AUTOCAR ACTT Xspotter 2018, Service Manual

Page 1: ...autocartruck com Preventive Maintenance AWE 00006 Rev 005a ACTT Service Manual ...

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Page 3: ...us development Vehicles and components produced after the manual release date may therefore have different specifications and repair methods This manual covers service of Autocar products as configured when they leave the factory This manual does not cover or apply to Autocar products that have been modified after leaving Autocar s factory Autocar is not liable for any damage or failure of compone...

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Page 5: ...NG Fuel Container Pressure Relief Devices PRDs 6 Eye Ear and Skin Protection 6 Testing the Equipment 6 Road Testing the Vehicle 7 While Servicing the Vehicle 8 Ground Straps and Antistatic Mats 8 Power Steering 8 Lockout Tagout Procedures 8 Introduction 9 PREVENTIVE MAINTENANCE PROGRAM 9 A Inspection 9 B Inspection 9 C Inspection 9 D Inspection 9 INSPECTION 150 HRS INTERVAL 10 Exterior Inspection ...

Page 6: ...tion 40 Additional Checks for Two Speed Fan Drives 42 Air Conditioning Refrigerant 42 Under Tractor Inspection 300 Hours 42 Road Test 300 Hours 43 Post Road Test Inspection 300 Hours 44 Inspection 1 200 Hours Interval 44 Description and Operation 1 200 Hours 44 Walk Around Inspection 1 200 Hours 45 Under Tractor Inspection 1 200 Hours 45 Inspection 2 400 Hours Interval 46 Description and Operation...

Page 7: ...n it This equipment can cause severe injury if not properly used and maintained Safety procedures are for your protection Do not operate the vehicle until you have read and understood the Operator Manual supplied with the vehicle General Safety There is no substitute for common sense and careful practices in the workplace Improper practices or carelessness can cause burns cuts mutilation asphyxiat...

Page 8: ...omatic Traction Control ATC prior to jacking up the vehicle and placing it on jack stands If the ABS is not disabled and one of the wheels starts to spin the ATC will compensate and the vehicle may come off the jack and or jack stands Refer to the Antilock Braking System Service Manual AWE 00178 Rev 000 for information on disabling the ABS system Pneumatic Compressed Air Components DANGER Pneumati...

Page 9: ...anding the characteristics of CNG and how the fuel system works will prevent injury and damage to persons and property Attempting to operate or maintain any CNG fuel system without proper training is dangerous Complete training and consult instructional bulletins from the CNG system suppliers such as Agility Fuel Systems Field Service Bulletin Safely Working on CNG Fuel Systems CNG LNG Safety WARN...

Page 10: ...and dispensers Ensure that emergency personnel are aware of proper precautions such as those provided in Agility s First Responder Guide CNG and LNG Vehicle Fuel Systems Eye Ear and Skin Protection WARNING ALWAYS wear appropriate eye protection to prevent the risk of eye injury Wear safety glasses to prevent eye contact with debris and fluids Wear a welding face mask to protect eyes and face when ...

Page 11: ...ke or Allison Retarder is not intended to replace the service brake system on the vehicle and cannot be relied on to bring the vehicle to a stop A vehicle speed retardation device is only intended to regulate the speed of the vehicle under certain conditions WARNING DO NOT EXCEED 15 MPH 24 KM H WHEN TOWING TRAILERS Operating at speeds in excess of 15 mph 24 km h may lead to loss of vehicle control...

Page 12: ...nd follow OSHA regulations concerning entry and working in CONFINED SPACE OSHA 1910 146 and LOCKOUT TAGOUT OSHA 1910 147 Follow OSHA regulations while performing any work on the vehicle The vehicle must be disabled by the following steps before performing any work on the vehicle 1 Place the transmission in NEUTRAL 2 Set the parking brake 3 Shut the engine OFF 4 Lock the cab doors Keep the key in y...

