Maintenance and Service

Maintenance Hazards

Danger

Before working inspecting a vehicle, set the parking brakes, place the transmission neutral and chock the Failure can result unexpected vehicle movement and can cause serious personal injury

Danger

NOT attempt repair service this vehicle without having suf ficient correct service literature and the proper Failure follow this could lead personal injury making your vehicle

Note: Read all safety information before working the

Engine

Service Schedules

*Under certain conditions (for example, irregular fuel quality), the fuel/water separator filters may require more frequent replacement.

**V alves must adjusted whenever the rocker shaft has been removed and reinstalled for any reason.

Cooling System

General Coolant Information

Danger

Coolant toxic; risk poisoning. NOT drink coolant. Use proper hand protection when handling. Keep coolant out reach children and animals. Failure follow these precautions can cause serious illness death.

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NOT raise the engine hood you see hear steam coolant escaping from the engine compartment. W ait until steam coolant cannot seen heard before raising the hood.

NOT remove the coolant fill cap the coolant the sur tank boiling. Also, NOT remove the cap while the engine and radiator are still hot. Scalding fluid and steam may blown out under pressure the cap taken f too soon and can cause personal injury .

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Coolant may

Coolant leaked spilled onto hot surfaces electrical components can cause a Clean coolant spills immediately .

Caution

MACK Inc. does not recommend using plain water the cooling system. W ater alone corrosive engine operating temperatures and does not provide adequate boiling protection. The engine may develop corrosion and cavitation problems the engine and radiator , and the boiling point the coolant lowered compared a proper antifreeze and water mixture. Failure follow MACK Inc. cooling system care/maintenance recommendations can render the warranty invalid.

The cooling system plays important role overall engine performance keeping the engine within the normal operating temperature range hot enough for ficient combustion, and cool enough prevent engine damage caused overheating. Good preventive maintenance practices, along with monitoring cooling system performance, a long way preventing engine damage that could result from cooling system problems. The maintenance items and tests outlined this section should performed the intervals specified ensure optimum performance from the cooling system.

Surge T ank Cap

MACK conventional models and TD) utilize a coolant sur tank mounted top the radiator . The sur tank has a fill cap located the top right - hand side the and a pressure cap rated which incorporates overflow tube located the left - hand side the Check the coolant level regularly , making sure the coolant level between the COLD MIN and COLD MAX lines the back the each C and D inspection inspect the rubber gaskets each the caps. Replace the cap(s) the gaskets show evidence damage which could fect sealing.

Warning

NOT remove the fill cap while the cooling system Allow the system cool suf ficiently before T urn the fill cap slowly counterclockwise and wait for the pressure the system After the pressure has completely remove the

MACK low cab forward models (MRU, LEU) utilize a sur tank which located the left - hand side the chassis, mounted a stanchion the rear the cab. This sur tank utilizes a standard radiator pressure cap. Check the coolant level regularly , making sure the coolant visible the sight glass located the side the tank. each C and D inspection interval, remove the radiator cap and inspect the gasket for any defects that would fect sealing. Also, pressure - test the cap using a suitable cooling system and radiator cap tester . Sur tank cap pressure specifications are follows:

• MP7 Engines (MRU and LEU Models) - pressure cap

• MP8 Engines (MRU Models only)lb. pressure cap

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NOT remove the fill cap while the cooling system hot. Allow the system cool suf ficiently before removing. T urn the fill cap slowly counterclockwise the first stop, and then wait for the pressure the system dissipate. After the pressure has dissipated, completely remove the cap.

The main purpose coolant transport heat from the hot parts the engine the radiator and protect the cooling system from corrosion.

addition this, the coolant must:

• Protect against pitting and cavitation erosion damage the water pump and cylinder liners.

• Protect against freezing and

• Prevent formation scale, sludge deposits and clogging.

• harmless polymer materials and seals the cooling

• Maintain its liquid properties cold climates.

Many engine failures can traced back a problem the cooling the coolant level allowed below the bottom the there the risk the engine shutting See the operators manual for more information the warning

Note: Always dispose coolant according Federal local regulations. T ake all used coolant a recycling waste collection center

Coolant mixture consisting antifreeze solution water should used year - round provide freeze and boil - over protection well providing a stable environment for seals and hoses.

