NOT attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools. Failure to follow this could lead to personal injury or making your vehicle unsafe. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 21 • DO NOT attempt repairs you do not understand. If you do not have the proper tools/knowledge to perform the repairs correctly, MACK recommends contacting your nearest MACK Truck dealer for all necessary repairs.
22 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Injury Prevention Burn Prevention Engine Parts WARNING Hot engine. Keep yourself clear of all hot engine parts and/or fluids. A hot engine and/or fluid can cause serious burns. WARNING DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment. Wait until steam or coolant cannot be seen or heard any longer before raising the hood.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 23 Coolant WARNING Coolant may be combustible. Coolant leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up coolant spills immediately. W0001527 To prevent personal injury, do not climb up on the engine to remove the filler cap. Use a suitable, properly positioned ladder to reach the cap. At normal operating temperature, the engine coolant is very hot and under pressure.
24 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Batteries WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Battery electrolyte contains acid and can cause injury.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 25 Fire or Explosion Prevention DANGER The diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage and severe injury and/or death from burns or explosion can occur.
26 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU W0001527 The engine should not be operated in an area where combustible gases are suspected to be in the air. These could be drawn into the engine through the engine air intake system and could cause the engine to over speed with possible serious damage to the engine and bodily injury or property damage.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 27 Starting Aids DANGER DO NOT use ether or other combustible starting aids on any engine equipped with a preheater. If the engine is equipped with a preheater, introduction of ether or similar starting aids could cause a fire or explosion resulting in severe property damage, serious personal injury or death.
28 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Respiratory Hazard Prevention DANGER Exhaust gases contain carbon monoxide. Always run the engine outdoors or use a properly vented exhaust hose. Prolonged or excessive exposure may cause serious illness or death. WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 29 Crushing or Cutting Prevention DANGER Before working on a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. WARNING DO NOT work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning.
30 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Climbing Up and Down DANGER Always have three limbs (one foot and two hands or two feet and one hand) in contact with the vehicle at all times when entering or exiting the cab or the area behind the cab. Failure to follow this warning can result in serious personal injury or death. DO NOT climb up on or jump off from the engine or stand on components that cannot support your weight.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 31 Engine Starting DO NOT start the engine or move any of the controls or disengage the parking brake if the warning tag DO NOT OPERATE is attached to the ignition key or located on the dash. Check with the person who attached the tag before starting. Make sure no one is working on or close to the engine or components driven by the engine before starting it. Always make an inspection of the engine before and after starting.
32 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Electric System Damage Prevention Electric and Electronic Systems WARNING Always wear eye protection when working around batteries to prevent the risk of injury due to contact with sulfuric acid or an explosion. W0001526 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 33 Electronic Engine Control System DANGER The engine uses high voltage to the electronic unit injectors. DO NOT come in contact with the unit injector terminals while the engine is running. An electric shock can cause an involuntary muscle spasm and cause loss of balance and falls leading to severe personal injury or death.
34 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Reporting Safety Defects USA The National Highway Traffic Safety Administration (NHTSA) and MACK Inc. should be informed immediately if you believe that the vehicle has a defect that could cause a vehicle accident, injury or death. Contact NHTSA by calling the Auto Safety Hotline at 1 (888) 327-4236, by writing to NHTSA, U.S. Department of Transportation, Washington, DC 20590, by TTY at 1 (800) 424-9153, or visit their website at www.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 35 General Engine Information Engine Overview, MP7 and MP8 Left Side View W2006034 MP8 Engine Shown, MP7 Engine Similar 1. Breather Tube 9. Fuel Filter 2. Intake Manifold 10. Hand-Priming Pump 3. Air Compressor 11. Crankcase Ventilator 4. Power Steering Pump 12. Alternator 5. Fuel Pump 13. AC Compressor 6. Engine Control Module (ECM) 14. Alternator/AC Compressor Belt 7. Fuel Filter 15. Fan/Coolant Pump Belt 8.
36 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Engine Overview, MP7 and MP8 Right Side View W2006035 MP8 Engine Shown, MP7 Engine Similar 17. Exhaust Manifold 24. Venturi Pipe 18. Valve Cover 25. Oil Filters 19. Intake Air Heater (IAH) optional 26. Oil Pan 20. Thermostat 27. EGR Cooler 21. Belt Tensioner 28. Turbocharger 22. Coolant Pump 29. Starter Motor 23. Coolant Filter 30.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 37 Engine Overview, MP10 Left Side View W2006037 1. Breather Tube 9. Fuel/Water Separator 2. Intake Manifold 10. Fuel Filter 3. Air Compressor 11. Hand-Priming Pump 4. Power Steering Pump 12. Alternator 5. Fuel Pump 13. AC Compressor 6. Crankcase Ventilator 14. Alternator/AC Compressor Belt 7. Engine Control Module (ECM) 15. Fan/Coolant Pump Belt 8. Fuel Filter 16. Venturi Pipe 17.
38 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Engine Overview, MP10 Right Side View W2006036 18. Exhaust Manifold 24. Coolant Filter 19. Valve Cover 25. Oil Filters 20. Intake Air Heater (IAH) 26. EGR Cooler 21. Thermostat 27. Oil Pan 22. Belt Tensioner 28. Starter Motor 23. Coolant Pump 29. Turbocharger 30.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 39 Electrical System Batteries WARNING CAUTION Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Disconnecting battery cables when vehicle is equipped with power door locks will result in automatic locking of doors.
