FSB-258-032
Service Bulletin Details
Public Details for: FSB-258-032
Mack: the aftertreatment diesel exhaust fluid (def) tank filler neck is being replaced with an improved filler neck . *pe updated 5/11/12. *pe
Models from 2012
| 2012 MACK GRANITE (GU) |
| 2012 MACK LEU |
| 2012 MACK MRU |
| 2012 MACK PINNACLE (CHU) |
| 2012 MACK PINNACLE (CXU) |
| 2012 MACK TD |
Models from 2011
| 2011 MACK GU |
| 2011 MACK LEU |
| 2011 MACK MRU |
| 2011 MACK PINNACLE (CHU) |
| 2011 MACK PINNACLE (CXU) |
Models from 2010
| 2010 MACK CHU |
| 2010 MACK CXU |
| 2010 MACK GU |
| 2010 MACK LEU |
| 2010 MACK MRU |
| 2010 MACK TERRAPRO (MRU) |
Field Service Bulletin Trucks Mack Trucks, Inc. Greensboro, NC USA SB-10044078-3166 Date Group No. Release Page 3.2012 258 032 01 1(14) Aftertreatment Diesel Exhaust Fluid (DEF) Filler Neck, Replacement CHU, CXU, GU, TD, LEU, MRU FSB 258-032, Aftertreatment Diesel Exhaust Fluid (DEF) Tank Filler Neck, Replacement March 2012 MACK Trucks North America has identified an issue with the Diesel Exhaust Fluid (DEF) tank filler neck inlet falling into the bottom of DEF tanks on CHU, CXU, GU, TD, LEU, and MRU trucks equipped with an aftertreatment system. The truck operator is unable to fill the DEF tank with the magnetic filler neck filter and inlet in the bottom of the tank. The magnetic filler neck filter activates the DEF pump when the pump nozzle is inserted in the filler neck of the DEF tank. Two tank filler neck setups are currently available on the affected trucks. A kit is available for replacement of the snap neck filler inlet containing an assembled snap neck inlet with the inner portion and a replacement o-ring. The parts are fixed together with a stainless steel rivet to prevent the filler neck inlet from falling into the DEF tank. A replacement tank with an improved filler neck is available for replacing an entire welded neck filler tank. Note: This bulletin does not apply to MACK Trucks Australia. W2072068 Aftertreatment DEF Filler Neck Components Item Qty Part Descriptions 1 1 Filler Neck Filter, Magnetic 2 1 Assembled Snap Neck Filler Inlet With Inner Portion of Filler Neck 3 1 Stainless Steel Rivet 4 1 O-Ring 5 1 DEF Fluid Tank with Welded Filler Neck 6 1 Old Filler Neck Snap Ring 7 1 Old Inner Portion of Filler Neck PV729-FSB258-032 _M USA52593 Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Required Parts Note: Welded filler neck tanks are replaced instead of repaired. Note: Welded neck tank kits include the new inlet assembly and filler neck filter. Aftertreatment DEF Filler Neck Inlet and Tank Replacement Kits Old DEF Tank Inlet Type New DEF Tank Kit New Inlet Kit Filter 21203885 Welded Neck 21839950 N/A N/A 21332138 Snap Neck N/A 21840784 82269261 21332143 Snap Neck N/A 21840786 82269261 21332145 Welded Neck 21839994 N/A N/A 21332147 Snap Neck N/A 21840786 82269261 21339786 Welded Neck 21840002 N/A N/A 21539608 Welded Neck 21840005 N/A N/A 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 Raise hood, if applicable. 2 Remove the side fairing, if applicable. 3 Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and prevent damage to electrical components. 4 Use coolant extractor/injector 85112740 to drain coolant from cooling system. 5 Remove the DEF filler cap. W2072055 Page 2(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 6 Remove drain plug from DEF tank and drain DEF fluid into a container. W2072056 7 Cut the lock windows with side cutters, and remove the filler neck. Note: Step 7 does not apply to DEF tanks with the welded filler neck. W2072057 Page 3(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 8 Disconnect harness from Aftertreatment Control Module (ACM). Cover harness connector with a plastic bag to protect connector. W2072058 9 Disconnect harness from DEF pump. Cover harness connector with a plastic bag to protect connector. W2072059 Page 4(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 10 Place container under tank to catch any additional DEF fluid and/or coolant leakage. 11 Disconnect DEF lines from DEF pump. W2072060 12 Disconnect coolant lines from DEF pump. Note: See steps 13 through 15 for removing a frame mounted DEF tank. After completion of step 15, skip to step 21. W2072061 13 Remove DEF tank mounting fasteners from bracket bolts. 