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MAINTENANCE AND LUBRICATION 37

Radiator Pressure Cap

At every C and D inspection, check the condition of the radiator cap gasket. Also,
pressure test the cap using a suitable cooling system and radiator cap tester. A 16-psi
pressure cap is currently used on all MACK Trucks, Inc., model chassis.

Thermostat

Check thermostat operation, particularly during cold weather, to make sure the
thermostat closes fully, does not allow any leakage and does not open too soon. Also,
the thermostat seal should be checked for leakage. Coolant leaking past the thermostat
can cause overcooling and may result in insufficient cab heat.

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Summary of Contents for LEU

Page 1: ...Mack Natural Gas 21607699 21607699 21607699 September 2010 Mack Trucks Inc 2010 Printed in U S A Mack Natural Gas LEU MRU Mack Natural Gas LEU MRU...

Page 2: ...ighway Traffic Safety Administration NHTSA and MACK Trucks Inc should be informed immediately if you believe that the vehicle has a defect that could cause a crash injury or death Contact NHTSA by cal...

Page 3: ...tem 29 Removing Pressure Before Working on the Tanks 30 Moving a Vehicle Using Auxiliary Fuel 30 ENGINE MAINTENANCE 32 Air Filter 32 Air Inlet System Ducts Hoses and Clamps 34 Chassis Mounted Charge A...

Page 4: ...46 Circuit Breaker and Relay Panel 46...

Page 5: ...as prepared to provide the driver with all relevant information concerning the natural gas engine its characteristics and its potential hazards if not maintained properly Please read it thoroughly pay...

Page 6: ...through the manufacturer of LNG CNG vehicles and equipment If you are unsure about your qualifications for operating refueling or recognizing and responding to potentially dangerous emergency situatio...

Page 7: ...fety program Only safety training and periodic practice drills can adequately train operators and local emergency personnel such as fire departments medical emergency units and police departments for...

Page 8: ...en the vehicle is parked for some time During venting a hissing sound may be heard The frequency and duration of this venting will vary depending on tank pressure and ambient temperature It will conti...

Page 9: ...Safety Information 5 C0032249...

Page 10: ...e There are three main causes of rapid pressure rise on LNG systems overfilling fuel system leaks or malfunctions and loss of vacuum A properly functioning properly filled LNG fuel system should build...

Page 11: ...lace The methane vapor detection system utilizes two sensors to identify methane vapors one located in the cab compartment and one located in the engine compartment of the vehicle The system operates...

Page 12: ...rmation Before Entering the Vehicle Green and red methane detector remote indicator lamps are easily viewed through the windshield and should always be checked before entering the vehicle See illustra...

Page 13: ...nually turn off the Fuel Shut Off Valve on each fuel tank to prevent further gas leakage Wait until the gas has dissipated and the alarm situation has cleared It is now safe to open the vehicle doors...

Page 14: ...has been repaired CAUTION AMGaDS III Plus is a propane CNG Compressed Natural Gas and LNG Liquid Natural Gas detector only However because the sensors detect all hydrocarbon vapors an alarm may be tr...

Page 15: ...fety gloves and eye protection such as goggles or a face shield should be worn when working with or around LNG CNG as when refueling If super cooled liquid or gas comes into contact with the skin or e...

Page 16: ...ss cannot be detected by human senses Even though CNG is sulfurized the smell may go unnoticed on some vehicles such as a refuse truck Without adequate ventilation natural gas will displace the oxygen...

Page 17: ...LNG CNG fuel tank s and remove any pressure on the system prior to removing parts or components of the tank for repair Releases or Spills During a release or spill shut off and eliminate all ignition...

Page 18: ...As described in your Operator s Handbook follow the Three Limb Contact Rule to enter and exit your vehicle DANGER Before opening either vehicle door always look through the driver side window at the m...

Page 19: ...see how the methane detector alarm system is arranged on a typical LEU instrument panel The exact layout may differ from your truck but the gas detection system will look the same W0059510 1 Gas Dete...

