PI-0796
Service Bulletin Details
Public Details for: PI-0796
Mack truck: information provided regarding modification of egr valve on engines and removal of poppet shaft end cap o rings. Models chu, cxu, gu, leu, mru. No model years listed. *pe
- 2012 - 2011 - 2010 - 2009 - 2008 - 2007 -
Models from 2012
2012 MACK GRANITE (GU) |
2012 MACK LEU |
2012 MACK MRU |
2012 MACK PINNACLE (CHU) |
2012 MACK PINNACLE (CXU) |
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) |
Models from 2009
2009 MACK CHU |
2009 MACK CXU |
2009 MACK GU |
2009 MACK LEU |
2009 MACK MRU |
2009 MACK TERRAPRO (MRU) |
Models from 2008
2008 MACK CHU |
2008 MACK CXU |
2008 MACK GU |
2008 MACK LEU |
2008 MACK MRU |
2008 MACK TERRAPRO (MRU) |
Models from 2007
2007 MACK CHU |
2007 MACK CXU |
2007 MACK GU |
2007 MACK LEU |
2007 MACK MRU |
SB-10045822-3750 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 This Service Program replaces program PI0796 dated 7.2012. Date Group No. Release Page 8.2012 293 014 02 1(12) EGR Valve Modification MP7 and MP8 US2010 CHU, CXU, GU, LEU, MRU P I 0 7 9 6 , E G R Va l v e M o d i f i c a t i o n (Au gust 2 012) Mack Trucks has authorized an EGR valve modification on certain EPA2010 emission level vehicles equipped with MACK MP7 and MP8 engines built April through June 2012 that have accumulated less than 8000 km (5000 mi). The poppet shaft end cap O-rings must be removed from the EGR valves on these engines. The O-rings were designed to be consumed during the first major heat cycle, but cases have been reported where the O-rings have caused the valve to malfunction. N o a c t i o n i s r e q u i r e d o n v e h i c l e s t h a t h a v e a c c u mu l a t e d 8 0 0 0 k m ( 5 0 0 0 mi ) o r m o r e a s t h e O - r i n g s h a v e b e e n c o n s u me d a s d e s i g n e d . Before proceeding, verify campaign eligibility by checking Service Program status in eWarranty. CA UTION Removal and installation of EGR valve can cause progressive damage if care is not taken. Please ensure that all components and mounting surfaces are clean and free of debris before removal and reassembly. N o t e : This bulletin does not apply to Mack Trucks Australia. P a rt s R equi re d P art N u mber De sc riptio n 20850815 EGR Valve Gasket (1) 20841816 Hot Pipe Gaskets (2) 21007187 Diffuser Gasket (1, MP7 only) 21095721 Exhaust Piping Gasket (1 for MP7, 2 for MP8) 976014 EGR Oil Line O-Ring (2) N o t e : Part number 976014 O-rings come in quantity of 25. For this procedure the existing EGR mounting bolts and EGR hot pipe mounting clamps are to be reinstalled unless damaged. P V 7 2 9 - PI0796 USA55094 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 293 014 02 P roc edu re You must read and understand the precautions and guidelines in Service Information, Function Group 20, "Engine Safety Practices" 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 Remove all cables from ground (negative) battery terminals to prevent personal injury from electrical shock. 3 Remove EGR valve from engine. Refer to Function Group 29. 4 Secure valve in vise, do NOT clamp on the EGR valve mounting surface. Remove 4 fasteners from EGR valve. Remove hydraulic actuator with heat shield, end cap and poppet from casting. Retain spacer for reassembly. N o t e : Mark orientation of actuator before removing from casting. W2075169 Page 2(12) 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 293 014 02 5 Remove T-shaped clevis joint on shaft by pushing the shaft in opposite directions to separate actuator and heat shield from end cap and poppet. W2075291 Page 3(12) M a c k Tr u c k s , I n c . S e rv ic e P ro gra m Date 8.2012 6 Retain the clevis joint washer for reassembly. W2075099 W2075265 Group No. Release 293 014 02 Page 4(12) 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 293 014 02 7 Remove the poppet shaft from end cap. N o t e : If the shaft is stuck and can not be removed from the casting, replace the EGR valve using part kit number 85133799. W2075295 8 Remove internal O-ring from end cap and discard. Check the bore surface and remove any additional debris. W2075167 Page 5(12) 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 293 014 02 9 If O-ring has been consumed, make sure any debris is thoroughly cleaned and removed. W2075306 10 Remove end cap external O-ring and discard. W2075168 Page 6(12) 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 293 014 02 11 Clean the end cap with proper cleaning material/solution to remove debris from the bore and enclosure area. CAUTION Removal and installation of EGR valve can cause progressive damage if care is not taken. Please ensure that all components and mounting surfaces are clean and free of debris before removal and reassembly. 12 Install poppet shaft in end cap. Slide the end cap to the poppet flange providing the maximum visibility and clearance for poppet and piston coupling. N o t e : Shaft should slide with no interference in the end cap bore. If interference exists, make sure all debris is removed from end cap bore. If cleaning does not allow shaft to slide with no interference, replace EGR valve using part kit number 85133799 and file under standard warranty procedures. W2075282 Page 7(12) 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 293 014 02 13 Position clevis joint washer with dished side toward the hydraulic actuator. W2075281 14 Connect the shaft clevis joint. W2075291 Page 8(12) 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 293 014 02 15 Position end cap aligning orientation marks on casting with spacer and install fasteners. 16 Tighten fasteners in three stages as shown. W2075169 Stage 1 Tighten fasteners 1 and 4 to 40 in-lbs, then tighten fasteners 2 and 3 to 40 in-lbs. Stage 2 Tighten fasteners 2 and 3 to 120 in-lbs, then tighten fasteners 1 and 4 to 120 in-lbs Stage 3 Retighten fasteners 2 and 3 to 120 in-lbs, then tighten fasteners 1 and 4 to 120 in-lbs 17 Activate poppet by hand to ensure proper function. Page 9(12) 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 293 014 02 18 Mark the valve with a punch to indicate work completed. W2075266 19 Install new gaskets into the EGR valve end of the hot pipe and the inlet of the EGR cooler. Make sure the gaskets lay flat against the flange surfaces with the bead of the gaskets facing toward the hot pipe. Install EGR valve. Refer to Function Group 29. For this procedure the existing EGR mounting bolts and EGR hot pipe mounting clamps are to be reinstalled unless damaged. CAUTION Hot pipe gaskets can easily slip out of position causing damage to turbocharger. Please insure gaskets are securely in place when reinstalling pipe. W2006187 Page 10(12) 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 293 014 02 20 Reconnect all previously removed cables to the negative (ground) battery terminals. 21 Start the engine. Check for leaks and proper operation. 22 To signify that the campaign has been completed, using a permanent-type marker (such as a Sharpie®) to write the campaign number (PI0796) 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 number 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 11(12) 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 293 014 02 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 v i a 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 . Sys.) 41 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 for EGR Valve Modification 2145G-01-96 — 0.3 hrs Labor Code for EGR Removal and Installation 214QD-36-45 • CHU, CXU GU with MP7 — 2.8 hrs • LEU, MRU with MP7 — 1.5 hrs 214QD-37-45 • CHU, CXU, GU, MRU with MP8 — 1.7 hrs Time to take charge and determine campaign status 101AA–0A–00 — 0.3 hrs Caus al P art Number 20940438 Other Ma teri al s Parts Dispo sition A ut hori z at io n N umbe r PI0796 Ex piration Date 30–Nov–12 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 12(12)