40 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Be sure that the batteries used in a particular vehicle are rated for the specified Cold Cranking Amperes (CCAs) necessary to ensure reliable cold weather starts. This is important, since even well-maintained batteries chilled to 18 °C (0 °F) may temporarily be capable of providing only 40% of their rated capacity at 27 °C (80 °F). Keep the terminals clean to prevent formation of power-robbing corrosion.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 41 Battery Warmer A battery warmer can be added to raise the temperature of the battery core and facilitate quick starting in cold weather. Battery Condition The first procedure when testing a battery is to check for external damage such as a cracked case, loose or corroded terminals, or signs of excessive gassing or overcharging. A battery must be fully charged before a load test is performed.
42 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU • Green dot visible Any green appearance should be interpreted as a green dot and means that the battery is at or above a 65% state of charge and is ready for use or testing. This does not automatically mean that the battery is in good condition. • Dark green dot not visible (black dot) This indicates that the battery is below a 65% state of charge and must be charged before testing.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 43 Completely Discharged Batteries Extremely cold or completely discharged batteries may not initially show a charge since the electrolyte is nearly pure water and, therefore, a poor conductor. As the acid level in the electrolyte increases during charging, the charging current will also increase. Use the following procedure when charging a completely discharged battery: 1 Measure the voltage at the battery terminals.
44 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Load Test A battery must be fully charged before performing a load test. To load-test a battery that is fully charged, proceed as follows: 1 Connect a load tester and voltmeter across the battery terminals. 2 Apply a load so that a figure of 300 amps is obtained for 15 seconds to remove the battery surface charge. 3 Wait 60 seconds to let the battery recover and then apply the proper test load to the battery to determine its condition.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 45 Wiring Harness/Cable and Connector Protection To help protect your vehicle’s external high amperage electrical cables and connections from corrosion due to the effects of newer salts (calcium chloride and magnesium chloride) on the roadways, MACK is offering a corrosion inhibitor part 20916273 for purchase through the PDC.
46 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Lighting WARNING Using incorrect bulbs or lamps may result in failures that could lead to a fire or a vehicle accident caused by improper lighting. Check all lights on the vehicle daily for proper function. Replace burned out inserts and bulbs. Replace any broken or cracked side or rear reflectors. Headlights should be checked for aim at least once per year.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 47 Precautions When Installing Electrical Equipment Connecting electrically powered or electrically controlled equipment to a vehicle may cause interference with other vehicle electrical or electronic equipment (such as ABS systems, Rollover Stability Systems, etc.). The amount of interference depends upon the operating frequency of any new signals and the degree to which transient signals are coupled to the vehicle system.
48 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU MACK Road Stability Advantage The MACK Road Stability Advantage (RSA) is an available option on certain MACK highway tractors and straight trucks. The RSA system, which is based on the Bendix ABS-6 Advanced with ESP (Electronic Stability Program) System, aids the operator in maintaining control of the vehicle during jackknife or rollover events by applying select brakes and reducing engine power as required by the specific situation.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 49 The location of the yaw rate/lateral acceleration sensor must not be altered. Aftermarket steering wheels must not be used. Only OEM-supplied replacement steering wheels should be used. During any procedure that involves removal and reinstallation or replacement of the OEM steering wheel, care must be used not to crush or damage the steering angle sensor which is mounted on the steering column.
50 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Engine Storage Engine Storage If the vehicle must be parked for a period (more than 30 days), protect it as follows: 1 Drain the engine oil. 2 Fill up to the proper level with oil of the recommended quality and viscosity. 3 Fill up the fuel tanks with the recommended grade of fuel. 4 Run the engine for two minutes around 1000 rpm. Shut the engine down. DO NOT drain the oil after this run.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 51 Maintenance and Service Maintenance Hazards DANGER Before working on or inspecting a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. DANGER DO NOT attempt to repair or service this vehicle without having sufficient training, correct service literature and the proper tools.
52 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Component Operation Km (Miles)/Maximum Months/Hours Coolant Filter (MP7, MP8 and MP10) Change 80 000 (50,000) or 6 months, whichever comes first Coolant Filter, Extended Life (ELC) (MP7, MP8 and MP10) Change 240 000 (150,000) or 12 months, whichever comes first (MP7, MP8 and MP10) Coolant Conditioner Euro 4 Change Traditional coolants requiring Supplemental Coolant Additive (SCA) 80 000 (50,000) or 6 months Valves/Injectors (
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 53 Component Operation Km (Miles)/Maximum Months/Hours Diesel Exhaust Fluid (DEF) Pump Filter (MP7, MP8 and MP10) Change First Change; 161 000 (100,000) or 3200 hours, whichever comes first 241 000 (150,000) or 4800 hours or three (3) years, whichever comes first Diesel Exhaust Fluid (DEF) Tank Filler Neck Filter Cleaning (MP7, MP8 and MP10) Clean 280 000 (175,000) or 12 months, whichever comes first *Under certain conditions (for
54 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Cooling System General Coolant Information DANGER Coolant is toxic; risk of poisoning. DO NOT drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death. WARNING DO NOT raise the engine hood if you see or hear steam or coolant escaping from the engine compartment.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 55 The cooling system plays an important role in overall engine performance by keeping the engine within the normal operating temperature range hot enough for efficient combustion, and cool enough to prevent engine damage caused by overheating. Good preventive maintenance practices, along with monitoring cooling system performance, go a long way in preventing engine damage that could result from cooling system problems.