Note: NOT use antifreeze formulated for automobile gasoline These have a very high silicate content that will clog the radiator and leave unwanted deposits the

Coolant System Capacities CAUTION

Capacities may vary due hoses and size radiator , well accessory cooling After running the engine until normal operating temperature reached, check the coolant level and add coolant

Use the chart shown conjunction with the Ethylene - Glycol and Propylene - Glycol Protection Charts this section determine the amount antifreeze needed protect your vehicle.

Manual transmission without auxiliary cooling package transmission with auxiliary cooling package

Automatic transmission without auxiliary cooling package

Automatic transmission with auxiliary cooling package

LEU*** MP7 Automatic transmission without auxiliary cooling package MP7 Automatic transmission with auxiliary cooling package

* Coolant capacities listed are for chassis equipped with manual transmissions. For automatic transmissions, add 9.5 liters (10 qts).

Allison automatic transmission not available option for MRU models equipped with MP8 engine.

*** LEU models are not available with a manual transmission.

Use the following antifreeze protection charts determine the percentage antifreeze needed achieve specific protection levels for various coolant systems.

Ethylene - Glycol Protection Chart

Ethylene Glycol Ambient Air T emperature

40%

° C (12 °

A

50%

Propylene - Glycol Protection Chart

° C (62 °

° C (34 ° 60%

Propylene Glycol Ambient Air T emperature

40%

° C ° 50%

° C (27 ° 60%

° C (56 ° well functioning and maintained cooling system important the engine performing regular oil changes using good fuel. T o get the best result use quality products and service the system the correct intervals. Please read this section carefully .

Keep the radiator (including char air cooler) and the frontal area free from bugs, (see Char Air Cooler and Radiator , page 107 for cleaning

Check the coolant level the tank regularly . Fill the tank necessary with the correct coolant.

Danger

NOT work near the fan with the engine The engine fan can engage any time without Anyone near the fan when turns could seriously Before turning the sure that one near the

Caution

Never add coolant a hot overheated Engine damage can Allow the engine cool

Additives

Additives help prevent rust, scale and mineral deposits from Additives also protect metals from corrosion, prevent water pump and cylinder liner cavitation and contain anti - foaming Additives are depleted during normal engine operation and need r eplaced For non - extended life coolant this means the addition Supplemental Coolant Additives (SCA) any time the additive goes below the recommended For extended life coolant this means extender package added halfway through the coolant

Regular Coolant Change Interval

Coolant SCA level must tested least twice per year whenever coolant loss For maximum coolant system ficiency , test the system every engine oil change every hours every 6 months (whichever comes For proper SCA consult Service

Regular Coolant Filter Change Intervals

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Hot Keep clear all hot engine parts and A hot engine and fluids can cause serious

The char ged coolant filter contains 8 units SCA that are released slowly over time maintain the recommended level during Consult engine service manual for proper SCA level and change

Extended Life Coolant Change Interval CAUTION

Extended life coolant will test out additives but SCA should not Shortened engine life may the result adding

Note: NOT add supplement coolant additives (SCA) extended life coolant.

Should the extended life coolant system become contaminated with regular coolant exceeding 10% the systems total capacity SCA added extended life drain the system and refill with new extended life coolant regular

Extended Lift Coolant Filter Change Interval W ARNING

Hot Keep clear all hot engine parts and A hot engine and fluids can cause serious

Caution

NOT use a filter that contains SCA. Damage components can result.

Fuel System

Fuel Safety Reminders

Danger

A diesel engine will operate any fuel which enters the cylinder , whether from the injectors from the air intake system. Therefore, any solvent used flush out the air cleaner element, the engine may over speed during startup. Engine damage, severe personal injury death from burns explosion may occur .

