Automatic Belt T ensioner Maintenance

The automatic belt tensioner designed maintain proper belt tension throughout the life the tensioner The belt tensioner cannot adjusted each D inspection interval once per year , whichever occurs first, check the following: • W ith the belt the drive, check the following:

Check see the tensioner resting against the install stop the free - arm the tensioner resting against either the tensioner must W0054013 main drive belt tensioners, check belt tracking. the belt tracking all the way one side the tensioner pulley (either the front - backside), replace the tensioner . Belt tracking can determined looking the witness mark (the shiny area the pulley where the belt rides). The witness mark should approximately the same width the belt.

Main Drive Belt T ensioner Belt T racking W itness Mark

Acceptable itness Mark Approximately Same W idth Belt)

Not Acceptable itness Mark T racking f Edge Pulley)

• Remove the belt using a 3/8 inch breaker bar pull the tensioner back the install Slowly return the tensioner the free - arm

• W ith the belt removed, use the breaker bar slowly pull the tensioner from the free - arm stop the install stop and then slowly releasing back the free - arm stop. Any excessive roughness hesitancy noticed while performing this check indicates that the tensioner must replaced.

• Check for metal - - metal contact follows:

Check for contact between the arm and the spring case. Replace metal - - metal contact seen.

Check for metal - - metal contact between the arm and the end Replace contact

W0054016

Checking for Contact Between Arm and End Cap

Check for cracks the tensioner body for broken stops the spring case. either replace the tensioner .

Reinstall the belt making sure that the belt properly seated the grooves ALL pulleys.

Caution

automatic belt tensioner must replaced, make sure that the proper tensioner used. T ensioner spring tension varies engine and chassis model. not substitute one tensioner part number for another , drive belt failure can

urbocharger and Charge Air Cooler

Danger

oil leaks internally from the turbochar ger the engine intake, the oil acts a fuel. W atch for excessive exhaust smoke. NOT operate engine until problem corrected. There way regulate the engine speed runs oil and may over speed. Loss control vehicle may lead accident causing severe personal injury

W Arning

NOT tighten turbochar ger air intake ducting while the engine operate the engine while the ducting

W orking around the turbochar ger with the ducting removed may cause severe personal injury

V isually inspect turbo mountings, intake and exhaust ducting and connections for leaks a daily basis. Check oil inlet and outlet for leaks signs restrictions oil flow . Check for unusual noise vibration. any faults are detected, not operate the engine until the cause determined and repaired.

Cleaning Charge Air Cooler and Radiator Package W ARNING

Always wear eye protection when cleaning radiator , char - air cooler and condenser Failure follow this recommendation may result eye injury

Caution

When using a pressure washer clean the not direct the spray electrical components the engine compartment such the alternator , starter and W ater spray from pressure washers can damage electrical

Periodically inspect the front the radiator/char - air - cooler package for buildup dirt, mud, insects, etc. Over time, there may a builddirt, mud, insects, etc., between the radiator and char air cooler . Inspect for build - and contact your authorized MACK T ruck dealer , necessary .

Over time, dirt and insects will accumulate between the fins the radiator , air conditioning condenser and char - air - cooler . The reduced air flow reduces the heat transfer from the components the air . This increases the load the fan and air conditioning compressor and can result engine overheating and other performance related problems, such high fuel consumption, etc.

The simplest method clean the package use air pressure a water stream. This should done from the back the core. Air pressure should not exceed psi (200 kPa) for radiator and char air cooler cores. The use a fin comb also a good tool loosen bugs and dirt from the fins. dirt cannot cleaned f with this procedure, consult your MACK T ruck dealer .

Cleaning Char Air Cooler and Radiator (typical radiator shown)

NOT operate the vehicle with a damaged broken char air cooler T o would void the warranty and the engine will not meet emission regulation

Inspect the char air cooler for cracks every

Preventive Maintenance Air Suspensions

Note: The following maintenance items should performed all air suspensions (including MACK AL, II,401LH, MAXAIR 40/40A, MAXLITE 2040, MAXLITE 2040 and Hendrickson PRIMAAX) each C and D inspection interval, every 234 (25,000 miles) six months, whichever comes first.

• V isual Inspection: Inspect all suspension checking for signs wear , damage unwanted Loof for bent cracked Replace all worn damaged components

• Air Spring: Inspect for chafing any signs spring components damage. Ensure that the upper bead plate tight against the underside the frame. Check for lateral slippage the lower air spring bracket. Slippage 3.3 (1/8 inch) either direction acceptable. Replace worn damaged components required.

• Support Beam Assembly: Inspect the overall condition the support beam for dings other Hendrickson PRIMAAX check the D - pin bushings for tearing extreme Check for metal - - metal contact the bushed Replace worn damaged components

• Frame Hanger Bracket: Inspect for any signs loosening damage. Hendrickson PRIMAAX suspension, check for loosening damage the QUIK - ALIGN connections longitudinal torque rod connections. Replace worn damaged components required.

• oss Beam: Inspect for metal shavings looseness the beam Replace worn damaged components

• T ransverse T que Rods: Inspect for signs looseness the transverse torque rod Check bushings for tearing excessive Check the transverse torque rod for dents Replace worn damaged components

• Shock Absorbers: Inspect for signs dents leaking (oil misting not considered leakage). Replace worn damaged shocks required.

• T e W ear: Inspect tires for wear patterns that might indicate suspension damage Replace worn damaged components

• Height Contr V alve and Air Lines: Check for loose, bent damaged parts. Check air lines for chafing any unwanted contact with moving components. Check height control valve and air lines for leakage. Replace worn damaged components required.

Steering and Brakes Maintenance

Steering System

Excessive play the steering system checked turning the steering wheel while the engine stopped. W ith the front wheels pointing straight turn the steering wheel until the front wheel starts turn the steering wheel the other way until the front wheel moves. Play should not more than in) the rim the steering wheel. the steering play excessive, check the steering linkage for looseness, wear , etc. Make necessary repairs before driving the vehicle.

Power Steering Fluid Reservoir

The power steering fluid reservoir filled with Automatic T ransmission Fluid TF) Dexron III for the power steering the fluid has indicates that the power steering system running hotter than normal and the fluid T ake the vehicle a MACK T ruck dealer for troubleshooting the overheating and have the fluid