56 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU MACK low cab forward models (MRU, LEU) utilize a surge tank which is located on the left-hand side of the chassis, mounted on a stanchion to the rear of the cab. This surge tank utilizes a standard radiator pressure cap. Check the coolant level regularly, making sure the coolant is visible in the sight glass located on the side of the tank.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 57 Note: Always dispose of coolant according to Federal or local regulations. Take all used coolant to a recycling or waste collection center. Coolant mixture consisting of an antifreeze solution in water should be used year-round to provide freeze and boil-over protection as well as providing a stable environment for seals and hoses. Note: DO NOT use antifreeze formulated for automobile gasoline engines.
58 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Chassis Model Engine Model Coolant Capacity in Liters (Quarts) CXU MP7* MP8* 52 (55) 54 (57) CHU MP7* MP8* 52 (55) 54 (57) TD7 MP10* 53 (56) GU7 MP7* MP8* 52 (55) 54 (57) GU8 MP7* MP8* 52 (55) 54 (57) MRU MP7 Manual transmission without auxiliary cooling package MP7 Manual transmission with auxiliary cooling package MP7 Automatic transmission without auxiliary cooling package MP7 Automatic transmission with auxiliary c
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 59 Use the following antifreeze protection charts to determine the percentage of antifreeze needed to achieve specific protection levels for various coolant systems.
60 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Inspection of the whole cooling system is important. Check for swollen or deteriorated heater and radiator hoses, loose hose clamps and connections, and radiator leaks. DANGER DO NOT work near the fan with the engine running. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured. Before turning on the ignition, be sure that no one is near the fan.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 61 Regular Coolant Change Interval Coolant SCA level must be tested at least twice per year or whenever coolant loss occurs. For maximum coolant system efficiency, test the system at every engine oil change interval, every 1,000 hours or every 6 months (whichever comes first). For proper SCA levels, consult Service Manual. Regular Coolant Filter Change Intervals WARNING Hot engine. Keep clear of all hot engine parts and fluids.
62 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Extended Life Coolant Change Interval CAUTION Extended life coolant will test as out of additives (SCA), but SCA should not be added. Shortened engine life may be the result of adding SCA. Note: DO NOT add supplement coolant additives (SCA) to extended life coolant.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 63 Fuel System Fuel Safety Reminders DANGER A diesel engine will operate on any fuel which enters the cylinder, whether it is from the injectors or from the air intake system. Therefore, if any solvent is used to flush out the air cleaner element, the engine may over speed during start-up. Engine damage, severe personal injury or death from burns or explosion may occur. DANGER DO NOT mix gasoline or alcohol with diesel oil fuel.
64 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Diesel Fuel Specification Quality CAUTION Diesel engines for 2007 and later model year vehicles are designed to operate only with Ultra Low Sulfur Diesel (ULSD) fuel. Use of fuel other than ULSD will reduce the efficiency and durability of the engine, permanently damage the advanced emission control systems, reduce fuel economy and possibly prevent the engine from running at all.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 65 Cetane Number Direct injected diesel engines require a minimum cetane number of 43 under normal starting conditions. Fuel with a higher cetane value may be required for high-altitude or cold-weather operation. Filtration Fuel should be clean and free of contamination. Clean fuels should have no more than 0.05% of sediment and water. Fuel Additives Fuel additives are generally not recommended or needed for fuels listed earlier.
66 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Some fuel additives can be used to provide temporary relief, but they do not replace good fuel handling practices. These products can be used: • Isopropyl Alcohol Use 1/2 liter per 450 liters (1 pint per 125 gallons) of fuel for winter freeze-up protection. • Biocide For treatment of microbe growth or black slime. Follow manufacturers instruction for treatment.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 67 Bio Diesel The only Bio Diesel Fuel approved by MACK Inc. for use in EPA 2010 MACK Engines is Soy Methyl Ester (SME or SOME) in blends up to B5 Concentration (5% blend). Note: Although higher concentrations are available, concentration up to B5 (maximum) are the only blends currently approved by MACK Inc. Fuel Storage If fuel is stored on site: • • Keep storage tank covered to prevent water entry.
68 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Fuel Filters A primary fuel filter can be located on the engine or remote mounted on the frame rail. This filter consists of a filter cartridge, a water separation bowl and may have a fuel heater built in. The secondary fuel filter is located on the left hand side, below the engine electronic control unit (EECU). The filter is a spin-on filter. MACK MP engines utilize a spin-on primary and secondary fuel filters.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 69 Primary Fuel Filter Replacement Procedures MACK MP Engines At each specified oil and filter change interval, change the primary fuel filter as follows: W0054023 MACK MP Primary Fuel Filter 1. Primary Filter 2. Water Separator Bowl 3. Water-in-Fuel Sensor Harness 4.
70 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 1 Thoroughly wash the area around the fuel filter and mounting adapter mating area with a suitable solvent and blow dry with compressed air. 2 Disconnect the water-in-fuel sensor harness connector from the plastic water separator bowl. 3 Using tool J 24783, remove the primary filter. 4 While holding the filter above a suitable container, open the drain valve on the plastic water separator bowl and allow the fuel in the bowl to drain.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 71 Secondary Fuel Filter Replacement Procedures At each specified oil and filter change interval, change the secondary fuel filter as follows: Note: Because of ice buildup in the fuel system or fuel waxing which can clog fuel filters, it may be necessary to reduce the time or mileage interval between fuel filter changes during extremely cold weather.