Danger

NOT mix gasoline alcohol with diesel oil This mixture can cause explosion and result severe personal injury

Danger

NOT remove the fuel tank cap near open Diesel fumes are combustible and can cause explosion fire resulting severe personal injury

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a fuel leak stop the engine immediately The vapors from hot fuel are highly flammable which may result a

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NOT store fuel containers the vehicle. They may leak, explode and cause feed a fire. Empty full, they present a hazard that may lead burns the event a fire.

Diesel Fuel Specification Quality

Caution

Diesel engines for 2007 and later model year vehicles are designed operate only with Ultra Low Sulfur Diesel (ULSD) fuel. Use fuel other than ULSD will reduce the ficiency and durability the engine, permanently damage the advanced emission control systems, reduce fuel economy and possibly prevent the engine from running all. Manufacturers warranties are likely rendered void usage improper incorrect fuel, and usage fuels other than ULSD fuel diesel - powered vehicles illegal and punishable with civil penalties. Use fuel additives compensate for the lower sulfur content NOT recommended MACK Inc.

The proper selection fuel essential for good economy , performance and engine No. ULSD should used when climatic conditions No. ULSD can used during cold weather Blends No. and No. ULSD fuels can used suit various climatic

Note: The use lighter fuels (grade No. 1 - can reduce fuel economy .

Note: Eur o 4 Engines

Ultra Low Sulfur Diesel (ULSD) fuel with a maximum sulfur content ppm required meet emission certification for Euro 4 emission engines. Using approved diesel fuel with a maximum sulfur content 500 ppm Euro 4 emission engines will meet all reliability standards.

The fuels used must completely stable and non - Always try keep the fuel tank NOT put alcohol into the fuel Fill the tank after completing driving for the day

Fuel Sulfur Content

Fuel sold for use diesel - powered engines for 2007 and later model year vehicles may only contain a maximum sulfur content 0.0015% weight. This was done reduce particle emissions the exhaust.

Note: The use ultra - low sulfur diesel fuel does not permit extension engine oil change intervals oil filter changes.

Cetane Number

Direct injected diesel engines require a minimum cetane number under normal starting conditions. Fuel with a higher cetane value may required for high - altitude cold - weather operation.

Filtration

Fuel should clean and free contamination. Clean fuels should have more than 0.05% sediment and water .

Fuel Additives

Fuel additives are generally not recommended needed for fuels listed earlier . Cetane improvers can used necessary . Biocides may needed eliminate microor ganism growth storage tanks. cold conditions, treatment for water the vehicle tanks may also necessary .

Consult your fuel supplier about the use additives prevent incompatibility among additives already the fuel and the additives

Supplemental Fuel Enhancers CAUTION

Supplemental additives are not recommended because a high risk injection system problems engine damage.

There are many aftermarket products available today which are intended added the customer . They generally increase operating cost without providing benefits. Included are a variety independently marketed products which claim be:

• Cetane improvers

• Emission control additives

• Deter gents

• Combustion improvers

• Smoke suppressants

• Cold weather flow improvers

Note: Repair expenses resulting from malfunctions the fuel system with engine components when fuel enhancers have been used are not covered under warranty .

Some fuel additives can used provide temporary relief, but they not replace good fuel handling practices. These products can used:

• Isopropyl Alcohol Use 1/2 liter per 450 liters pint per 125 gallons) fuel for winter freezeprotection.

• Biocide For treatment microbe growth black Follow manufacturers instruction for

Prohibited Additives

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The addition gasoline diesel fuel will create a serious fire Serious personal injury can

The following additives are specifically NOT allowed and must NOT mixed with the vehicle diesel fuel:

• Gasoline Adding gasoline diesel fuel will reduce the cetane number and increase combustion a tank contains a diesel fuel/gasoline should drained and cleaned soon

• Used lubricating oil MACK Inc. does not recommend the use any type used lubricating oil extender the diesel fuel. Used lubrication oil contains solids and acids from the combustion process that can severely corrode parts the injection system, resulting reduced power and higher maintenance cost over time.

Alternative Fuels

Alternative fuels can several dif ferent There are vegetable based aviation fuel and recycled petroleum based fuels that are used combustion These are general not compatible with modern heavy - duty over - the - road diesel

The use unauthorized fuels may compromise the levels pollutants the exhaust the point where the engine does not meet the emission requirements. This would make the vehicle illegal drive public roads. NOT use any kind alternative fuel unless specifically authorized MACK Inc.

