Prevost Aware Adaptive Cruise Braking (ACB) – FLR10 to FLR21 Radar Sensor Upgrade

SEOCONTENT-START

Writer: EL <QF7720959 rev 5>
Instruction Sheet IS-19922
PREVOST AWARE ADAPTIVE CRUISE BRAKING (ACB) –
FLR10 TO FLR21 RADAR SENSOR UPGRADE
First Release June 2019
MATERIAL
Kit #IS19922 includes the following parts:
Part No. Description Qty
069043 CABLE 1
145206 SUPPORT 1
145207 PLATE, RADAR MOUNTING 1
560468 FLR21 RADAR SENSOR 1
564257 STAND-OFF ADJUSTER KIT
– Stand-off adjuster (3x)
– Mounting screw (6x)
1
504637 NYLON TIE 6
5001648 SCREW, CAP HEXS SS NSS M6-1.0 X18mm LG 4
5001833 WASHER, BELLEVILLE SPR SS 301 6.65X17.4X1.27 4
IS-19922 INSTRUCTION SHEET 1
FI-19922 FEUILLE D’INSTRUCTIONS 1
NOTE
Material can be obtained through regular channels.
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.
IS-19922
Page 2 / 10
Writer: EL <QF7720959 rev 5>
IMPORTANTE NOTE
BEFORE PROCEEDING TO THE REPLACEMENT, MAKE SURE THAT THE BUMPER IS PROPERLY
POSITIONED, IF NOT THE RADAR SENSOR AND ACB SYSTEM MAY NOT OPERATE PROPERLY.
IF THE BUMPER SUFFERS DAMAGES AFTER A CHOCK AND IS IMPROPERLY POSITIONED, A REPOSITIONING OR
ADJUSTMENT OF THE BUMPER WILL BE NECESSARY BEFORE PROCEEDING TO THE ALIGNMENT OF THE RADAR
SENSOR. RADAR SENSOR ALIGNMENT IS DONE IN RELATION TO THE BUMPER, IF THE BUMPER POSITION IS NOT
ADEQUATE, THE RADAR AND ACB SYSTEM MAY NOT OPERATE PROPERLY.
RADAR SUPPORT PREASSEMBLY
STAND-OFF ADJUSTOR ASSEMBLIES
ARE PRE-ADJUSTED BEFORE
DELIVERY IN ORDER TO RESPECT A
PRECISE MEASUREMENT BETWEEN
THE RADAR SENSOR AND THE
SUPPORT, DO NOT SCREW, UNSCREW
OR ALTER THE INITIAL POSITION OF
THE STAND-OFFS ADJUSTMENT
SCREW.
DO NOT SEPARATE THE STAND-OFF
CLIP FROM THE RADAR SENSOR
RECEPTACLE. DOING SO WILL
DAMAGE THE STAND-OFF CLIP.
1. Secure the three (3) stand-offs to the
radar sensor mounting plate #145207.
Use the six (6) mounting screws
included with the stand-off kit.
Prescribed torque : 25 lb-ft
FIGURE 1
IS-19922
Page 3 / 10
Writer: EL <QF7720959 rev 5>
2. Engage the stand-offs in the radar
assembly receptacles, placing the side
that has no decal on top and the
connector on L.H. side.
= no decal on this side
FIGURE 2
3. Stand-off height is pre-adjusted.
However, validate dimension A at the
three stand-offs and adjust height only
if necessary.
A = 39.5mm ±0.5 (1.55 in ± 0.02)
FIGURE 3
4. Install the radar mounting plate on
support #145206 using four (4)
washers #5001833 and four (4)
screws #5001648.
FIGURE 4
IS-19922
Page 4 / 10
Writer: EL <QF7720959 rev 5>
5. Connect the radar cable. Secure the
cable’s “tree” mounts to the holes
provided for this purpose.
Make sure that the cable forms a
low point loop to allow water to
drip without seeping into the
connector.
FIGURE 5
REMOVAL OF THE EXISTING RADAR
6. Lower the reclining bumper.
7. Place a lift table under the bumper to
support it in reclined position.
8. Using a marker, draw a line around the
four (4) identified washers. This will be
useful to keep the current bumper
adjustment at time of reinstallation.
FIGURE 6
FIGURE 7
IS-19922
Page 5 / 10
Writer: EL <QF7720959 rev 5>
9. Unscrew the four (4) nuts identified on
the image in order to separate the
bumper from the panel which closes
the spare wheel compartment. Keep
the nuts and washers.
FIGURE 8
10. Close the spare wheel compartment
access panel.
FIGURE 9
11. Disconnect the radar cable and cut the
nylon ties.
FIGURE 10
IS-19922
Page 6 / 10
Writer: EL <QF7720959 rev 5>
12. Lower the spare wheel compartment
access panel.
13. Remove the four (4) screws identified
on the image and then remove the
radar sensor.
FIGURE 11
FIGURE 12
14. Close the spare wheel compartment
access panel.
15. Using a cutting tool (cutting wheel),
remove the welded radar support.
FIGURE 13
IS-19922
Page 7 / 10
Writer: EL <QF7720959 rev 5>
16. Cut where indicated by the red dotted
lines.
17. Remove excess of metal in order to
have a smooth finish.
FIGURE 14
18. Remove the weld nut identified on the
image at right.
FIGURE 15
CUTTING OUT OF THE BUMPER SKIN
19. It is necessary to cut out an opening
larger than the existing one on the
bumper skin.
FIGURE 16
IS-19922
Page 8 / 10
Writer: EL <QF7720959 rev 5>
20. The cutout dimensions are 120
mm X 94 mm (4.72 in X 3.7 in).
This new opening is centered
horizontally on the existing one.
Using an oscillating multi-tool gives
good results.
21. Drill two (2) holes of 7mm.
FIGURE 17
6mm = 15/64″
7mm = 9/32″
8mm = 5/16″
13mm = 33/64″
94mm = 3’ 45/64″
120mm = 4’ 23/32″
RADAR INSTALLATION
22. Install support #145206 inside the
bumper. Place the support in relation
with the opening of the radar using
existing mounting points.
FIGURE 18
IS-19922
Page 9 / 10
Writer: EL <QF7720959 rev 5>
23. Secure the radar cable at the bottom
of the spare wheel compartment
access panel. Use one (1) nylon tie
#504637.
FIGURE 19
24. Secure the radar cable to the bumper
as shown. Use four (4) nylon ties
#504637.
FIGURE 20
25. Plug the connector.
IS-19922
Page 10 / 10
Writer: EL <QF7720959 rev 5>
26. Bolt the bumper and the spare wheel
compartment access panel together.
FIGURE 21
27. Keep the cover plate and the hardware
of the former installation and install the
cover plate on the spare wheel
compartment access panel.
Limit dirt intrusion by plugging the holes on
this plate. You can use ‘duct tape’ for
example.
FIGURE 22
RADAR ALIGNEMENT
28. After installation, a realignment of the radar sensor may be necessary. Refer to Maintenance
Information MI14-34 for the alignment procedure. This document is available on the Technical
Publications website.
https://techpub.prevostcar.com/
MI14-34
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)