Mack LEU Service manual

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)

Foreword
TheinformationinthismanualappliestovehiclesbuiltJanuary2010
andlater.Pleasekeepthismanualinthevehicleatalltimes.
ThisHandbookonlyappliestoLEUandMRUmodelsequippedwith
naturalgasengines.Formodelsequippedwithdieselengines,please
refertoMackTerraProSeriesOperator’sHandbook.
Note:Illustrationsinthismanualareusedforreferenceonlyandmay
differslightlyfromtheactualvehicle.However,keycomponents
addressedinthisdocumentarerepresentedasaccuratelyaspossible.
TheNationalHighwayTrafcSafetyAdministration(NHTSA)and
MACKTrucks,Inc.shouldbeinformedimmediatelyifyoubelieve
thatthevehiclehasadefectthatcouldcauseacrash,injuryordeath.
ContactNHTSAbycallingtheAutoSafetyHotlineat1(888)
327-4236,bywritingtoNHTSA,U.S.DepartmentofTransportation,
Washington,DC20590,byTTYat1(800)424-9153,orvisittheir
websiteatwww.nhtsa.dot.gov.
MackTrucks,Inc.
Greensboro,NCUSA
Ordernumber:PV776-21607699
©2010MackTrucks,Inc.,Greensboro,NCUSA
Allrightsreserved.Nopartofthispublicationmaybereproduced,
storedinretrievalsystem,ortransmittedinanyformsbyanymeans,
electronic,mechanical,photocopying,recordingorotherwise,without
thepriorwrittenpermissionofMackTrucks,Inc.

Contents
OPERATOR’SHANDBOOKCUMMINS-WESPORTISL-GNA TURALGAS
ENGINE.......................................................................................................................1
INTRODUCTION..........................................................................................................1
TOTHEOWNER........................................................................................................1
AboutThisHandbook..............................................................................................1
SafetyInformation.........................................................................................................2
INSTRUMENTSANDCONTROLS...........................................................................15
CABINTERIOR..........................................................................................................15
MethaneDetector/AlarmSystem.............................................................................19
OPERATION..................................................................................................................20
LIQUIDNA TURALGASSYSTEM..........................................................................20
LNGTank................................................................................................................20
LNGFueling............................................................................................................23
COMPRESSEDNA TURALGASSYSTEM..............................................................26
CNGFueling............................................................................................................26
MAINTENANCEANDLUBRICATION....................................................................27
MAINTENANCEINTRODUCTION.........................................................................27
DAILYLNG/CNGFUELSYSTEMCHECKS..........................................................27
BEFOREPERFORMINGMAINTENANCEONTHELNGORCNGTANKS
ORFUELSYSTEM....................................................................................................29
RemovingPressureBeforeWorkingontheEngineFuelSystem...........................29
RemovingPressureBeforeWorkingontheTanks..................................................30
MovingaVehicleUsingAuxiliaryFuel..................................................................30
ENGINEMAINTENANCE........................................................................................32
AirFilter...................................................................................................................32
AirInletSystemDucts,HosesandClamps.............................................................34
Chassis-MountedChargeAirCooling(CMCAC).......................................................34
FuelSystem..............................................................................................................35
COOLINGSYSTEM...................................................................................................36
RadiatorPressureCap..............................................................................................37
Thermostat...............................................................................................................37
FederalEmissions..........................................................................................................39
FEDERALEMISSIONREQUIREMENTS................................................................39
TamperingwithGaseousEmissionControlSystemsProhibited............................39
GaseousEmissionControlSystemsWarranty.........................................................40
GASEOUSEMISSIONSCONTROLSYSTEMW ARRANTYFEDERAL
EMISSIONREQUIREMENTS...................................................................................41
ItemsNotCoveredbytheEmissionControlSystemsWarranty.............................41
EmissionControlSystemsWarranty—California.................................................42
EMISSIONSCONTROLSYSTEMW ARRANTY—CALIFORNIA......................44
ProceduresforHandlingEmissionsControlSystemWarranty...............................44
ELECTRICAL...............................................................................................................46

.....................................................................................................................................46
CircuitBreakerandRelayPanel..............................................................................46

INTRODUCTION1
TOTHEOWNER
AboutThisHandbook
ThishandbookisreferredtoastheCummins-WesportISL-G™NaturalGasEngine
Handbook.ItcoversallNaturalGasEnginemodels.Keepthishandbookwiththe
vehicleatalltimestoensurethateachownerand/oroperatorwillhaveaccesstoall
pertinentinformationrelatingtotheoperationandhandlingofthisvehicle.
Thissupplementwaspreparedtoprovidethedriverwithallrelevantinformation
concerningthenaturalgasengine,itscharacteristicsanditspotentialhazardsifnot
maintainedproperly.Pleasereaditthoroughly;payparticularattentiontoadvisory
labelsthathavebeenincludedtodrawattentiontoimportantissuesofoperatorsafety
andoverallperformance.
Informationandillustrationsinthishandbookarebasedonthelatestproductionusage
atthetimeofprintingandaresubjecttochangewithoutpriornotice.
Refertoyourvehicle’sOperator’sHandbookforadditionalvehicleinformation.

