NHTSA ID Number: 10045821
Manufacturer Communication Number: PI-0795
TSB/Document Date: 2012-09-18
Summary
MACK TRUCK
: AFTERTREATMENT DIESEL PARTICULATE FILTER (DPF) INLET PIPE MAY POSSIBLY EXHIBIT AN EXHAUST LEAK. TO IMPROVE SEALING FUNCTION OF DPF INLET PIPE, THE DPF INLET PIPE FLANGE WAS MODIFIED. MODEL GU. MODEL YEARS 2011-12. *PE
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TSB/Document ID: PI-0795
Replacement Service Bulletin Number:
MFR Communication Date: 2012-08-01
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:
Previous TSB | Next TSB |
SB-10045821-1548
S ervic e P rogram
Tr u c k s
M a c k Tr u c k s , I n c .
Greensboro, NC USA
Date
Group
No.
Release
Page
8.2012
258
795
01
1(10)
Aftertreatment Diesel Particulate Filter (DPF)
Inlet Pipe
GU
Cummins ISL
P I0 7 9 5 , A fte rtre a tme n t D ie s e l P a rti c u la te Fi lte r
(DP F) Inlet Pipe
August 2012
Certain Mack GU trucks with the Cummins ISL engine built from 8-25-2011 to 4-11-2012 may
exhibit an exhaust leak at the Aftertreatment Diesel Particulate Filter (DPF) inlet pipe. The
DPF inlet pipe flange has been modified to improve the sealing function of the DPF inlet pipe.
Trucks built between these dates should replace the DPF inlet pipe (21534291) with new inlet
pipe (21921104). New gaskets are installed on both ends of the new DPF inlet pipe.
Additionally, a new v-band clamp (21601828) is required to complete the installation.
N o t e : This bulletin does not apply to MACK Trucks Australia.
W2076382
DPF Inlet Pipe Pa rts
P V 7 2 9 - PI0795
Item #
QTY
P art N umb er
Des cription
1
1
21921104
2
1
21601828
V-Band Clamp, DPF Inlet Pipe to DPF
3
1
21601830
Gasket (DPF Inlet)
4
1
21095721
Gasket (Flex Pipe)
5
1
N/A
V-Band Clamp to Flex Pipe, Existing
USA55078
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
P roc edu re
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 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all battery cables from the negative (ground) battery terminals to prevent
personal injury from electrical shock and prevent damage to electrical components.
3 Remove fasteners securing the DPF heat shield assembly.
W2076383
4 Remove DPF heat shield assembly.
W2076384
Page
2(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
5 Remove fasteners from inlet pipe heat shield and remove heat shield.
W2076385
6 Loosen DPF inlet pipe clamp fastener and remove clamp.
W2076386
Page
3(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
7 Remove DPF inlet pipe to DPF flex pipe clamp v-band clamp.
N o t e : Inspect the existing DPF inlet pipe to DPF flex pipe v-band clamp for damage.
Replace the clamp if damage is present. If no damage is present, store the clamp for
reuse.
W2076387
8 Remove DPF inlet pipe to DPF v-band clamp and discard.
N o t e : Do not reuse the v-band clamp to the DPF inlet.
W2076388
Page
4(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
9 Remove the DPF inlet pipe with gaskets and discard.
N o t e : Do not reuse old Gaskets.
W2076389
10 Clean sealing surfaces on DPF inlet and exhaust pipe from engine.
11 Position new gasket (Item 3, part number 21601830) on DPF inlet and (item 4, part
number 21095721) on flex pipe as shown in figure below.
W2076390
Page
5(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
12 Position new clamp (item 2, part number 21601828) on the DPF inlet.
N o t e : Do not tighten clamps at this time.
13 Position existing v-band clamp (Item 5) on flex pipe.
N o t e : Reuse the existing flex pipe v-band clamp.
N o t e : Do not tighten clamps at this time.
W2076391
14 Position new DPF inlet pipe (part number 21921104) to DPF inlet and flex pipe.
W2076392
Page
6(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
15 Tighten DPF inlet pipe to DPF v-band clamp (Item 2) 13 +2/-0 Nm (10 +1/-0 ft-lb).
16 Tighten DPF inlet pipe to DPF flex pipe v-band clamp (Item 5) 8 +2/-0 Nm (6 +1/-0 ft-lb).
W2076393
17 Install DPF inlet pipe clamp and tighten fastener to 24 ± 4 Nm (18 ± 3 ft-lb).
W2076386
Page
7(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
18 Position inlet pipe heat shield and tighten fasteners to 24 ± 4 Nm (18 ± 3 ft-lb).
W2076385
19 Install DPF heat shield assembly.
W2076394
Page
8(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
20 Install fasteners securing the DPF heat shield assembly and tighten fasteners to 24 ± 4
Nm (18 ± 3 ft-lb).
W2076383
21 Reconnect all previously removed cable to the negative (ground) battery terminals.
22 Start engine and check for leaks.
N o t e : To signify that the campaign has been completed, using a permanent-type marker
(such as a Sharpie®) to write the campaign number (PI0795) 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.
W8034103
Page
9(10)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
258
795
01
R ei mbu rs ement
Thi s repai r is c ov ered by an aut hori z ed S erv i c e P rogram. R ei mburs ement i s
obt ain ed throu gh the n ormal c l ai m hand li ng proc es s .
C l a i m Ty p e ( u s e d o n l y w h e n u p l o a d i n g f r o m t h e D e a l e r B u s . S y s . )
B
Rec all Sta tus
Vehicle inspected, repair not required
1- Inspected OK
Vehicle repaired per instruction
2- Modified per
instruction
Labor Code
Primary Labor Code
2344M-ZZ-96
0.7 hrs.
Time to take charge and determine campaign status
101AA–0A–00
0.3 hrs.
Caus al P art
21534291
A ut hori z at io n N umbe r
PI0795
Ex piration Date
28 AUG 2013
N o t e : 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
10(10)
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