FSB 366-002

Mack Trucks, Inc.
Greensboro, NC USA
Field Service Bulletin
Trucks
Date
Group
No.
Release
Page
3.2016
366
002
01
1(19)
Front Radar, Failure
CHU, CXU, GU
FSB 366-002, Front Radar, Failure
(March 2016)
Certain MACK CHU, CXU, and GU trucks built between 11/11/2013 and 01/14/2015,
equipped with front radar may experience loss of front object detection or erratic operation of
cruise control functions. The terminal seals of the harness is allowing moisture and corrosion
to build up in the front radar harness. To ensure proper operation of the front radar, the
harness is inspected for the proper seal and/or corrosion. If the harness or seal fail
inspection, replacement of the harness is required. Follow the inspection and repair
procedures outlined in this document.
Note: This bulletin does not apply to MACK Trucks Australia.
PV729-FSB366-002_M
USA75753
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
W3109331
Required Parts
Front Radar Replacement Parts
Item
Description
Part Number
Qty
1
Harness, Front Antenna
22638506
1
2
Clamp, Universal
20428158
3
3
Cable Tie
980464
2
Page
2(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
Decommissioning the Truck for Repair
You must read and understand the precautions and guidelines in Service Information,
group 30, "General Safety Practices, Electrical" before performing this procedure. If you
are not properly trained and certified in this procedure, ask your supervisor for training
before you perform it.
NOTE: Information is subject to change without notice. Illustrations are used for reference
only and can differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
1 Park the vehicle on a flat and level surface.
2 Apply the parking brake.
3 Place the transmission in neutral or park.
4 Install the wheel chocks.
W7086748
5 Disconnect all of the cables from the battery’s negative terminals.
W3086747
Page
3(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
Front Radar Inspection
1 Disconnect the radar connector.
W3103584
2 Inspect the radar connector for water intrusion and corrosion on the terminal pins.
Note: If there are signs of water intrusion, corrosion of the harness , continue to page 5
(Front Radar Harness Replacement) section and follow the replacement procedure.
3 Inspect the harness to determine if the proper seal was installed in the connector housing.
Note: If the color of the terminal seals are (BLACK) , connect the radar connector, and no
further action is required. Continue to page 18, (Commission the truck for Operation),
and follow steps 1 – 2.
Note: If the color of the terminal seals are (YELLOW), continue to page 5, (Front Radar
Harness Replacement) and replace the harness.
W3103448
Page
4(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
4 If corrosion is found in the front radar module, clean the connector pins with contact
cleaner to remove any trace of corrosion or debris. If corrosion is still present after
cleaning, continue to page 5, (Front Radar Harness Replacement) section and follow the
replacement procedure.
Front Radar Harness Replacement
1 Open the hood.
W8090572
2 Remove the fasteners and flat washers securing the front radar sensor and shroud.
Note: Store the flat washers, and fasteners in a clean and secure location for installation.
W3103585
Page
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Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
3 Remove the front radar sensor, spacers, and shroud.
Note: Store the front radar sensor, spacers, and shroud in a clean and secure location for
installation.
W3103588
4 Remove the cable ties securing the front radar harness.
5 Disconnect the front radar harness from the main cab harness.
W3103450
Page
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Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
6 Remove the existing front radar harness.
Note: Note the routing of the existing harness for installation of the replacement harness.
7 Route the replacement front radar harness into position as noted.
8 Connect the replacement front radar harness to the main cab harness.
W3103450
9 Use the cable ties listed on page 2 to secure the front radar harness.
Note: Ensure there is enough harness at the other end to connect to front radar sensor.
10 Position the front radar sensor, spacers, and shroud.
W3103588
Page
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Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
11 Install the fasteners and flat washers securing the front radar sensor and shroud.
W3103585
12 Tighten the fasteners securing the front radar sensor and shroud to 27 ± 4 Nm (20 ± 3 ftlb).
13 Connect the front radar harness to the radar module.
W3103584
Page
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Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
14 Close the hood.
W8090584
15 Continue to page 18, and (Commission the truck for Operation).
Front Radar and Harness Replacement
1 Open the hood.
W8090572
Page
9(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
2 Remove the fasteners and flat washers securing the front radar sensor and shroud.
Note: Store the flat washers, and fasteners in a clean and secure location for installation.