Bio Diesel

The only Bio Diesel Fuel approved MACK Inc. for use A 2010 MACK Engines Soy Methyl Ester (SME SOME) blends Concentration (5% blend).

Note: Although higher concentrations are available, concentration (maximum) are the only blends currently approved MACK

Fuel Storage fuel stored site:

• Keep storage tank covered prevent water entry

• NOT use a tank made galvanized metal any galvanized piping for diesel oil storage. Diesel will react with the zinc, forming solids that can clog fuel filters and cause engine damage.

• Fuel stored for a long time may oxidize and form causing filtering

• Keep the area around the fill cap clean. T ilt the tank slightly toward the drain plug area water and sediment can easily drained.

Generally , fuel contamination occurs the result improper fuel The most common types contamination are water , dirt and microbial growth (black The formation varnishes and gums resulting from poor fuel stability long storage (stale fuel) also fects fuel quality The best treatment for contamination prevention maintaining a clean storage system and choosing a reputable fuel supplier

Fuel Filters

A primary fuel filter can located the engine remote mounted the frame This filter consists a filter cartridge, a water separation bowl and may have a fuel heater built

The secondary fuel filter located the left hand side, below the engine electronic control unit (EECU). The filter a spin - filter .

MACK engines utilize a spin - primary and secondary fuel filters. Both filters are located the right - hand side the engine.

The primary fuel filter MACK engines incorporates a plastic water separator Additionally , the plastic bowl includes a water - - fuel sensor . A warning lamp the instrument panel illuminates when water detected the Refer Fuel/W ater Separator

Note: There are optional fuel filter systems (such Davco, Conmet, etc.) available for MACK These fuel filter systems use a single remote - mounted filter , eliminating the spin - primary and secondary filters. For service information concerning these refer the specific fuel filter manufacturers service

Primary Fuel Filter Replacement Procedures MACK Engines

each specified oil and filter change change the primary fuel filter follows:

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 - - fuel sensor harness connector from the plastic water separator bowl.

3 Using tool J remove the primary filter .

4 While holding the filter above a suitable container , open the drain valve the plastic water separator bowl and allow the fuel the bowl drain. Dispose the drained fuel environmentally safe manner .

5 Unscrew the plastic separator bowl from the bottom the spin - primary filter

6 Apply a thin film clean engine oil the water separator bowl O - ring the bottom the new primary filter cartridge.

7 Install the plastic water separator bowl the primary filter cartridge, and tighten the bowl hand 1/4 1/2 turn after the bowl contacts the Oring.

8 Apply a thin film clean engine oil the sealing gasket the new filter

9 Prime the filter pouring clean filter fuel through the series small holes the top the filter the installation fill line. NOT prime the filter through the center hole. Use care avoid dirt entering the center hole the filter .

Install the new filter and tighten additional 1/2 3/4 turn hand after the gasket contacts the 1 1 Reconnect the water - - fuel sensor harness connector .

Prime the engine required prior starting the engine (refer the Fuel System MACK , page Start the engine and check for leaks.

Secondary Fuel Filter Replacement Procedures

each specified oil and filter change change the secondary fuel filter follows:

Note: Because ice buildup the fuel system fuel waxing which can clog fuel filters, may necessary reduce the time mileage interval between fuel filter changes during extremely cold weather .

T o install a new filter:

1 Thoroughly wash the area around the fuel filter and mounting adaptor mating area with a suitable solvent and blow dry with compressed air .

2 Using tool J remove the old

3 Apply a thin film clean engine oil the sealing gasket the new filters.

4 Prime the filter pouring clean filtered fuel through the series small holes the top the filter . NOT prime the filter through the center Use care avoid dirt entering the center hole the filter .

5 Install the new filters and tighten additional 3/4 1 turn hand after the gasket contacts the

6 Prime the engine required prior starting the engine (refer the Fuel System MACK , page

7 Start the engine and check for