14 Position floor jack under DEF tank to support the weight of the tank. 15 Remove bolts from mounting bracket and remove DEF tank. Note: See steps 16 through 20 for removing a fuel tank mounted (integrated) DEF tank. After completion of step 20, continue on with step 21. Page 5(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 16 Remove inner fender (front left side). 17 Remove left side inner fender lower mounting bracket. 18 Remove pump and bracket assembly. Tie pump and bracket assembly out of the way. 19 Remove DEF tank mounting fasteners. 20 Remove DEF tank. 21 Remove DEF lines from level sensor. Note: Mark the positions of lines before removal. The lines are different sizes. W2072062 22 Remove coolant lines from the level sensor. W2072063 Page 6(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 23 Disconnect level sensor harness. Cover harness connector with a plastic bag to protect connector. W2072064 24 Loosen clamp and remove level sensor. Note: Skip to step 27 for complete tank replacement of a welded neck DEF tank. See table on page 1 for the appropriate replacement tank part number. W2072065 25 Remove the broken section of the filler neck and filler neck filter from the DEF tank through the filler neck opening. Remove filler neck filter from filler neck. Inspect filler neck filter and store for repair of an existing DEF tank if deemed reusable. Note: Use the level sensor opening to help locate and remove the broken filler neck inlet section. Note: Step 25 applies to repair of existing DEF tanks equipped with snap neck filler inlets. Page 7(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Note: If filler neck filter is damaged, replace filter with a new one. See the table on page 2 for the appropriate filter part number. Note: See step 26 for installing the snap neck filler inlet. W2072066 26 Install new snap neck filler inlet, new O-ring, and filler neck filter on existing DEF tank. Note: Follow steps 27 through 30 for installation of frame mounted DEF tanks. W2072067 Page 8(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 27 Install level sensor on DEF tank and tighten clamp to 5 + 0.5 Nm (44 + 4 in-lb). W2072065 28 Connect level sensor harness. W2072064 29 Use a floor jack to position and install DEF tank in brackets. Loosely install bolts and fasteners. Lower and remove floor jack. 30 Torque all tank mounting fasteners to 85 ± 15 Nm (63 ± 11 ft-lb). Note: Follow steps 31 through 35 for fuel tank mounted (integrated) DEF tanks. 31 Install level sensor on DEF tank and tighten clamp to 5 + 0.5 Nm (44 + 4 in-lb). 32 Use a floor jack to position and align mounting fasteners with holes. Loosely install bolts and fasteners. Lower and remove floor jack. 33 Connect level sensor harness. Page 9(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 34 Torque all tank mounting fasteners to 85 ± 15 Nm (63 ± 11 ft-lb). 35 Install DEF pump bracket. Note: Steps 36 through 50 apply to frame mounted and Fuel tank mounted (integrated) DEF tank installation. 36 Connect coolant lines to the level sensor. W2072063 37 Connect DEF lines to the level sensor. W2072062 Page 10(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 38 Connect coolant lines to DEF pump. W2072061 39 Connect DEF lines to DEF pump. W2072060 Page 11(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 40 Connect electrical harness to DEF pump and secure harness as needed. W2072059 41 Connect electrical harness to ACM and secure harness as needed. W2072058 Page 12(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 42 Install DEF tank drain plug and ensure drain plug is torqued to 48 ± 8 Nm (35 ± 6 ft-lb). W2072056 43 Fill DEF tank with DEF fluid. 44 Install the DEF filler neck cap. W2072055 45 Use coolant extractor/injector 85112740 to fill cooling system. 46 Reconnect all previously removed cables to the negative (ground) battery terminals. 47 If applicable, install inner fender lower mounting bracket and torque fasteners to specification. 48 If applicable, install inner fender (left front). 49 Install and secure the side fairing, if applicable. 50 Start engine, check for proper operation and check for leaks. Page 13(14) Mack Trucks, Inc. Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Reimbursement This repair may be eligible for reimbursement if a product failure was experienced within time and mileage limits of the applicable Warranty coverage. Reimbursement is obtained via the normal claim handling process. Claim Type (used only when uploading from the Dealer Bus. Sys.) W Labor Code Primary Labor Code Frame Mounted DEF Tanks 2352H-42–80 2.0 hrs. Primary Labor Code Fuel Tank Mounted DEF Tanks (Integrated) 2352J-42–80 1.8 hrs. Causal Part 21332138 MACK Trucks Inc. engages in a continuous program of testing and evaluating to provide the best possible product. MACK Trucks Inc., however, is not committed to, or liable for updating existing chassis. Page 14(14) SB-10044078-4903 Volvo Trucks North America Greensboro, NC USA Field Service Bulletin Trucks Date Group No. Release Page 3.2012 258 032 01 1(14) Aftertreatment Diesel Exhaust Fluid (DEF) Filler Neck, Replacement VN, VHD, VT, VAH FSB 258-032, Aftertreatment Diesel Exhaust Fluid (DEF) Tank Filler Neck, Replacement March 2012 VOLVO Trucks North America has identified an issue with the Diesel Exhaust Fluid (DEF) tank filler neck inlet falling into the bottom of DEF tanks on VN, VHD, VT, and VAH trucks equipped with an aftertreatment system. The truck operator is unable to fill the DEF tank with the magnetic filler neck filter and inlet in the bottom of the tank. The magnetic filler neck filter activates the DEF pump when the pump nozzle is inserted in the filler neck of the DEF tank. Two tank filler neck setups are currently available on the affected trucks. A kit is available for replacement of the snap neck filler inlet containing an assembled snap neck inlet with the inner portion and a replacement o-ring. The parts are fixed together with a stainless steel rivet to prevent the filler neck inlet from falling into the DEF tank. A replacement tank with an improved filler neck is available for replacing an entire welded neck filler tank. W2072068 Aftertreatment DEF Filler Neck Components Item Qty Part Descriptions 1 1 Filler Neck Filter, Magnetic 2 1 Assembled Snap Neck Filler Inlet With Inner Portion of Filler Neck 3 1 Stainless Steel Rivet 4 1 O-Ring 5 1 DEF Fluid Tank with Welded Filler Neck 6 1 Old Filler Neck Snap Ring 7 1 Old Inner Portion of Filler Neck PV729-FSB258-032_V USA52408 Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Required Parts Note: Welded filler neck tanks are replaced instead of repaired. Note: Welded neck tank kits include the new inlet assembly and filler neck filter. Aftertreatment DEF Filler Neck Inlet and Tank Replacement Kits Old DEF Tank Inlet Type New DEF Tank Kit New Inlet Kit Filter 21203885 Welded Neck 21839950 N/A N/A 21279977 Welded Neck 21839953 N/A N/A 21332133 Snap Neck N/A 21840783 82269261 21332136 Snap Neck N/A 21840783 82269261 21332138 Snap Neck N/A 21840784 82269261 21332143 Snap Neck N/A 21840786 82269261 21332147 Snap Neck N/A 21840786 82269261 21539608 Welded Neck 21840005 N/A N/A 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 Raise hood, if applicable. 2 Remove the side fairing, if applicable. 3 Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and prevent damage to electrical components. 4 Use coolant extractor/injector 85112740 to drain coolant from cooling system. 5 Remove the DEF filler cap. W2072055 Page 2(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 6 Remove drain plug from DEF tank and drain DEF fluid into a container. W2072056 7 Cut the lock windows with side cutters, and remove the filler neck. Note: Step 7 does not apply to DEF tanks with the welded filler neck. W2072057 Page 3(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 8 Disconnect harness from Aftertreatment Control Module (ACM). Cover harness connector with a plastic bag to protect connector. W2072058 9 Disconnect harness from DEF pump. Cover harness connector with a plastic bag to protect connector. W2072059 Page 4(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 10 Place container under tank to catch any additional DEF fluid and/or coolant leakage. 11 Disconnect DEF lines from DEF pump. W2072060 12 Disconnect coolant lines from DEF pump. Note: See steps 13 through 15 for removing a frame mounted DEF tank. After completion of step 15, skip to step 21. W2072061 13 Remove DEF tank mounting fasteners from bracket bolts. 14 Position floor jack under DEF tank to support the weight of the tank. 15 Remove bolts from mounting bracket and remove DEF tank. Note: See steps 16 through 20 for removing a fuel tank mounted (integrated) DEF tank. After completion of step 20, continue on with step 21. Page 5(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 16 Remove inner fender (front left side). 17 Remove left side inner fender lower mounting bracket. 18 Remove pump and bracket assembly. Tie pump and bracket assembly out of the way. 19 Remove DEF tank mounting fasteners. 