W3103585
3 Remove the front radar sensor, spacers, and shroud.
Note: Return radar assembly to the Core Hub for credit and processing.
Note: Store spacers and shroud in a clean and secure location for installation.
W3103588
Page
10(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
4 Remove the cable ties securing the front radar harness.
5 Disconnect the front radar harness from the main cab harness.
W3103450
6 Remove the existing front radar harness.
Note: Note the routing of the existing harness for installation of the replacement harness.
7 Route the replacement front radar harness into position as noted.
8 Connect the replacement front radar harness to the main cab harness.
W3103450
Page
11(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
9 Use the cable ties listed on page 1 to secure the front radar harness.
Note: Ensure there is enough harness at the other end to connect to the front radar
sensor.
10 Position the replacement front radar sensor, spacers, and shroud.
W3103589
11 Install the fasteners and flat washers securing the front radar sensor and shroud.
W3103587
Page
12(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
12 Tighten the fasteners securing the front radar sensor and shroud to 27 ± 4 Nm (20 ± 3 ftlb).
13 Connect the front radar harness to the radar module.
W3103586
14 Close the hood.
W8090584
Page
13(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
15 Perform the Sensor, VOLVO Enhanced Cruise (VEC), Alignment Check and Adjustment
procedure as shown in steps 17 – 26.
16 Place a digital angle gauge on top of the vehicle frame rail as shown. Reset the digital
gauge to 0 degree.
W8085795
17 Attach Bendix Alignment tool (part number K065284) to the front of the radar sensor cover.
Note: A cover (2) is included with the replacement radar sensor. If the cover is missing,
use assistance to hold the alignment tool (1) on the radar sensor.
W3103590
Page
14(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
18 Attach the digital angle gauge to the alignment tool.
19 Check the vertical alignment tool and ensure the digital angle gauge is reading 0 degrees.
Note: If the vertical alignment tool with the angle gauge is not reading 0 degrees,
adjustment of the radar sensor’s vertical angle is required.
W3103591
20 If applicable, adjust the vertical alignment of the radar sensor to 0 degrees.
Note: Periodically recheck the alignment tool and angle gauge during the vertical
alignment procedure.
W3103592
Page
15(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
21 Using the alignment tool. turn the laser on and check the sensor’s lateral alignment.
CAUTION
Do not stare into the laser beam (2).
Note: Use the tow hook receptacles (1) or frame rail ends as a measuring point if
possible.
22 After the first lateral measurement (3), turn the laser off.
23 Flip the laser and orient it towards the opposite side of the truck.
24 Turn the laser on, and record the second lateral measurement (3) from the tow hook
receptacle (1).
Note: If the lateral measurements vary by more than 3 mm (0.125 in) of each other, adjust
the lateral alignment of the radar sensor.
W3104819
Page
16(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
25 If applicable, adjust the lateral alignment of the radar sensor until the two measurements
are (Less than 3 mm (.125 in) of each other.
W3103593
26 If applicable, remove the cover from the front of the radar sensor.
Note: Failure to remove the cover will cause a Diagnostic Fault Code (DTC).
W3103594
27 Continue to page 18, and (Commission the truck for Operation).
Page
17(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
01
Commissioning the Truck for Operation
1 Connect all of the cables to the battery’s negative terminals.
W3086758
2 Remove the wheel chocks.
W7086759
3 Check the operation of the (Adaptive Cruise Control).
Note: If a diagnostic trouble code (DTC) is logged after the repairs are complete,
connected the truck to a PC with BENDIX A-Com software to clear the DTC.
4 Test drive the truck and check the operation of the adaptive cruise control.
Note: This is a separate operation.
Page
18(19)
Mack Trucks, Inc.
Field Service Bulletin
Date
3.2016
Group
No.
Release
366
002
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.
UCHP Reimbursement
Claim Type (used only when uploading from the Dealer
Bus. Sys.)
01
Labor Code
Primary Labor Code (Front Radar Harness Inspection)
3000–06–09–01
0.3 hrs
Labor Code (Front Radar Harness Replacement)
3665–03–09–02
1.2 hrs
Labor Code (Front Radar and Harness Replacement)
3665–03–09–03
1.4 hrs
Causal Part
22134349
MACK Trucks North America reserves the right to make any changes in design or to make
additions to or upon its products without incurring any obligations to install the same on
vehicles previously built.
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