72 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Priming the Fuel System MACK MP Engines On MACK MP engines, the priming pump is located on the primary fuel filter mounting adapter. Prime the fuel system as follows: DANGER Before working on or inspecting a vehicle, apply the parking brakes, place the transmission in neutral and block the wheels to prevent the vehicle from moving. Failure to do so can result in unexpected vehicle movement and cause severe personal injury or death.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 73 1 Unlock the primer pump handle by pushing the handle downward and then turning it counterclockwise. W0054026 Unlocking Fuel System Primer Pump Handle 2 Operate the pump handle until pumping effort increases. W0054027 Pumping Hand Primer Pump Note: With a fuel system that is completely empty, 200 or more strokes of the pump may be necessary to properly prime the system.
74 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Fuel/Water Separator MACK MP Engines The primary fuel filter on MACK MP engines includes a plastic water separator bowl with an integral water-in-fuel sensor and a drain assembly. A warning lamp on the instrument panel illuminates when water is detected in the fuel. When the lamp illuminates, drain the water from the separator by opening the drain valve and allowing the water to drain from the bowl into a suitable container.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 75 Engine Oil General Keep the engine oil at the proper level and change it at the recommended intervals. Always replace the oil filters at the same time as when the oil is changed. Oil Quality MACK Inc. recognizes engine oils that meet or exceed the standards given by American Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API symbol should be used.
76 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Oil Filters There are three filters on the engine, one of which is a bypass filter. This should be changed at the same time as the full-flow filter(s). CAUTION MACK branded oil filters are designed to provide the proper level of filtration and protection for MACK engines. Filters that do not meet the same stringent requirements may void engine warranty. W0054029 Spin-On Oil Filters 1.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 77 Synthetic Lubrication Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum based oils for engines. These oils may be used in MACK engines, provided they meet the quality levels specified on the previous pages, that is: both VDS-4 and EO-O Premium Plus. The use of synthetic oils does not permit the extension of the recommended oil change intervals. It is the contamination rate, i.e.
78 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Oil Additives CAUTION Extra oil additives must never be added to any engine oil used. Additives such as break-in oils, top oils, graphitizers, and friction reducing liquids are not necessary and may even harm the engine. Using oils to the quality standards recommended in this manual makes the use of extra oil additives unnecessary, as these oils already contain a balanced treatment of additives.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 79 Oil Change WARNING A hot engine or engine oil can be dangerous. Serious burns can result from contact with a hot engine or oil. Take precautions when draining the oil. Wear gloves or let the engine cool down before draining. WARNING When draining the oil, use the proper tools and keep away as far as possible. Raise the elbow so the forearm is parallel to the ground to prevent oil running down the arm, causing burns.
80 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Oil Filters Change WARNING Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. CAUTION MACK-branded oil filters are designed to provide the proper level of filtration and protection for MACK engines. Filters that do not meet the same stringent requirements may cause unsatisfactory results. 1 Coat the filter gasket with oil.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 81 Checking Oil Level CAUTION DO NOT let the oil level fall below the marking on the dipstick. DO NOT overfill so the level is above the upper marking on the dipstick. This could lead to excessive oil temperature and/or poor crankcase breather performance. Ensure that the vehicle is parked on level ground before checking the oil level. Wait five minutes after shutting off the engine, then proceed with checking oil.
82 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Engine Air Filter The air cleaner prevents dust, dirt and other harmful contaminants from entering the engine through the air intake system. Maximum engine protection can only be achieved through regularly scheduled maintenance practices that include periodic air intake system inspections and air filter element changes.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 83 Damage to the air filter element, such as holes in the filter medium, will give an inaccurate restriction reading. Therefore, even if maximum restriction is not indicated, the air filter element should be changed yearly or at 160 000 Km (100,000 mile) intervals, whichever comes first.
84 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Note: DO NOT attempt to clean the air filter element with compressed air, as this could damage the filter medium and possibly result in severe engine damage.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 85 Exhaust After-Treatment System CHU, CXU, GU and TD Standard System View W2029933 1. Selective Catalytic Reduction (SCR) Catalyst 2. Aftertreatment DEF Dosing Unit 3. Aftertreatment Diesel Particulate Filter (DPF) 4.
86 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU LEU and MRU Standard System View W2031562 1. Selective Catalytic Reduction (SCR) Catalyst 2. Aftertreatment DEF Dosing Unit 3. Aftertreatment Diesel Particulate Filter (DPF) 4.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 87 DANGER The SCR/DPF shield should not be removed while the vehicle is in use. Also, only remove the shield, once the vehicle is out of use and the SCR/DPF is sufficiently cooled. Failure to follow these instructions can result in fire, which can cause component damage, personal injury or death. CAUTION The Diesel particulate filters and their components, can not be moved or altered from the OEM installation in any fashion.
