NHTSA ID Number: 10246096
Manufacturer Communication Number: S3036 202311
TSB/Document Date: 2023-12-05
Summary
Service Campaign: Mack Trucks
has determined that certain LRBe trucks could exhibited insufficient cab heat. To improve cab heat a retro fit of trucks coolant circuit is needed. Please follow the instructions below to complete the needed retro fit of the coolant circuit.
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TSB/Document ID: S3036 202311
Replacement Service Bulletin Number:
MFR Communication Date: 2023-11-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM
MFR Component System:
MFR Component Subsystem:
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Service Campaign S3036
June 2023
Mack LRBE Cooling Box Refit
Service Category Service
Section Function Group 2619
Technician Skill Level A
Market North America
Applicability
MACK
Years
2022-2023
Models
LRBE
Introduction
Mack Trucks has determined that certain LRBe trucks could exhibited insufficient cab heat. To
improve cab heat a retro fit of trucks coolant circuit is needed. Please follow the instructions
below to complete the needed retro fit of the coolant circuit.
Production Change Information
This bulletin applies to vehicles built within the specified production changes below.
Brand
Engine
Emission Level Starting Build Date Ending Build Date
EM-ZE
22-April-2021
19-September-2022
Mack
BEV
Warranty Information
This repair is covered by an authorized Service Program. Reimbursement is
obtained through the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
B
Main Labor Code
Description
3100-09-01-03
Traction Voltage system Commissioning
1.3
3100-09-01-04
Traction Voltage system Decommissioning
1.0
3222-03-03-03
Charging Switch Unit (CSU) Replacement
1.6
2609-01-01-04
Coolant system Draining
1.0
2609-02-01-01
Coolant system fill
1.6
Campaign General x95
0.1
1720-16-09-01
Causal Part
SCC Authorization
Code
Expiration Date
Hours
24129397
S3036
June 30, 2024
Service Campaign S3036
June 2023
Parts Information
To order the following parts please send an email to chris.mann@volvo.com. Please include the
following in the email.
• Campaign Number
• Part numbers below
• Shipping address
• Point of contact
Part Number
24491984
24150179
24143306
24134183
Description
Wires
Tube
Tube
Tube
Qty
1
1
1
1
Order the following part using the normal process.
Part Number
24150386
24134132
24192569
24170409
24134179
24143293
21320698
952630
24129397
995450
990949
24134720
24134116
24128020
Description
Restricting Valve
Support
Bracket
Hose
Hose
Hose
Hose
Clamp
Solenoid Valve
Flange Screw
Flange Lock Nut
Pipe
Pipe
Pipe
Qty
1
1
1
1
1
1
1
2
1
2
2
1
1
1
Service Campaign S3036
24128006
24134121
24134126
24128023
24151688
24128010
24128013
24128017
24128029
24151678
995520
994847
984726
984993
980881
20885496
990940
984734
21078880
June 2023
PIPE
PIPE
PIPE
HOSE
HOSE
HOSE
HOSE
PIPE
PIPE
PIPE
FLANGE SCREW
WASHER
FLANGE SCREW
HOSE CLAMP
CABLE TIE
RETAINER
FLANGE NUT
FLANGE SCREW
HOSE CLAMP
Required Tools & Equipment
•
Access to IMPACT & PTT
Calibration Information
•
None
1
1
1
1
1
1
1
1
1
1
1
1
4
2
5
2
1
1
3
Service Campaign S3036
June 2023
Refit Instructions
1. Follow Traction voltage system decommissioning instructions (ID 3100-09-01-04) in
Impact.
2. Follow Coolant draining instructions (ID 2609-01-01-04) in Impact.
3. Follow Charging switch Unit (CSU) replacement (ID 3222-03-03-03) steps 1 through 29
in Impact.