Page 20: ...On Indicator Green 6 Relay On Off Indicator 2 Significant Alarm Indicators Red 7 Relay Reset Button 3 Trace Sensor Alarm Indicators Amber 8 System Test Button 4 Audible Alarm Silence Button 9 Sensor...

Page 21: ...he following procedure Remove all personnel from the area Turn off electrical circuits and sources of ignition in the immediate area Manually turn off the Fuel Shut Off Valve on each fuel tank to prev...

Page 22: ...ter pressing the Shutdown Reset button the Relay Engaged LED goes off 8 System Test Button Pressing the button will cause the system to perform a self test of all electrical and sensor functions and s...

Page 23: ...event the methane alarm red light comes on and the alarm sounds the cab windows should immediately be opened the vehicle should be safely stopped and turned off and personnel should exit the cab Follo...

Page 24: ...el tank is for simplicity of explanation designed like a vacuum Thermos bottle which can withstand pressures up to 230 psi or whatever maximum pressure is posted on the manufacturer s label see illust...

Page 25: ...ank 6 Fuel Shut Off Valve 2 Manual Vent 7 Excess Flow Valve 3 Fuel Tank Pressure Gauge 8 Fuel Tank Fill Fitting 4 Tank Manufacturer s Manual Inside Bottom half of Tank Door 9 Fuel Gauge Sending Unit 5...

Page 26: ...e evacuation plug indicates an inner vessel leak The evacuation plug is protected from the environment and tampering by a plastic cap Do not remove the plastic cap or evacuation plug 6 Fuel Shut Off V...

Page 27: ...ttached to the intake stack by disposable plastic straps The piping should be removed from the intake stack and plumbed up and over the body by the body installers as shown in the illustration at the...

Page 28: ...detected by human senses Without adequate ventilation natural gas will displace the oxygen and give no warning that a non life supporting atmosphere is present Store LNG in a well ventilated area Gro...

Page 29: ...ly terminated when the pressure reaches a preset value at the fueling station Remove the filling hose from the fitting Warm Tank Filling The LNG vehicle fuel tank is considered to have a warm inner ve...

Page 30: ...Without adequate ventilation natural gas will displace the oxygen and give no warning that a non life supporting atmosphere is present Store CNG in a well ventilated area DANGER KEEP AWAY FROM FLAME O...

Page 31: ...ng liquid or gas fuel from the fuel tanks to the vaporizer are stainless steel The tubing from the vaporizer throughout the remainder of the fuel delivery system is specialized high pressure tubing An...

Page 32: ...lumbed up and over the body by the body installers CAUTION It is important to keep the primary pressure vent free of blockage due to ice snow or debris CAUTION If LNG vehicles must be parked or worked...

Page 33: ...ual WARNING REMOVE PRESSURE Before working on the LNG CNG fuel system close the fuel valves on each tank and relieve the pressure in the fuel line by opening the drain on the fuel filter or by running...

Page 34: ...fter the vehicle has used most of its on board fuel WARNING Never bleed the tanks in an enclosed area Be sure there are no sources of ignition in the area Moving a Vehicle Using Auxiliary Fuel When LN...

Page 35: ...vehicle from an auxiliary tank Turn the valve to ON to operate from the main tank s and be sure to turn the valve to OFF when parking the vehicle C0032260 1 Three Way Fuel Valve 3 Front Edge of Fuel...

Page 36: ...er or the restriction gauge red signal locks in full view Regardless of the gauge reading change the element at least once yearly Note As damage or holes in the filter medium will give an inaccurate r...

Page 37: ...or coarse Scotch Brite pad Thoroughly wash the area with PPG DX 440 or equivalent wax and grease remover Etch and prepare with PPG Metal Prep 79 DX 579 or equivalent Rinse with water and dry thoroughl...

Page 38: ...by using a firm bristle brush and soapy water CAUTION Do not use a caustic solution to clean CMCAC Every 45 days of usage or 150 hours Check all air ducting and gasket connections Proper hose clamp to...