88 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU New stringent standards for exhaust emission control begin with the 2010 model year. The Diesel Particulate Filter (DPF) system has been developed to act in combination with Ultra Low Sulphur Diesel (ULSD) fuel to reduce particulate emissions to meet the requirement. The Exhaust After-Treatment System (EATS) includes all the engine and exhaust emissions control components that are required to meet the stringent 2010 standard.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 89 Selective Catalytic Reduction (SCR) Selective Catalytic Reduction (SCR) is an emissions-reduction technology with the ability to deliver near-zero emissions of nitrogen oxides (NOx), a smog-causing pollutant and greenhouse gas. SCR’s performance has been proved in millions of miles of real-world truck operations in other countries, as well as in long-term field tests in the U.S.
90 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU CAUTION Do not put diesel fuel in the Aftertreatment DEF tank. Diesel fuel, if sprayed into the hot exhaust along with the DEF, could ignite explosively causing a fire resulting in personal injury or damage to the exhaust system. There are two different configurations for the SCR catalysts, they are vertical and horizontal.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 91 Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) is a reactant that’s key to the SCR process. It’s a nontoxic, aqueous solution of urea and water. Urea is a compound of nitrogen that turns to ammonia when heated. It is used in a variety of industries, perhaps most commonly as a fertilizer in agriculture. The fluid is not flammable, nor is it dangerous when handled normally.
92 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Diesel Exhaust Fluid (DEF) Handling When handling DEF solution, it is important that electrical connectors to be connected or well encapsulated. Otherwise there is a risk that the DEF will cause oxidation that cannot be removed. Water or compressed air do not help, since DEF quickly oxidizes metal.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 93 Diesel Exhaust Fluid (DEF) Consumption DEF consumption is related to fuel consumption. A highway truck may travel 225-300 miles or more on one gallon of DEF. A gauge much like a fuel gauge will indicate the level of DEF in the tank. A DEF low-level warning will activate when DEF is low. If a driver runs out of DEF completely, vehicle power will be reduced to derate mode. When the DEF tank is refilled, the engine will resume normal power.
94 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Drive Belt Replacement Intervals If belts squeak or squeal, clean with hydraulic brake fluid or an approved cleaning fluid. Replace belts that are severely worn or frayed. Rib Cracking An in-service poly V-belt will go through several phases of cracking during its life. After an extended time in service, minor rib cracks may appear, usually one or two cracks per inch. This cracking is normal.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 95 Belts should not be replaced unless the ribs exhibit severe multiple cracking as shown below. Multiple cracking will lead to rib chunking.
96 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Rib Sidewall Glazing When the belt ribs appear to have a shiny surface that is hard and brittle, it is usually an indication of belt slippage. This is attributed to inadequate tension and/or extreme temperature. Both these conditions will lead to severe cracking and belt failure, often with little advance warning. If this occurs, locate the cause and correct before installing a new belt.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 97 Foreign Objects Any object protruding in the path of the belt drive and contacting the belt will cause damage and eventual failure. Locate the object before installing a new belt. (See ) W0054011 Damage from Object Protruding in Belt Path Noise, Vibration and Harshness (NVH) Poly V-belt drive systems were designed to prevent Noise, Vibration and Harshness (NVH) problems.
98 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Possible Causes Insufficient belt tension may create a high-pitched howl (squeal) or rasping sound during engine acceleration or deceleration. Misalignment may cause a chirping noise, especially at, or near, idle speed. Rigid bracketing of accessories is a must for reasonably vibration-free belt spans. Some span vibration is to be expected during the range of engine speed and accessory loading.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 99 Drive Belt Installation To install a poly V-belt, swing the automatic tensioner to the full sprung position (fully toward the install stop), then place the belt over the pulleys. Slowly return the automatic tensioner back to its original position. Do not allow the tensioner to snap against the stops. For proper belt routing, refer to the following belt routing diagrams.
100 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU W0054017 Drive Belt Routing MP7 and MP8 Engines 1. 2. 3. 4. 5. 6. Crankshaft Pulley Automatic Tensioner Idler Pulley Water Pump Main Drive Belt Fan Drive 7. Idler Pulley (when applicable) 8. Accessory Drive Belt 9. Automatic Tensioner 10. Alternator 11. Air Conditioner Compressor (if equipped) Drive Belt Routing MACK MP7 and MP8 engines, all models.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 101 W0054041 Drive Belt Routing MP10 Engine 1. 2. 3. 4. 5. Crankshaft Pulley Idler Pulley Automatic Tensioner Water Pump Main Drive Belt 6. Fan Drive 7. Automatic Tensioner 8. Alternator 9. Accessory Drive Belt 10.
102 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Automatic Belt Tensioner Maintenance The automatic belt tensioner is designed to maintain proper belt tension throughout the life of the tensioner. The belt tensioner cannot be adjusted or repaired. At each D inspection interval or once per year, whichever occurs first, check the following: • With the belt on the drive, check the following: Check to see if the tensioner is resting against the install stop or the free-arm stop.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 103 W0054014 Main Drive Belt Tensioner Belt Tracking Witness Mark 1. Acceptable (Witness Mark Approximately Same Width as Belt) 2. Not Acceptable (Witness Mark Tracking Off Edge of Pulley) • Remove the belt by using a 3/8 inch breaker bar to pull the tensioner back to the install stop. Slowly return the tensioner to the free-arm stop.
104 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU W0054015 Checking for Contact Between Arm and Spring Case
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 105 Check for metal-to-metal contact between the arm and the end cap. Replace if contact is seen. W0054016 Checking for Contact Between Arm and End Cap Check for cracks in the tensioner body or for broken stops on the spring case. If either is seen, replace the tensioner. Reinstall the belt making sure that the belt is properly seated in the grooves of ALL pulleys.