2SafetyInformation
ImportantSafetyInformationforAll
OperatorsofNaturalGasV ehiclesDANGER
Donotoperate,occupyorrefuelan
LNG/CNGvehicleifyouareunsure
ofyourqualicationsforoperating,
refuelingorrecognizingandresponding
topotentiallydangerousemergency
situationsthatcouldariserelatedto
LNG/CNGvehiclesandequipment.
Althoughformalcerticationisnotcurrentlyrequired-fromanoperational,safety
andliabilityperspective-itmaybedesirableforpersonnelhandlingLNG/CNG
equipmenttocarryawrittencerticateattestingtosuchtraining.Itistheresponsibility
oftheownerandoperatorofanyLNG/CNGfacilityorequipmenttohaveproper
safetytrainingbeforeoperatingLNG/CNGequipment.Informationconcerning
properLNG/CNGsafetytrainingisavailablethroughthemanufacturerofLNG/CNG
vehiclesandequipment.Ifyouareunsureaboutyourqualicationsforoperating,
refuelingorrecognizingandrespondingtopotentiallydangerousemergency
situationsthatcouldariserelatedtotheoperatingofanLNG/CNGvehicle,contact
yourimmediatesupervisororcallMACKOneCall™CustomerSupportSystem
at1-800-866-1177.
ThescopeofthishandbookisnottocoverallsituationsrelatedtoLNG/CNGsafety.
EffectivesafetytrainingprogramsarerequiredatallLNG/CNGvehiclefacilitiesto
ensurethesafetyofpersonnel,protectpropertyandmaintainfacilityperformance
requirements.FamiliarizingallpersonnelwithbasicLNG/CNGinformationwill
allowthemtomakewell-informedsafetyjudgments.Asafetyprogramatthefacility
shouldinclude:
1Scheduledequipmentinspections
2Operationalsafetyprocedures
3Personneltrainingandcertication
4Emergencyresponseproceduresandperiodicpracticedrills
5Emergencyresponsecommunityinteraction

SafetyInformation3
Althoughthishandbookcontainssafetyinformationthatmaybeusedinconjunction
withasafetytrainingprogram,itisnottobeviewedasasafety-trainingmanual.The
safetyinformationcontainedinthismanualisforreferenceandrecallofinformation
alreadycoveredinanongoingsafetyprogram.Onlysafetytrainingandperiodic
practicedrillscanadequatelytrainoperatorsandlocalemergencypersonnel(suchas
redepartments,medicalemergencyunitsandpolicedepartments)forsafelyhandling
potentiallydangeroussituationsinthecommunityproximatetoLNG/CNGfacilities
andLNG/CNGvehicleoperation.
DANGER
Itisrecommendedthatpersonnelnever
enteravaporcloud.Ifthevaporignites,
theycouldbeseverelyburned.Inhaling
thevaporcancausebreathingproblems
orasphyxiation.

4SafetyInformation
PropertiesofLNG:
LiqueedNaturalGas/Methane(LNG)isacolorless,odorlessgasorliquid.
Atambienttemperatures,theproductisagas,butatcryogenic(super-cooled)
temperaturesitisaliquidorheavygasthatmaytravelalongtheground,riseasit
warmsandvaporizes,andbecometrappedunderanyclosed-inspace.
PropertiesofCNG:
CompressedNaturalGas/Methane(CNG)isacolorless,odorless(sulfur)gas.Itis
compressedat2400to3600poundspersquareinchandstored/usedinspecially
designedcylinders.
NormalMethaneVenting
Themethanefueltanksautomaticallyventtoreleasepressurewhenthevehicleis
parkedforsometime.Duringventingahissingsoundmaybeheard.Thefrequency
anddurationofthisventingwillvarydependingontankpressureandambient
temperature.Itwillcontinuetoventuntilthetruckisoperatedagain,therebydropping
thepressure,oruntilthetank(s)isempty.
PrimaryLNGTankVentPiping
Fromthefactory,theventpipingfromtheprimaryLNGtankventsisattachedtothe
intakestackbydisposableplasticstraps.Thepipingshouldberemovedfromthe
intakestackandplumbedupandoverthebodybythebodyinstallersasshownin
thefollowingillustration.Formoreinformation,seethesectiontitled"LNGTank
PressureV ents"intheOPERATIONsectionofthismanual.
CAUTION
Itisimportanttokeeptheprimary
pressureventfreeofblockagedueto
ice,snowordebris.