Page 13: ...r dealer to develop the Preventive Maintenance Program that is best suited to your application The vehicle be serviced based on operating hours Maintenance intervals based on months or mileage do not take into consideration actual operating hours Major vehicle components such as engine transmission axles and retarders may have their own recommended preventive maintenance intervals Refer to each co...

Page 14: ...s lubrication Major vehicle components such as engine transmission and axles may have their own Preventive Maintenance Inspection procedures and Autocar recommends reviewing each component s documentation for its recommended maintenance schedule While conducting these inspections record the results using the Preventive Maintenance Inspection form available from Autocar EXTERIOR INSPECTION 150 HOUR...

Page 15: ...ecurely latch the LH side and rear door BEFORE tilting the cab Failure to do so could result in personal injury and damage to the door s and or cab structure If the door must be opened once the cab is in the tilted position the door must be properly supported DO NOT allow the weight of the door to be supported by the door check strap alone Check that cab mounts are securely bolted to the frame Che...

Page 16: ...ndition of the mounting brackets and hardware Tighten the wheel nuts to the proper torque Figure 5 All disc wheels used on the ACTT series require a torque of 450 lb ft 610 N m For all other wheels refer to the decal affixed to the frame rail or if no decal is found refer to the wheel manufacturers specification Figure 5 DANGER Failure to properly torque tighten the wheel nuts can result in breaka...

Page 17: ...the turning circle No specific interval can be given as the requirement changes depending on operational conditions 1 8 in 3 mm 1 16 in 6 mm Steer Tire Drive Tire Figure 6 Fuel System Fuel Tank s Inspect fuel tank for damage leaks or rust Figure 7 Figure 7 Examine the mounting straps for cracks and ensure that the rubber insulators are secure Ensure that the tanks have not rotated in their mounts ...

Page 18: ...spect DEF reservoir Figure 10 for damage leaks or rust Examine the mounting straps for cracks or other damage Clean any debris from around the base on the tank in the mounting bracket 2 Inspect all DEF and DEF heater lines for wear damage and secure clamping Figure 10 3 D Inspection or annually Replace DEF system filter Figure 11 Figure 11 ...

Page 19: ...ridge Note Desiccant may require more frequent service in humid climate operation Check mounting wiring and connections Check operation per equipment manufacturer s recommendation Check heater element if equipped Refer to manufacturer s recommendation for inspection procedures Air Reservoirs WARNING When draining the air tanks do not look into the area of the escaping air Dirt or sludge particles ...

Page 20: ... shoe Check the brake lining for cracks Check and note drum to lining clearance Maximum acceptable clearance is 0 063 in 1 60 mm Note For a complete listing of preventive measures and their intervals refer to the Preventive Maintenance Schedule in this manual Electrical System Battery Hold Down Hardware Inspect the battery hold down hardware and fasteners for proper placement Ensure the batteries ...

Page 21: ...he engine is idling in neutral The oil level in Allison transmissions can be checked using push button or bump shift selector if equipped with an oil level sensor refer to the manufacturer s documentation for more information WARNING NEVER remove the coolant surge tank cap or radiator cap when the engine is warm The explosive escape of scalding coolant or steam will result Coolant level should be ...

Page 22: ... hydraulic fluid level Figure 16 The fluid level may be checked with the engine running or not The fifth wheel must be completely lowered to check fluid level Add Castol Transynd or equivalent as required Do not overfill the reservoir 1 2 3 1 ADD Sight Glass 3 One Piece Sight Glass 2 FULL Sight Glass Figure 16 Cooling System Radiator Charge Air Cooler and Condenser Check grille and behind grille a...

Page 23: ...ent Dry thoroughly before reassembly The cause of the moisture or contamination must be determined and action must be taken to correct the condition Intake Air Piping Examine air intake piping from the air cleaner to the intake manifold checking for loose clamps or connections cracks and punctures or tears Disconnect intake piping and examine inside of intake pipes for buildup deposits or foreign ...

