NHTSA ID Number: 10044333
Manufacturer Communication Number: PI-0772
TSB/Document Date: 2012-06-13
Summary
MACK
: ON CERTAIN TRUCK CHASSIS, DUE TO A POTENTIAL CRACKING FROM THERMAL EXPANSION, THE AFTERTREATMENT DPF (DIESEL PARTICULATE FILTER) COMBUSTION MODULES ARE BEING REPLACED. MODELS LEU, MRU, MP7. MODEL YEAR 2010. *PE
Service Program
Trucks
Mack Trucks, Inc.
Greensboro, NC USA
Date
Group
No.
Release
Page
5.2012
258
772
01
1(21)
Aftertreatment DPF Combustion Housing
SB-10044333-9095
LEU, MRU
MP7
PI0772, Aftertreatment DPF Combustion Housing
(May 2012)
Campaign PI0772 is available for the replacement of the Aftertreatment DPF (Diesel
Particulate Filter) combustion modules on certain Mack LEU and MRU chassis built between
August 9, 2010 and September 29, 2010. The affected combustion modules have the
potential of cracking from thermal expansion during the Regeneration process. The housing
improvements includes an improved welding process, and new base material with a greater
wall thickness which will prevent issues with fatigue of the base material and welds in the
combustion housing.
Note: This bulletin does not apply to MACK Trucks Australia.
W2071581
Aftertreatment DPF Combustion Housing Kit 21797818
PV729-PI0772
Item
Qty
Part Number
Description
1
1
21048521
V-Band Clamp
2
1
21424458
DPF Body Gasket
3
1
21797816
Combustion Module
USA51544
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
Procedure
You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing this procedure. If you
are not properly trained and certified in this procedure, ask your supervisor for training
before you perform it.
1 Apply parking brake and place shift lever in neutral.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Remove Diesel Particulate Filter (DPF) heat shield.
W2071582
4 Remove DPF inlet and DPF outlet V-band clamps. Discard old V-band clamps.
Page
2(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
W2071583
5 Disconnect the main body harness connector from the DPF.
W2071584
6 Disconnect DPF burner fuel line from the atomization module and burner nozzle.
W2071585
Page
3(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
7 Remove the igniter plug wires.
W2071586
8 Remove the DPF igniters.
W2071587
9 Disconnect the DPF combustion air line from the combustion air valve and the combustion
air inlet pipe elbow.
W2071588
Page
4(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
10 Remove fasteners securing DPF wiring harness raceway cover and position cover out of
the way.
W2071589
11 Remove DPF burner temperature sensor and module from the bottom of the DPF and
position out of the way.
CAUTION
To prevent damage to the DPF temperature sensor, do not bend sensor element during
removal.
W2071590
Page
5(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
12 Position hoist over DPF and secure.
13 Raise hoist to support the weight of the DPF.
14 Remove the DPF strap fasteners and clevis pins.
15 Remove DPF straps.
W2071591
16 Using help as needed lift DPF and swing away from the exhaust aftertreatment system
rack. Place DPF in a secure location using support stand (85111327) prior to removing
the hoist.
W2071592
Page
6(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
17 Loosen the differential pressure sensor pipe fittings from the DPF.
W2071593
18 Remove the NOX sensor from the DPF outlet and position out of the way.
W2071594
Page
7(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
19 Remove the DPF inlet and outlet temperature sensors and position out of the way.
W2071595
20 Remove the DPF wiring harness raceway bracket with the wiring and sensors attached.
W2071596
Page
8(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
21 Remove the DPF V-band clamp between the DPF burner and DPF filter. Discard old
V-band clamp.
Note: Note the location of the alignment indicator on the DPF filter for proper V-band
clamp orientation during installation.
W2071597
22 Separate the DPF filter from the DPF combustion module and place filter in a secure
location.
Note: Discard old gasket.
W2071598
Page
9(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
23 Remove the old DPF combustion module from the DPF support stand (85111327) and
position it on its side.
W2071599
24 Remove the fuel nozzle from the old DPF combustion module.
W2071600
Page
10(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
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TSB/Document ID: PI-0772
Replacement Service Bulletin Number:
MFR Communication Date: 2012-05-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
MFR Component System:
MFR Component Subsystem:
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