106 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Turbocharger and Charge Air Cooler DANGER If oil leaks internally from the turbocharger to the engine intake, the oil acts as a fuel. Watch for excessive exhaust smoke. DO NOT operate engine until problem is corrected. There is no way to regulate the engine speed if it runs on oil and it may over speed. Loss of control of vehicle may lead to an accident causing severe personal injury or death.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 107 Cleaning Charge Air Cooler and Radiator Package WARNING Always wear eye protection when cleaning radiator, charge-air cooler and condenser. Failure to follow this recommendation may result in eye injury. CAUTION When using a pressure washer to clean the vehicle, do not direct the spray at electrical components in the engine compartment such as the alternator, starter and compressors.
108 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU The simplest method to clean the package is to use air pressure or a water stream. This should be done from the back of the core. Air pressure should not exceed 30 psi (200 kPa) for radiator and charge air cooler cores. The use of a fin comb is also a good tool to loosen bugs and dirt from the fins. If dirt cannot be cleaned off with this procedure, consult your MACK Truck dealer.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 109 Preventive Maintenance Air Suspensions Note: The following maintenance items should be performed on all air suspensions (including MACK AL, AL II, AL-401LH, MAXAIR 40/40A, MAXLITE 2040, MAXLITE 2040 EZ and Hendrickson PRIMAAX) at each B, C and D inspection interval, or every 40 234 Km (25,000 miles) or six months, whichever comes first.
110 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Steering and Brakes Maintenance Steering System Excessive play in the steering system is checked by turning the steering wheel while the engine is stopped. With the front wheels pointing straight ahead, turn the steering wheel until the front wheel starts moving. Then, turn the steering wheel the other way until the front wheel moves. Play should not be more than 25 mm (1 in) at the rim of the steering wheel.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 111 Brake System DANGER DO NOT use replacement parts anywhere in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicles brake system could cause a malfunction, leading to loss of control of the vehicle resulting in severe personal injury or death.
112 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 7 Have an assistant check for proper results by observing the movement of the slack adjusters as indicated below: TRUCK: • The brakes on the rear drive axle(s) should always apply as indicated by movement of the slack adjuster. • The low-air warning buzzer and warning lamp should activate for at least two of the tests.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 113 Air Dryers Effective mid-September 2008, all MACK chassis are equipped with air dryers which utilize an oil coalescing desiccant cartridge which removes atomized oil and other particulate matter from the air system. The oil coalescing desiccant cartridge must be changed yearly. Refer to the specific air dryer service literature for detailed information.
114 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Tires, Wheels and Hub Maintenance Wheel Safety Information DANGER DO NOT attempt to repair wheels or tires unless you are trained and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment. Failure to follow this may lead to serious personal injury or death. DANGER Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 115 DANGER DO NOT install tires with a load rating that is less than stated on the Certification Label in the door frame. The tire could be unintentionally overloaded, leading to an accident, causing serious personal injury or death. DANGER DO NOT use mismatched tires on the same axle. Always use the same type (radial or bias ply) or size.
116 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Wheel Nut Tightening DANGER Failure to properly torque-tighten the wheel nuts can result in the breakage of wheel studs and the subsequent loss of wheels. This can lead to loss of vehicle control and serious personal injury or death. After the initial tightening, retightening must be made within the first 800 Km (500 miles). After the first retightening, only normal inspection of nut tightness is needed.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 117 Tire Inflation and Wear WARNING DO NOT operate the vehicle with under-inflated tires. Always keep your tires inflated to the manufacturers recommendation. Increased flexing in the tire sidewall produces heat. The heat can build to the point of blowing the tire out causing an accident. WARNING Check tire pressure when the tire is cool. Never bleed the air from hot tires. Increased tire pressure measured in a hot tire is normal.
118 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Tire Hints Hints on How to Avoid Unnecessary Tire Wear • • • • • • • • Maintain correct tire pressure Check the tire pressure when the tires are cold Check that valve caps are not missing Keep the wheels balanced Tire wear increases with speed Overloading not only decreases tire life but also creates a hazard Incorrect front end alignment causes increased wear Unnecessary tire rotation may cause excessive wear Note: A cold weather in
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 119 T1006457 Incorrect Camber Incorrect camber gives abnormal wear on one half of the tire.
120 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Incorrect Toe and Axle Alignment A. Incorrect toe-in B. Incorrect toe-out C. Out-of-line axle D. Steering arm defect T1006459 Dual Wheel Mounting A. Excessive road camber, different types of tire, different circumference or off-center loading give faster wear on one tire. B.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 121 T1006718 Incorrect Caster and Imbalance A. Caster angle B. Imbalance Also rapidly wears the mechanical parts of steering linkage, kingpin and wheel bearing.
122 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Cuts in the Tire Tread A. Cuts B. Flaking cuts C. Rubber flaking Cuts are due to poor roads, air pressure too high or incorrect tire type. T1006720 Cuts in the Tire Tread A. Cuts B. Flaking cuts C. Rubber flaking Cuts are due to poor roads, air pressure too high or incorrect tire type.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 123 Spot Wear Sudden braking, locking brakes or out-of-round brake drums give spot wear.