SafetyInformation5
C0032249

6SafetyInformation
MethaneLeaks
Duringthedailywalkaround,inspecttheoutsideoftheLNGfueltankforfrost.
FrostedLNGtank(s),otherthanattheshroudarea*,indicatesthattheinnertank
isleakingintotheoutertank.Theappearanceofavaporcloudaccompaniedbya
hissingnoisemayalsoindicateamethaneleak.Aleakrequiresserviceonthetank(s)
beforethevehiclecanbeoperated.
*Rearfueltankdoorandplumbingxtures.
WARNING
Donotoperateavehiclewhichhasa
methaneleak.
RapidPressureRise
TherearethreemaincausesofrapidpressureriseonLNGsystems;overlling,fuel
systemleaksormalfunctionsandlossofvacuum.Aproperlyfunctioning,properly
lledLNGfuelsystemshouldbuildlessthan15psig/day.Anysystembuildingmore
than40psig/dayneedstroubleshootingtondthecause.
VacuumLoss
TotalvacuumlossisanunusualeventforanLNGtank(resultinginfrostingtheentire
shell),howeverthevacuumwillslowlydecaywithtimeasgassesdiffuseoutof
thetankmaterials.Thiswillshowupovertimeasamorerapidpressurerisetime,
eventuallyexceeding40psig/day.Oncethevacuumhasdecayedtothispoint,the
tankwillneedtobere-evacuatedbyacompetentmaintenancefacility.

SafetyInformation7
METHANEDETECTOR/ALARMSYSTEM
Note:Thefollowinginformationappliestoequipmentlocatedonthevehicle
only.Separatemethanedetector/alarmsystemsshouldbeinstalledinfacilitiesthat
frequentlyhousenaturalgasvehicles.Inaddition,hand-heldmethanedetector/alarm
devicesshouldbeusedwhenworkingonnaturalgasvehicleswithnon-functioning
ordisconnectedmethanedetector/alarmsystemsandwherenoauxiliarymethane
detector/alarmsystemisinstalled.
Note:Consultyourlocalrecodeand/or
reinspectortomakesuethatadequate
detectionandpreventionmeasuresarein
place.
Themethanevapordetectionsystemutilizestwosensorstoidentifymethanevapors;
onelocatedinthecabcompartmentandonelocatedintheenginecompartmentof
thevehicle.Thesystemoperateswithbothavisualandanaudiblealarmtowarn
theoperatorofpotentialdanger.Thealarmsaretriggeredattracelevels(20%LEL
[LowerExplosiveLimit])andatsignicantlevels(50%LEL)ofvaporconcentration.
Thesystemandsensoroperationisconstantlymonitored.Aninternalrelaycontrols
twoindicatorlamps(1greenand1red)thatcanbeseenthroughthewindshield.The
greenlampwillgooutandtheredlampwillilluminate15secondsafterasignicant
levelofmethanehasbeendetected.Themethanedetectoralsohasapassto-test
buttonthatcanbeusedtotesttheindicatorlampsandtheaudiblealarm.

8SafetyInformation
BeforeEnteringtheVehicle
Greenandredmethanedetectorremoteindicatorlampsareeasilyviewedthrough
thewindshieldandshouldalwaysbecheckedbeforeenteringthevehicle.(See
illustration.)
W0059509