20 Remove DEF tank. 21 Remove DEF lines from level sensor. Note: Mark the positions of lines before removal. The lines are different sizes. W2072062 22 Remove coolant lines from the level sensor. W2072063 Page 6(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 23 Disconnect level sensor harness. Cover harness connector with a plastic bag to protect connector. W2072064 24 Loosen clamp and remove level sensor. Note: Skip to step 27 for complete tank replacement of a welded neck DEF tank. See table on page 1 for the appropriate replacement tank part number. W2072065 25 Remove the broken section of the filler neck and filler neck filter from the DEF tank through the filler neck opening. Remove filler neck filter from filler neck. Inspect filler neck filter and store for repair of an existing DEF tank if deemed reusable. Note: Use the level sensor opening to help locate and remove the broken filler neck inlet section. Note: Step 25 applies to repair of existing DEF tanks equipped with snap neck filler inlets. Page 7(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Note: If filler neck filter is damaged, replace filter with a new one. See the table on page 2 for the appropriate filter part number. Note: See step 26 for installing the snap neck filler inlet. W2072066 26 Install new snap neck filler inlet, new O-ring, and filler neck filter on existing DEF tank. Note: Follow steps 27 through 30 for installation of frame mounted DEF tanks. W2072067 Page 8(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 27 Install level sensor on DEF tank and tighten clamp to 5 + 0.5 Nm (44 + 4 in-lb). W2072065 28 Connect level sensor harness. W2072064 29 Use a floor jack to position and install DEF tank in brackets. Loosely install bolts and fasteners. Lower and remove floor jack. 30 Torque all tank mounting fasteners to 85 ± 15 Nm (63 ± 11 ft-lb). Note: Follow steps 31 through 35 for fuel tank mounted (integrated) DEF tanks. 31 Install level sensor on DEF tank and tighten clamp to 5 + 0.5 Nm (44 + 4 in-lb). 32 Use a floor jack to position and align mounting fasteners with holes. Loosely install bolts and fasteners. Lower and remove floor jack. 33 Connect level sensor harness. Page 9(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 34 Torque all tank mounting fasteners to specification 85 ± 15 Nm (63 ± 11 ft-lb). 35 Install DEF pump bracket. Note: Steps 36 through 50 apply to frame mounted and fuel tank mounted (integrated) DEF tank installation. 36 Connect coolant lines to the level sensor. W2072063 37 Connect DEF lines to the level sensor. W2072062 Page 10(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 38 Connect coolant lines to DEF pump. W2072061 39 Connect DEF lines to DEF pump. W2072060 Page 11(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 40 Connect electrical harness to DEF pump and secure harness as needed. W2072059 41 Connect electrical harness to ACM and secure harness as needed. W2072058 Page 12(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 42 Install DEF tank drain plug and ensure drain plug is torqued to 48 ± 8 Nm (35 ± 6 ft-lb). W2072056 43 Fill DEF tank with DEF fluid. 44 Install the DEF filler neck cap. W2072055 45 Use coolant extractor/injector 85112740 to fill cooling system. 46 Reconnect all previously removed cables to the negative (ground) battery terminals. 47 If Applicable, install inner fender lower mounting bracket and torque fasteners to specification. 48 If applicable, install inner fender (left front). 49 Install and secure the side fairing, if applicable. 50 Start engine, check for proper operation and check for leaks. Page 13(14) Volvo Trucks North America Field Service Bulletin Date 3.2012 Group No. Release 258 032 01 Reimbursement This repair may be eligible for reimbursement if a product failure was experienced within time and mileage limits of the applicable Warranty coverage. Reimbursement is obtained via the normal claim handling process. Claim Type (used only when uploading from the Dealer Bus. Sys.) W Labor Code Primary Labor Code Frame Mounted DEF Tanks 25813-0–01 2.0 hrs. Primary Labor Code Fuel Tank Mounted DEF Tanks (Integrated) 25813-0–02 1.8 hrs. Causal Part 21332138 VOLVO Trucks Inc. engages in a continuous program of testing and evaluating to provide the best possible product. VOLVO Trucks Inc., however, is not committed to, or liable for updating existing chassis. Page 14(14)