Page 24: ...ront wheels are securely chocked before elevating the drive wheels ABS must be deactivated before lifting rotating wheels Perform chassis lubrication per the Chassis Lubrication Chart in this manual For chassis lubrication use Delo Grease EP NLGI 1 and 2 minimum or equivalent Be sure that grease fittings are clean and free from debris prior to application of grease Ensure that each grease fitting ...

Page 25: ...Always use new bolts when reinstalling any u joint DO NOT reuse old fasteners Change the engine oil per engine manufacturer s recommendation Remove and replace full flow and bypass filters Check crankcase capacity and fill to proper level using oil recommended by the engine manufacturer Transmission Change the transmission fluid and replace the filter per transmission manufacturer s recommendation...

Page 26: ...ings Inspect spring hangers for cracks Tighten the spring hanger to frame bolts to specification Check center bolt and springs for shifting on the axle Check U bolts for proper torque and to ensure that the bolts have not shifted Refer to the Special Torque Chart in this Service Manual section Check spring eyes and pins for wear and cracks Wear must not exceed 0 125 in 3 18 mm Steering Check the s...

Page 27: ...d for proper contact with strikers Lubricate strikers Inspect door seals for damage or deterioration Inspect hinges for looseness and lubricate Operate windows through full cycles Inspect sliding window for correct fit and latch operation Cab Interior Check condition of cab interior floor seats and panels Visually check the condition of the floor mats panels and visors Check interior sheet metal f...

Page 28: ...beacon flood lights and back up lights Verify switch illumination if applicable operates properly Check that all reflectors are secure and not damaged Figure 23 Figure 23 Instrument and Dash Lighting Turn the key to the ON position Figure 24 Figure 24 Check that all applicable telltale indicator lamps illuminate and that all instruments respond appropriately The indicator on all gauges should swee...

Page 29: ...on gauge run the engine at maximum rated speed Observe and record the reading on the gauge Replace the air filter if the reading is 25 inch WC or less or if the gauge indicates that the filter needs replacing After filter replacement check and record air cleaner restriction gauge reading If the tractor is not equipped with an air restriction gauge on the intake piping run the engine at maximum rat...

Page 30: ...r cut in cutout as follows Pump the brake pedal until the pressure drops to 30 psi 207 kPa At idle it should take approximately one minute to restore pressure to 100 psi 689 kPa Windshield Wiper and Washer Check windshield wiper and washer wiper operation Figure 30 With the windshield wet turn on the wipers and check the following Washer fluid output Blades and wipers for wear and contact Operatio...

Page 31: ... Road Test 150 Hours WARNING DO NOT EXCEED 15 MPH 24 KM H WHEN TOWING TRAILERS Operating at speeds in excess of 15 mph 24 km h may lead to loss of vehicle control NEVER take turns at excessive speeds this may cause the vehicle and trailer to roll over The majority of roll over accidents are caused by excessive cornering speed Roll over accidents may lead to serious injury or death WARNING Never to...

Page 32: ...l pressure Figure 33 Check the engine for excessive smoke surging misfiring and noise indicating a malfunction Verify that the parking brake operates properly While in motion apply the brakes to check for even lockup and release Check the ABS system if equipped Allow the transmission to shift through all gears and check smooth operation Check the gear pattern making sure the transmission shifts ge...

Page 33: ...ocumentation for its recommended maintenance schedule While conducting these inspections record the results using the Preventive Maintenance Inspection form available from Autocar Walk Around Inspection 300 Hours Wheels and Tires Check dual matching Air Filter Replace the air filter element every 300 hours or when the restriction indicator reaches 25 in WC whichever comes first If the tractor is n...

Page 34: ...ilter s with clean fuel prior to installation to reduce air in fuel system refer to manufacturers documentation for procedure Figure 35 Figure 36 Brake System Slack Adjuster Inspect the slack adjuster operation mounting and adjustment Refer to equipment manufacturer s documentation for service intervals procedures and specifications ...