SafetyInformation9
DANGER
WHENAPPROACHINGTHECAB
TOENTER:Donotopenthevehicle
doorsiftheREDLAMPISON!Donot
openthevehicledoorsiftheALARM
ISSOUNDING!Donotopenthe
vehicledoorsiftheGREENLAMP
isNOTON!Iftheindicatorlampis
red,ifthealarmissoundingorifthe
greenlampisNOTON,itisunsafeto
openthevehicledoorsbecauseeven
staticelectricitycanigniteconcentrated
methanefumesinanenclosedarea.
Immediatelyimplementthefollowing
procedure:*Removeallpersonnelfrom
thearea.Turnoffelectricalcircuitsand
sourcesofignitionintheimmediate
area.ManuallyturnofftheFuelShut-
OffV alveoneachfueltanktoprevent
furthergasleakage.Waituntilthegas
hasdissipatedandthealarmsituation
hascleared.Itisnowsafetoopenthe
vehicledoorsandwindowstoventthe
vehicle.Donotoperatethevehicleuntil
thesourceoftheleakhasbeenrepaired.
Note:Whenthebatteryisdisconnected,themethanedetector/alarmsystemwillnot
operatesothegreenlightswillnotbeon.Themethanedetector/alarmsystemis
poweredbythebatteryandisactiveatalltimesunlessthebatteryisdisconnectedor
thefuseisblown.
Hand-heldmethanedetector/alarmdevicesshouldbeusedwhenworkingonnatural
gasvehicleswithanonfunctionalordisconnectedmethanedetector/alarmsystemand
wherenoauxiliarymethanedetector/alarmsystemisinstalled.

10SafetyInformation
DANGER
Intheeventofanalarmwhileoperating
thevehicle,immediatelyopenthe
cabwindows,safelystopthevehicle,
shutdowntheengineandturnoffthe
ignition.Exitthecabandleavethe
doorsandwindowsopentoventthe
vehicle.ManuallyturnofftheFuel
Shut-OffV alveoneachfueltankto
preventfurthergasleakage.Waituntil
thegashasdissipatedandthealarm
situationhascleared.Donotoperate
thevehicleuntilthesourceoftheleak
hasbeenrepaired.
CAUTION
AMGaDSIIIPlusisapropane,CNG
(CompressedNaturalGas)andLNG
(LiquidNaturalGas)detectoronly.
However,becausethesensorsdetect
allhydrocarbonvapors,analarmmay
betriggeredbytheuseofchemicals
suchascleaners,paint,polish,lacquer,
etc.Donotexposesensorstoliquids
orchemicalsunnecessarily.When
usingsuchsubstances,keepthevehicle
wellventilatedanddonotallowdirect
contactwiththesensors.Forcleaning
andmaintenanceoftheGasDetection
System,refertotheAMGaDSIIIPlus
Owner’sManualsuppliedwiththe
vehicle.
Note:Foradditionalinformation,refertoandintheINSTRUMENTSAND
CONTROLSsectionofthishandbook.

SafetyInformation11
PotentialHazardAssociateswithLNG/CNG:
Skin/Eyes
LNGisstoredatcryogenictemperatures(low-temperaturestate,startsatorbelow
-240°F(about-150°C)andCNGisstoredinspeciallydesignedtanksunder
extremelyhighpressure.Therefore,properlyinsulatedsafetyglovesandeye
protectionsuchasgogglesorafaceshieldshouldbewornwhenworkingwithor
aroundLNG/CNGaswhenrefueling.Ifsuper-cooledliquidorgascomesintocontact
withtheskinoreyes,seeaphysicianimmediately.
WARNING
COVEREYESANDEXPOSEDSKIN.Accidentalcontactoftheeyesorskin
withLNGmaycauseafreezinginjurysimilartoaburn.Protecttheeyesand
covertheskinwheneverthepossibilityofcontactwithsuper-coldmetals,liquids
orgasexists.

12SafetyInformation
Inhalation
LNG/CNGisnottoxic,butcancauseasphyxiationinconcentrationorinenclosed
areasbecauseitreducestheoxygenavailableforbreathing.Forthisreason,methane
detectorsarelocatedintheenginecompartmentandinsidethecab.Thesedetectors
willtriggeranalarminsidethecabifmethaneconcentrationgoesaboveasafelevel.
Thesedetectorsarealwaysactivewhetherthevehicleisonoroff,aslongasthebattery
isconnectedandthefuseisinplaceandnotblown.Ifovercomebyvapor,removethe
individualfromexposureandcallaphysicianimmediately.Ifbreathingisirregularor
hasstopped,startresuscitation(iftrainedinCPR)andadministeroxygenifavailable.
DANGER
KEEPTHEEQUIPMENTAREA
WELLVENTILATED.Although
LNG/CNGisnon-toxic,itcancause
asphyxiationinaconnedareawithout
ventilation.Anyatmospherethatdoes
notcontainenoughoxygenforbreathing
cancausedizziness,unconsciousness,
orevendeath.LNG,beingcolorless,
odorlessandtasteless,cannotbe
detectedbyhumansenses.Eventhough
CNGissulfurized,thesmellmay
gounnoticedonsomevehicles,such
asarefusetruck.Withoutadequate
ventilation,naturalgaswilldisplace
theoxygenandgivenowarningthat
anon-lifesupportingatmosphereis
present.StoreLNG/CNGinawell
ventilatedarea.
IfvehiclesequippedwithanLNGenginemustbeparkedorworkedonindoorsfor
shortperiodsoftime,pipingfromtheprimaryLNGtankventpipetotheoutsideof
thebuildingshouldbeprovided.See"PrimaryLNGTankV entPiping"attheendof
theSAFETYsection.De-fuelingorremovaloftheLNGtank(s)isrecommendedfor
vehiclesstoredindoorsforlongperiodsoftime.
Separatemethanedetector/alarmsystemsshouldbeinstalledinfacilitiesthat
frequentlyhouseLNG/CNGvehicles,consultlocalcodesandordinancestoensure
compliance.Inaddition,handheldmethanedetector/alarmdevicesshouldbeused
whenworkingonLNG/CNGvehicleswithnon-functioningordisconnectedmethane
detector/alarmsystemandwherenoauxiliarymethanedetector/alarmsystemis
installed.
Note:DuetothecryogenicstateofLNGfuel,itcannotbeodorized,therefore,itwill
notsmelllikeCNGorpipelinegasinahome.

