PI-0802

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
12.2012
371
802
01
1(8)
Battery Cable Routing
CXU
P I0 8 0 2 , B a tte ry C a b le R o u ti n g
(D ec emb er 2 012)
On certain Mack Trucks built between August 14,2009 to October 21, 2011, the battery
cables may rub on the over slung cross member. The cable contact point is located between
the clutch housing and the clipping point on the frame behind the battery box. This is due to
improper routing of the cables.
To correct this issue follow the procedures below.
N o t e : This bulletin does not apply to MACK Australia.
R eq ui red P a rt s
Qua nit y
Part Number
Des cription
2
20378961
4 battery configuration
1
20378961
3 battery configuration
1
995462 (975197)
M8 x 30 bolt
1
965558
Bracket
1
990950
Nut
A/R
8079360
Double Headed Cable Tie
A/R
948211
Cable Tie
If n e w c l a mp is required use parts below:
Qua nit y
P V 7 2 9 - PI0802
Part Number
Des cription
1
21658909
Clamp
1
994950
Spring Nut
1
995536
Bolt
USA55635
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
W3077591
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.
Repair
1 Disconnect batteries.
2 Remove drivers seat and attachments.
3 Remove the shifter knob, airlines and boot.
N o t e : Mark airline location for future reference.
4 Remove center floor mat.
5 Remove center floor pan.
Page
2(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
6 Remove battery cables from the bracket at frame edge.
W3077593
7 Remove and discard bolt (1) and L-bracket (3), remove bolt (2) then re-install bolt (2) to
secure air discharge line.
N o t e : Battery cable clamp can be removed from the L-bracket and reused in next step.
W3077675
Page
3(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
8 Install the new L-bracket onto the over slung cross member in the position as indicated.
Torque to 8.8 Nm (77 in lb).
Install spring nut onto L-bracket and then install the new battery clamp or the one removed in
previous step.
N o t e : Use the lower slot in the upper position
N o t e : Replace defective cable(s) if there are areas on the coating that have been heavily
chaffed, cut or worn to the point where the copper is exposed, before proceeding with new
routing and clipping procedures.
W3077592
Page
4(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
9 Lay the battery cables in place at the frame edge.
W3077593
10 Remove battery cable bracket and clamp. Reinstall bolt into bell housing .
Torque to 68 Nm (50 ft lbs).
W3077595
Page
5(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
11 Remove the bolt and install the bracket and clamp 1 hole clockwise from original location
on clutch housing.
Torque to 68 Nm (50 ft lbs).
W3077612
12 Lay the battery cables in place at the clutch housing.
W3077963
Page
6(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
13 Torque the new clamps to 8.1 Nm (6 ft lb) and the old existing clamps to 6.8 Nm (5 ft lb).
14 Install cable ties as shown and or as needed to keep cables from touching or rubbing other
objects.
W3077594
1. Cable Ties
15 Install the center floor pan.
16 Install the center floor mat.
17 Install the shifter boot, airlines and knob.
N o t e : Less than a perfect flush fit for the boot seal is considered unacceptable and will
possibly cause exhaust gases or other unwanted fumes to leak into the cab area. Make
certain the seal is fitting properly inside and outside the cab.
N o t e : Check the seal is properly seated above and below the cab floor by inspecting
inside and underside of cab.
18 Install driver’s seat and attachments.
19 Connect batteries.
20 Start vehicle and air up the system. Ensure all electrical and pneumatic components work
as they should.
Page
7(8)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
12.2012
Group
No.
Release
371
802
01
N o t e : To signify that the campaign has been completed, using a permanent-type marker
(such as a Sharpie®) write the campaign number (PI0802) 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 610264- 9465.
W8034103
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
(includes inspection and take charge)
7211E-ZP-96
1.6 hours
Caus al P art
21658909
A ut hori z at io n N umbe r
PI0802
Ex piration Date
05-DEC-13
Page
8(8)