Page 39: ...e valves on each tank to the OFF position This will stop more fuel from entering the lines to the engine Allow the engine to run until it dies C0032264 1 Engine Mounted Filter Adapter For clarity the...

Page 40: ...rod to hold the filter in place Reinstall and hand tighten the canister over the filter element Close the filter drain Open the valves on each tank to allow fuel to re enter the system Start the engi...

Page 41: ...tester A 16 psi pressure cap is currently used on all MACK Trucks Inc model chassis Thermostat Check thermostat operation particularly during cold weather to make sure the thermostat closes fully doe...

Page 42: ...38 MAINTENANCE AND LUBRICATION...

Page 43: ...in Canada 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 mo...

Page 44: ...es or 10 800 hours of engine operation whichever first occurs Equipment such as turbochargers injection equipment and charge air coolers not manufactured by MACK Trucks Inc are excluded from the above...

Page 45: ...ol of MACK Trucks Inc Inconvenience loss of use of the vehicle or commercial loss Any vehicle on which the odometer has been changed so that mileage cannot be readily determined The repair or replacem...

Page 46: ...emission control system DEFECTS WARRANTY Owner s Warranty Responsibilities As the motor vehicle engine owner you are responsible for the performance of the required maintenance listed in this manual...

Page 47: ...ch component be warranted for less than five years after delivery of the vehicle or engine to the original purchaser or 160 000 km 100 000 miles of operation of such vehicle or of the vehicle in which...

Page 48: ...arts and paid invoices must be presented at a MACK Trucks Inc facility as a condition of reimbursement for emergency repairs performed elsewhere 3 Repairs by Non MACK Trucks Inc Facilities Owners may...

Page 49: ...airing such damage WILL NOT BE COVERED under warranty CAUTION Any unauthorized adjustments can cause severe damage to the engine In the event that damage results from unauthorized adjustments as evide...

Page 50: ...46 ELECTRICAL Circuit Breaker and Relay Panel LEU Series with CNG Engine C0032284...

Page 51: ...ELECTRICAL 47 LEU Series with LNG Engine C0032285...

Page 52: ...ly Solenoid 13 10A 14 10A 15 5A 16 10A Anti Lock Brake System Anti Lock Brake System Spare Body Buzzer 17 10A 18 5A 19 15A 20 15A Kysor Control Anti Lock Brake System Gauges Indicator Lamp Woodward En...

Page 53: ...A 40 15A Tail Lamps No Circuit Body Ignition Power Reserve Fuel Tank 41 15A 42 20A 43 44 20A Hydraulic Pump Solenoid Reverse Lamps Back Up Alarm No Circuit Air Dryer Drain Valve 45 46 15A 47 20A 48 10...

Page 54: ...wer Indicator Lamps 13 15A 14 10A 15 15A 16 20A Gauge Panel Kysor Warning Mirror Heat Air Dryer 17 20A 18 10A 19 30A 20 20A Ignition Power Feed Engine Brake Heater RH Wiper 21 20A 22 10A 23 10A 24 15A...

Page 55: ...otection 37 15A 38 39 40 2 Way Radio No Circuit D Full ABS Battery No Circuit 41 42 43 44 15A No Circuit No Circuit No Circuit D Basic ABS Battery 45 46 20A 47 48 10A No Circuit Beacon Lamps No Circui...

Page 56: ...52 ELECTRICAL MRU Series C0032286...

Page 57: ...r Shutdown NG Woodward ECU Gauges Mirror Heat 21 20A 22 20A 23 20A 24 10A LH Wiper RH Wiper Battery Box Ignition Stud Spare 25 30A 26 10A 27 5A 28 15A Heater A C Spare ABS HD Automatic Transmission 29...

Page 58: ...e Pressure Natural Gas Temperature Engine Coolant Temperature Pre Turbine Pressure NGTP TK Temperature Return Exhaust Back Pressure Relay 2 4 F4 15A UEGO Connection Oxygen Sensor Low Pressure Lockoff...

Page 59: ......

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