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
No.
Release
258
772
01
25 Remove the combustion air inlet pipe elbow fitting from the combustion module.
Note: Mark the position of the combustion air inlet pipe elbow for installation on the
new combustion module.
W2071601
26 Unpack the replacement DPF combustion module (21797816).
27 Clean the exhaust pipe mounting surfaces and the DPF filter sealing surface.
28 Transfer the position markings from the old combustion module to the new combustion
module.
29 Apply thread sealant to the air inlet pipe elbow.
30 Install the combustion air inlet pipe elbow fitting in the same position.
W2071601
Page
11(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
31 Using a new sealing gasket (21048677), install the fuel nozzle into the replacement
DPF combustion module.
W2071602
32 Position the replacement DPF combustion module into DPF support stand (85111327).
W2071603
Page
12(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
33 Using a new gasket (21424458), install the DPF filter on top of the DPF combustion
module.
W2071598
34 Install a new V-band clamp (21048521) and tighten to 20 ± 3 Nm (180 ± 24 in-lb).
Note: Use alignment indicator to aid in the proper alignment of the DPF modules and
V-band clamp.
W2071597
Page
13(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
35 Install the DPF wiring harness raceway bracket with the wiring and sensors attached.
W2071596
36 Install the DPF temperature sensors.
W2071595
Page
14(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
37 Install the NOX sensor into the DPF outlet.
W2071594
38 Assemble and Tighten the differential pressure sensor pipe fittings to the DPF assembly.
W2071593
Page
15(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
39 Connect the hoist to the DPF assembly. Using help as needed, position the DPF assembly
on the exhaust aftertreatment system rack. Install the DPF band clamps and clevis pins.
Note: Use the DPF heat shield as a guide for the alignment of the DPF and V-band
clamps.
40 Tighten DPF mounting straps to 44 ± 4 Nm (33 ± 3 ft-lb).
W2071591
41 Remove hoist.
42 Install DPF burner temperature sensor and module.
W2071590
Page
16(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
43 Install raceway cover and tighten fasteners to 10 ± 1.5 Nm (14 ± 2 in-lb).
W2071589
44 Connect the DPF combustion airline to the combustion air valve and combustion air
inlet pipe elbow fitting
Note: Apply thread sealant to air line end connecting the air inlet pipe elbow fitting.
.
W2071588
Page
17(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
45 Install the DPF igniters.
W2071587
46 Install the igniter plug wires.
W2071586
47 Connect and hand tighten the DPF fuel line to the atomization module and burner nozzle.
48 Using a wrench, tighten fuel line connections one 3/4 turn.
W2071585
Page
18(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
49 Connect the main body harness connector to the DPF assembly.
W2071584
50 Install new gaskets (21095726) on DPF inlet and outlets. Install new V-band clamps
(21021850) and tighten to 81 ± 0.5 Nm (60 ± 5 in-lb).
W2071583
Page
19(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
51 Install DPF heat shield and tighten fasteners to 24 ± 4 Nm (18 ± 3 ft-lb)
W2071582
52 Reconnect all previously removed cables to the negative (ground) battery terminals.
53 Lower cab
54 Check for proper operation, Check for leaks, and Clear DTC's.
Note: To signify that the campaign has been completed, using a permanent-type marker
(such as a Sharpie®) to write the campaign number (PI0772) and completion date in the
spaces provided on the Campaign Completion label located inside the cab as shown in the
illustration below. If a label is not already affixed inside the cab, apply a label (part No.
TS897) and supply the information as required. Campaign Completion labels are available
in packs of 50 and can be ordered by faxing a completed BR313 to Pacesetters Business
Services at 610-264- 9465.
W0037061
Page
20(21)
Mack Trucks, Inc.
Service Program
Date
5.2012
Group
No.
Release
258
772
01
Reimbursement
This repair is covered by an authorized Service Program. Reimbursement is
obtained via the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
B
Recall Status
Vehicle inspected, repair not required
1- Inspected OK
Vehicle repaired per instruction
2- Modified per
instruction
Labor Code
Primary Labor Code
2351T-26-96
1.7 hrs.
Time to take charge and determine campaign status
101AA–0A–00
0.3 hrs.
Causal Part
21707560
Authorization Number
PI0772
Expiration Date
10 NOV 2012
Note: Take Charge Time is not included in the Labor Code for this operation. Take charge
may be eligible but can only be used once per repair visit. If vehicle is having other warranty
repairs performed, take charge should be charged to the warranty repair, otherwise take
charge can be charged to this service program.
Page
21(21)
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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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