4. Remove and discard the bleeders.
5. Remove and discard the deaeration lines.
Service Campaign S3036
6. Remove the equalizer and bracket.
7. Remove and discard the pipe.
June 2023
Service Campaign S3036
June 2023
8. Remove the power connections to the heater relays. Disconnect the coolant lines.
9. Remove and discard the hose and pipe.
Service Campaign S3036
10. Remove the bracket.
11. Disconnect the hoses.
June 2023
Service Campaign S3036
June 2023
12. Disconnect the lower radiator hose. Remove the P clamps.
13. Disconnect the cooling box grounds and connector.
Service Campaign S3036
June 2023
14. Disconnect the cooling fan connector. Remove the radiator hose.
15. Remove the bolts.
Service Campaign S3036
June 2023
16. Remove the bolts.
17. Remove the cooling box (octopus).
Service Campaign S3036
June 2023
18. Remove and discard the relay mount. Keep the relays for reuse.
19. Remove and discard the hose and nipple.
Service Campaign S3036
June 2023
20. Remove and discard the hoses, valve and pipe.
21. Remove and discard the pipes. Remove and keep the temp sensor for reuse.
Service Campaign S3036
June 2023
22. Remove and discard the pipes.
Cooling box new part installation:
23. Install the new pipes.
Part# 24134116
Part# 24134121
Service Campaign S3036
June 2023
24. Install the pipes and hose. Install the original coolant temp sensor.
Part# 24128020
Part#24128010
Part#24134126
Reuse coolant temp sensor
Service Campaign S3036
June 2023
25. Install the pipes and hoses.
Part # 24128023
Part #24170409
Part # 24128006
Part # 24128029
Part # 24128013
Part # 21078880
Service Campaign S3036
June 2023
26. Install the bracket and fitting. Install the original relays.
Part # 24150386, 994847, 995520
Part # 24134132
Reuse Original Relays
Service Campaign S3036
June 2023
27. Install the bracket and solenoid. Install the hose.
Part # 24151688
Part # 24129397
Part # 24151678
Part # 984726 x 4
Part # 20885496 x 2
Part # 984734, 990940
Service Campaign S3036
June 2023
28. Install the hoses.
Part # 24150179
Part # 24134179
Part # 24143306
Part # 24143293
Part # 24134183
Part 980881 x 5
Service Campaign S3036
June 2023
Some trucks may have been built with coolant sensor labels and pinouts
incorrect. Follow these steps to ensure coolant temp sensors are correctly connected.
29. Check for continuity between the cooling box interface connector and the cooling temp
sensor for the pump.
Check continuity between pin 20 of the interface connector and signal circuit on the sensor
connector. (White wire orange tracer) Interface pin 20:
If continuity exists between the
terminals no further action is necessary.
If continuity does not exist, the interface connector will need to be corrected.
Only perform step 27 if checks from steps 26 did not show continuity
Service Campaign S3036
June 2023
30. If previous checks do not show continuity, swap pins 16 and 20 on the MPB harness
side of the cooling box interface connection.
Service Campaign S3036
June 2023
Pins to be swapped if issue found:
Cooling box upgrades are now complete. Follow removal instructions in reverse to install
the cooling box.
Service Campaign S3036
June 2023
31. During Cooling Box Installation, Torque Tighten Heater Relay Power Connections.
32. Install the pipe.
Part#
24128017
Service Campaign S3036
June 2023
33. Follow Charging switch Unit (CSU) replacement (ID 3222-03-03-03) steps 30 through 63
in Impact.
34. Install the pipe.
Part # 24134720
35. Install the hose and bracket.
Part # 21320698
Part # 24192569
Part # 952630, 995450 x2, 990949 x2
Service Campaign S3036
June 2023
36. Replace the heater hose. Use bulk hose 82149596 or equivalent 15mm ID silicone hose.
Cut length = 45”
37. Connect the heater hoses.
Service Campaign S3036
June 2023
Overlay harness, 24491984, installation.
38. Disconnect connector B1 on the FRC(ECEC)
39. Remove the connector back shell. Move the secondary lock to the pre-locked position as
shown.
Service Campaign S3036
June 2023
40. Insert circuit A399B1A1 into cavity 10. Move the secondary lock to the locked position.
41. Install the back shell. Install the cable tie securing the existing harness and the new
circuit to the back shell as shown.
Service Campaign S3036
June 2023
42. Disconnect connector B from the EVCM.
43. Remove the back shell. Move the secondary lock to the pre-locked position.
Service Campaign S3036
June 2023
44. Insert circuit A397B49A1 into cavity 49. Move the secondary lock to the locked position.
Install the tie band and back shell. Reconnect to the EVCM.
Service Campaign S3036
June 2023
45. Secure the overlay harness to the MPB harness.
46. Route the jumper along the cooling box harness. Connect the solenoid and secure the
jumper as shown.
Service Campaign S3036
June 2023
47. Follow Traction voltage system commissioning instructions (ID 3100-09-01-03) in
Impact.
48. Follow Coolant filling instructions (ID 2609-02-01-01) in Impact.
49. Connect to truck using PTT.
50. Installed Aftermarket conversion kit: 85165234
51. Release truck back to service.
Service Campaign S3036
June 2023
The overlay harness and new cooling box harness is adding the circuit highlighted below.
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