PI 0859

Service Program
Trucks
Mack Trucks, Inc.
Greensboro, NC USA
This Service Program replaces PV729–PI0859, “Front Radar, Failure
(USA71755)” dated 08.2015.
Date
Group
No.
Release
Page
10.2015
366
859
02
1(19)
Front Radar, Failure
CHU, CXU, GU
PI0859, Front Radar, Failure
(October 2015)
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 and/or radar antenna module. To ensure proper
operation of the front radar, the harness is inspected for the proper seal and/or corrosion, and
the module is inspected for signs of corrosion. If the harness, seal or module fail inspection,
replacement of the harness and/or radar antenna is required. Follow the inspection and repair
procedures outlined in this document.
If the truck is eligible for this repair, call 1-877-986-5862 and provide the following information:
17 digit Vehicle Identification Number (VIN), Product Improvement Number (PI0859), Dealer
Code, and the Purchase Order (PO) Information.
Note: This bulletin does not apply to MACK Trucks Australia.
W3103581
Required Parts
Front Radar Replacement Parts
PV729-PI0859
Item
Description
Part Number
Qty
1
Sensor, Front Radar
745-K105425X
1
2
Harness, Front Antenna
22638506
1
3
Clamp, Universal
20428158
3
4
Cable Tie
980464
2
USA72879
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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
Page
2(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
5 Disconnect all of the cables from the battery’s negative terminals.
W3086747
Front Radar Inspection
1 Disconnect the radar connector.
W3103584
Page
3(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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 and front radar module,
continue to page 9 (Front Radar and Harness Replacement) section and follow the
repair procedure.
3 Inspect the connector to determine if the proper seal was installed in the connector
housing.
Note: If the color of the terminal seals are (BLACK) and no corrosion is present, 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), and no corrosion is present,
continue to page 5, (Front Radar Harness Replacement) and replace the harness only.
W3103448
Page
4(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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
5(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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
6(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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 1 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
7(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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
8(19)
Mack Trucks, Inc.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
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.
Service Program
Date
10.2015
Group
No.
Release
366
859
02
Reimbursement
This repair is covered by an authorized
Service Program. Reimbursement is obtained
via the normal claim handling process.
UCHP
Reimbursement
eWarranty
Reimbursement
Claim Type (used only when uploading from
the Dealer Bus. Sys.)
B
B
Recall Status
Vehicle inspected, repair not required
1- Inspected OK
Vehicle repaired per instruction
2- Modified per
instruction
Labor Code
Primary Labor Code (Front Radar Harness
Inspection)
3000–06–09–01
0.3 hrs
2733M–01–96
0.3 hrs
Labor Code (Front Radar Harness Replacement)
3665–03–09–02
1.2 hrs
2733N–01–96
1.2 hrs
Labor Code (Front Radar and Harness
Replacement)
3665–03–09–03
1.4 hrs
2733P–01–96
1.4 hrs
Take to take charge and determine campaign
status
1700–16–01–01
0.3 hrs
101AA–0A–00
0.3 hrs
Causal Part
22134349
221234349
SCC Code
S6931
NA
Authorization Number
NA
PI0859
Expiration Date
30-AUG-2016
30-AUG-2016
Note: 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.
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