124 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Feathered Edges Normal occurrence on non-driving wheels on good roads and high mileage. T1006722 Cupping Cupping is a normal occurrence that depends on the tread pattern; the higher the load, the greater the wear.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 125 Front Wheel Hubs DANGER Failure to keep wheel bearings properly adjusted and lubricated may result in accelerated tire wear, poor handling and, in extreme cases, wheel separation from the hub or from the spindle resulting in loss of vehicle control and serious personal injury or death. The front wheel hubs can be filled with one of several types of oil. Motor oil should be SAE 30 or 15W40.
126 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Unitized Front Hubs The non-tapered axle hubs are sealed with lubricant inside the hub and do not require lubrication.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 127 W1000212 Tapered Axle End
128 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Chassis Maintenance Springs Note: This work is best performed by a MACK Truck dealer or other service outlet having the proper equipment. The spring package is fastened to the axle beam with U-bolts. It is important that the U-bolt nuts are properly tightened. The nuts may loosen up with time. Severe roads and service will loosen them faster.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 129 Spring Bushings When lubricating the springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces. If the spring bushings are greased without taking the load off, high wear and lower lifetime will occur because grease is not able to reach the contact surfaces.
130 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Cab Maintenance Cab Air Filter To provide comfortable and clean fresh air in the cab, the heating and air conditioning system is designed with a replaceable filter. Under normal operating conditions the filter should be replaced every 6 months to ensure the efficiency of the heating and air conditioning system. Failure to replace the filter may cause damage to heater/AC components. Dusty conditions may require more frequent replacement.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 131 Doors The door lock mechanism should be greased annually using white grease. Lubricate the door lock cylinder with liquid graphite annually, or more often in climates with a lot of snow and salt on the roads. Coat the door stop arm with white grease annually. On wet and salted roads, road spray can enter the door lock key cylinder. Lubricate the cylinder with liquid graphite annually or more often if necessary.
132 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Hood The hood latch mechanism should be greased with white grease yearly. If the mechanism is hard to work or binds, the latch should be cleaned before greasing. C0029317 Rust Protection The rust protection applied when the cab was produced is adequate for normal use and service.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 133 Paint and Brightwork Care Cab CAUTION When using a pressure washer to clean the vehicle, do not direct the spray at electrical components in the engine compartment such as the alternator, starter and compressors. Water spray from pressure washers can damage electrical components. Wash all exterior painted surfaces frequently to remove dirt. It is especially important to wash off salt-laden snow and ice during the cold season.
134 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Stainless Steel Stainless steel will rust if exposed to salt for too long. Wash frequently, especially during the cold season, to remove salt-laden snow and ice. If rust appears, wash the surface and use a rubbing compound to remove the rust. Apply a coat of wax as a finish (do not wax parts that get hot, such as exhaust pipes, etc.). Note: Never use steel wool to clean stainless steel.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 135 Alcntera Suede-Like Material Suede-like upholster can be cleaned with a soft cloth and mild soap solution. Leather Care MACK’s Leather upholstery is manufactured with a protectant to repel soiling. Over time, sunlight, grease and dirt can break down the protection. Staining, cracking, scuffing, and fading can result. CAUTION DO NOT use gasoline, naphtha or similar cleaning agents on the plastic or leather since these can cause damage.
136 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Lubrication Chassis Lubrication DANGER Before working on or servicing a vehicle, set the parking brakes, place the transmission in neutral and chock the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. General lubrication includes lubricating all the grease fittings in the drivetrain, front and rear suspensions, power steering, and front axle, using a grease gun.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 137 Lubrication Chart W1055585
138 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU The numbers in the lubrication chart correspond with the numbered notes in the Lubrication Chart Notes section. For more information refer to “Lubrication Notes”, page 139. * Grease Coolant Hub Oil Aut. Transm. Fluid Engine Oil Man. Transm.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 139 Lubrication Notes 1 Spring hanger: Use a lithium based grease with specification API NLGI No. 2. When lubricating the left and right sides of the front springs, lift the axle off of the floor, suspend the frame with axle stands and lower the axle. The spring bushings are now in the position where grease can be added to the contact surfaces. Note: The rock guard will have to be removed (if equipped).
140 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 9 Clutch bearing linkage: Use a lithium based grease with EP additives to specification API NLGI No. 2. Note: Inspection cover removal is necessary. Lubricate according to Eaton’s lubrication document and reinstall the inspection cover. See http://www.roadranger.com for the latest heavy-duty clutch service information. 10 U-Joints: Use a lithium based grease with EP additives to specification API NLGI No. 2.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 141 plug in the housing. The oil should be level with the bottom of the fill/level plug hole. Add oil if necessary. CAUTION Most rear differentials have a large screw and nut protruding from the housing. The screw and nut hold the thrust plate shoe against the ring gear and are not to be confused with the fill/level plug. Note: Refer to Service information for Oil Types and for Approved/Correct Oils.
142 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Oil Capacity Tables and Viscosity Charts Note: Use the information in the table below to determine the operating condition and usage applicable to your vehicle. MP7 and MP8 Engine Oil and Filter Change Intervals Engine Operating Condition Medium Heavy Severe Very Severe Fuel Consumption (mpg) more than 6.0 more than 4.7 more than 3.7 more than 2.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 143 Eaton Fuller Transmission 9,10, 13, 15 and 18-speed For oil quality and oil change intervals, see the manufacturers operators manual. Capacity 9-speed 12.0 liters (13.5 quarts) 10, 13, 15 and 18-speed 13.0 liters (14.