SafetyInformation13
Flammability
SinceLNGisextremelyammable,thetank(s)shouldbegroundedwhenfueling,to
avoidcreatingsparksfromstaticelectricity.Keepanysourceofignition,suchasalit
cigarette,farawayfromLNG/CNGtanksandfuelingareas.
WARNING
KEEPAWAYFROMFLAMEOR
SPARK.
Naturalgasisammable.Smoking,
openames,andgeneralpurpose
electricalequipmentshallbeprohibited
wherenaturalgasisstoredorhandled.
Pressure
TheLNG/CNGfuelsystemsarepressurizedsystems.Therefore,automaticand
manualsafetyvents,reliefvalvesandshutoffpointsareinstalledthroughoutthe
systemtopreventexcesspressurefrombuilding.
WARNING
REMOVEPRESSURE.Alwaysempty
theLNG/CNGfueltank(s)andremove
anypressureonthesystempriorto
removingpartsorcomponentsofthe
tankforrepair.
ReleasesorSpills
Duringareleaseorspill,shutoffandeliminateallignitionsources.Ifdesired,stop
thesourceofthereleaseorspill.Keeppeopleaway.Minimizebreathingvapors.
Absolutelyavoidskincontact.Ventilateconnedspaces.Nodisposalmethodis
necessary,norshoulditbeattempted,becauseextremelyrapidevaporationofthe
naturalgaswilltakeplace.Ifaspillisindangerofigniting,useawaterspray(donot
usesolidstreamsofwater)todirectgas-airmixturesawayfromignitionsources
Ifaspillhasignited,usewatertokeepre-exposedcontainersandequipmentcool
andtoprotectpersonnelwhomayhavetostopthesourceoftheleak.Ifitisdesirable
toextinguishthere,usedrychemical,carbondioxideorhalogenatedextinguishing
agents.

14SafetyInformation
SPECIFICSAFETYINFORMATIONREGARDINGTHEINSTRUMENTS
ANDCONTROLS,THEOPERATION,ANDTHEMAINTENANCEOFTHE
CHASSISWILLBECOVEREDINYOUROPERATOR’SHANDBOOK.
CabEntry/Exit
AsdescribedinyourOperator’sHandbook,followtheThree-LimbContactRule
toenterandexityourvehicle.
DANGER
Beforeopeningeithervehicledoor,
alwayslookthroughthedriverside
windowatthemethanealarmbox
locatedoninstrumentpanel(MRU
andLEU).DoNOTopenthedoorifa
redalarmlightisonorifyouhearthe
audiblealarmsounding.DoNOTopen
thedoorifthegreenlightisnotON.

INSTRUMENTSANDCONTROLS15
CABINTERIOR
Belowyouwillseehowthemethanedetector/alarmsystemisarrangedonatypical
LEUinstrumentpanel:(Theexactlayoutmaydifferfromyourtruck,butthegas
detectionsystemwilllookthesame.)
W0059510
1.GasDetectionSystem—Seebelowfordetaileddisplayinformation

16INSTRUMENTSANDCONTROLS
C0032252
1.PowerOnIndicator(Green)6.RelayOn/OffIndicator
2.SignicantAlarmIndicators(Red)7.RelayResetButton
3.TraceSensorAlarmIndicators
(Amber)
8.SystemTestButton
4.AudibleAlarmSilenceButton9.SensorFaultIndicators
5.AlarmSilencedIndicator