Page 35: ...CCA rating for 15 seconds Or turn the headlights on high beam for two to three minutes per battery Allow the batteries to recover for 30 seconds then check the voltage using a voltmeter If the reading is less than 12 40 volts charge or replace the batteries before proceeding Voltage Output Test Connect a DC voltmeter to the positive and negative output terminals at the alternator Measure the volta...

Page 36: ...t for wobble and evidence of leaks Inspect idler pulley for cracks Check bearing for smooth quiet operation Torsional Vibration Damper Inspect torsional vibration damper for evidence of dents fluid loss wobble swelling and deformation COOLING SYSTEM SERVICE Coolant Drain and Fill Deaeration Procedure NOTICE The following information is provided courtesy of Cummins Engine Company To avoid costly re...

Page 37: ...ect maximum heat allowing maximum coolant flow through the heater core The blower motor must be turned ON to activate the water control valve WARNING Do not stand near the surge tank or radiator while operating the engine with the radiator pressure cap removed If the vehicle is equipped with a fill door on the side of the surge tank keep the door closed due to coolant expansion 7 Operate the engin...

Page 38: ...on Repeat this test four more times If the cap fails any of the tests replace with a new one 5 Check for damaged hoses and loose or damaged hose clamps Replace as required 6 Check the radiator for leaks damage and buildup of dirt Clean and replace as required 7 Check the engine coolant level sensor for proper operation Flush Cooling System Fleetguard Restore Fleetguard Restore is a heavy duty cool...

Page 39: ... 000 rpm Note Some applications can have a manual bleed valve that is required to be opened to properly fill the system The upper radiator pipe is a common location for bleed valves NOTICE Do not allow the engine speed to exceed 2 000 rpm while the EGR valve is disconnected Operation at higher rpm in this mode can result in engine damage 3 If applicable open the manual bleed valve before filling t...

Page 40: ...ne with the pressure cap off If the vehicle is equipped with a fill door on the side of the surge tank keep it closed 8 Open all coolant flow valves to the heater if equipped Wait two to three minutes without starting the engine to allow the coolant level to stabilize 9 Turn the HVAC temperature control knob fully clockwise to select maximum heat allowing maximum coolant flow through the heater co...

Page 41: ...flow through the heater core The blower motor must be turned ON to activate the water control valve 23 With the pressure cap off Operate the engine at LOW idle for two minutes Turn engine OFF and add plain water to bring the level back to FULL 24 With the pressure cap off Operate the engine at LOW idle for one minute to allow adequate oil pressure to build throughout the engine Operate the engine ...

Page 42: ...uring filling air must be purged from the engine coolant passages NOTICE Be sure to open the petcock on the aftercooler if equipped Wait two to three minutes to allow the air to be vented then add the mixture to bring the coolant level to the top NOTICE During all coolant fill procedures all coolant flow valves to equipment heating systems must be opened in order to purge air from those systems as...

Page 43: ... allow the coolant level to stabilize Add a 50 50 mixture to bring the coolant level back to FULL 10 Turn the HVAC temperature control knob fully clockwise to select maximum heat allowing maximum coolant flow through the heater core The blower motor must be turned ON to activate the water control valve WARNING Do not stand near the surge tank or radiator while operating the engine with the pressur...

Page 44: ...ck the vehicle s wheels 1 Start the vehicle s engine and build air pressure in excess of 90 psi 621 kPa Manually engage and disengage the fan drive by disconnecting and reconnecting the harness connector from the solenoid valve Observe the fan and fan drive from a distance Look for vibration fan blade contact fan drive slippage and fan drive operation 2 Refer to Figure 39 and inspect for air leaks...

Page 45: ...is distance to determine wear Fan Drive Drive Pulley Aluminum Spring Housing Friction Liner Figure 41 6 Check the electrical wiring at the air conditioning trinary pressure switch and the solenoid valve Ensure there are no loose wires or connections 7 Check the fan drive for proper engagement and disengagement Turn on the ignition switch but do not start the engine Be certain at least 90 psi 621 k...