144 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Meritor Single RS23, 25, 26 and 30, Meritor Tandem RT40, 44 and 46 For oil change intervals, see the manufacturers operators manual Capacity RS23-160 19 liters (20 quarts) RS23-185 22.5 liters (23.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 145 Eaton Single; 23080, 23105, 26105 and 30105, and Eaton Tandem; DS405, DD405, DDH44 and DS462 For oil change intervals, see the manufacturers operators manual Capacity 23080 19 liters (20 quarts) 23105 and 26105 26.5 liters (28 quarts) DD404, front tandem DD404, rear tandem 14.5 liters (15.5 quarts) 13 liters (14 quarts) DS404, front tandem DS404, rear tandem 14.5 liters (15.
146 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Service Check List Preventive Maintenance Note: Once you determine the applicable operating condition for your vehicle, use the information in the table below to perform preventive maintenance.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 147 TYPE OF OPERATION CHECK / CHANGE BASIC (4 MONTHS) CHECK / CHANGE ANNUAL (12 MONTHS) Check BatteriesDirt, Leakage, Attachment, Specific Gravity of Battery Acid, Fluid Level Connections and Battery Box X X Check Fuel Tank, Hoses, Pipes Venting and Mounting X X Check Fuel Water Separator for the Fuel system, Draining of Condensation.
148 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU TYPE OF OPERATION CHECK / CHANGE BASIC (4 MONTHS) CHECK / CHANGE ANNUAL (12 MONTHS) Check Rear Spring Bolts X X Check Mounting for Front and Rear Axle X X Check Chassis Frame and Crossmembers X X Check Rear Wheels and Bearings X X Check Brake Linings X X Check Brake Cylinders, Levers and Forks X X Check Oil Level in Manual Transmission (If Applicable) X X Check Oil in Retarder X X Check Oil Level in Power Stee
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 149 TYPE OF OPERATION Check Transmission Oil Cooler hoses and Connections for leaks CHECK / CHANGE BASIC (4 MONTHS) X CHECK / CHANGE ANNUAL (12 MONTHS) X X Valve Adjustment ADDITIONAL SERVICE Check Drive Belts X X Check Radiator Fan, Bearing Tolerance, Bolt Unions, Fan Cover and Fan Ring with Rubber Seal X X Check Turbocharger X X Check Discharge Lines and Hoses X X REQUIRED: Once a year, every 209 000 Km, (130,000 miles)
150 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Service Charts Scheduled Services The vehicle had a pre-delivery inspection before being delivered to you, the customer. Regular maintenance inspections should be continued. The maintenance program and lubrication intervals that are listed in this manual may not suit your operation. Contact your nearest MACK Truck dealer, who can help with designing a maintenance program that works in your application.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 151 Scheduled Service Date Preventive Maintenance (See local MACK Truck dealer for Service Information in group 17, Preventive Maintenance Basic Service and group 17, Preventive Maintenance Annual Service) Work Completed Date Mileage
152 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Noise Control Log NOISE CONTROL SYSTEM MAINTENANCE LOG DATE MILEAGE MAINTENANCE PERFORMED MAINTENANCE FACILITY
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 153 Repair Record Keep track of repairs being made. This helps over the lifetime of the vehicle to spot trends that can be used to alter maintenance schedules, for example. Repair Record Date Mileage Work Order or Invoice No.
154 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Tire Record Tire Record Date Type Front Type Rear Notes (Tire Pressure, Tread Depths)
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 155 Fuel and Oil Record Keeping track of the fuel and oil consumption gives a record of what is normal for the vehicle. This can be compared with other vehicles in the same service application to indicate what is normal fuel and oil consumption for a certain application. Keep a record of how much fuel was filled between oil fill up or oil change. Accumulated Date Mileage Fuel Qty. (Gallon) Oil Qty. SAE No.
156 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Engine Data Consult your authorized MACK Truck dealer.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 157 Literature Service Assistance and Manuals Your MACK Truck dealer is trained and equipped to perform expert service on your MACK vehicle. Your dealer has direct access to MACK Inc. for technical help, parts or service information. MACK Action Service (VAS), provides on-call assistance. For help, contact VAS directly: 24 hours a day at 1 (800) 528-6586 or 1 (800) 52-MACK. Also on the internet: www.vas.MACK.com.
158 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU CUSTOMER SERVICE Call 1-800-866-1177 for MACK One-Call™ The One-Call customer support system is a toll-free nationwide hotline that operates 24 hours a day, seven days a week, including holidays. If you break down on the road, simply call 1-800-866-1177. There is a staff of trained, experienced technicians ready to help.
Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU 159 Addresses The addresses, telephone and fax numbers of the MACK Trucks, Inc. regional offices are: United States Northeast Region – 7900 National Service Road., Mail: P.O. Box 26259, Greensboro NC 27402 , TEL: (336) 291-9001 Southeast Region – 6768 Southlake Parkway, Morrow, GA 30260, TEL: (770) 960-0511, FAX: (770) 960-0593 Central Region –900 S. Frontage Rd.
160 Operator’s Manual Vehicle Maintenance CXU, CHU, GU, TD, MRU and LEU Additional Assistance If additional assistance is required, MACK Trucks, Inc. maintains a Customer Service Department (staffed by experienced personnel) to aid customers who need information or assistance not provided at the local or regional level. The Customer Service Department phone number is (610) 709-3961.
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