Page 46: ...Check all air conditioning system lines hoses and connections for evidence of leakage Current production tractors use a fluorescent dye in the refrigerant Use a black light to look for leaks Under Tractor Inspection 300 Hours Note Any fastener or driveline component with a shiny metallic appearance or having rust streaks indicates a loose or broken part Driveline Check U joints and slip yokes for ...

Page 47: ...are tightened to the correct torque Check torque arm bushings and mounts if equipped Interior and Instrumentation CAUTION NEVER use fuel tanks unless nonslip steps are part of the tank or the tops of the battery boxes as steps Always face the cab when entering or exiting the cab NEVER exit the cab face first Use a three point mounting approach to enter exit the cab Always have two hands and one fo...

Page 48: ...gure 42 Post Road Test Inspection 300 Hours Major Components Check all major components for fluid leaks engine transmission cooling system fuel system power steering system and rear axles Record Keeping Check and record the date of the last inspection and inspection interval every 150 hours Complete inspection form and apply new sticker INSPECTION 1 200 HOURS INTERVAL Description and Operation 1 2...

Page 49: ...ment manufacturer s documentation for service intervals procedures and specifications Cab Tilt Pump Check cab tilt hydraulic oil level Air Conditioning Inspect the sight glass to determine if moisture is present If the sight glass shows a blue indicator the A C dryer is in good working condition If the sight glass shows a pink indicator the A C dryer must be replaced Change air conditioning system...

Page 50: ...ch 9 5 mm should be observed on full lock between stub axle and steering stop adjusting bolt INSPECTION 2 400 HOURS INTERVAL Description and Operation 2 400 Hours Perform this inspection every 2 400 hours of operation or yearly maximum recommended interval whichever comes first This is commonly referred to as an annual inspection for single shift tractors NOTICE This inspection includes everything...

Page 51: ...replace them Torque 5 8 axle flange nuts 190 10 lb ft 258 N m Torque 3 4 axle flange nuts 275 25 lb ft 373 N m Torque wheel lug nuts to 450 lb ft 610 N m Brake System Air Dryer Replace the air dryer desiccant Refer to manufacturer s recommendation Slack Adjusters Inspect the slack adjuster operation mounting and adjustment Hydraulic and Power Steering System Hydraulic and Power Steering Reservoir ...

Page 52: ...e fan drive bearing x Check the fan drive friction facing x Check the electrical wiring x Check the fan drive for proper engagement and disengagement x Check two speed fan clutch mechanism if equipped x Test coolant concentration x Pressure test pressure cap x Test block heater if equipped x Install new coolant filter if equipped Refer to engine manufacturer s service intervals Drain and refill co...

Page 53: ...al section x Lubricate driveline x Check for looseness of components x Slip joint x U joints x Engine Replace engine oil and filter Refer to the engine manufacturer s documentation for procedures specifications and service intervals Check all engine mounting fasteners for proper torque x Transmission Check for loose rear transmission bearing driveshaft yoke x Check oil level x Replace fluid and fi...

Page 54: ... steering column for secure mounting and bearing smoothness x Inspect tie rod ends x Tighten draw key nut to specification x Check steering arm bolt torque x Inspect pitman arm and nut x Check steering knuckle vertical play Refer to steer axle manufacturer s documentation for procedures specification and service interval Check and record king pin movement Lubricate steering and front suspension Ch...

Page 55: ...1 2 in hex head 80 5 lb ft 108 6 8 N m 1 2 in flange head 105 10 lb ft 142 13 5 N m 9 16 in 139 6 lb ft 188 8 N m 5 8 in 200 20 lb ft 271 27 N m 3 4 in 280 15 lb ft 380 20 N m Frame Bolts 1 2 in 105 10 lb ft 142 13 5 N m 5 8 in 200 20 lb ft 271 27 N m 3 4 in 300 30 lb ft 414 41 N m Pitman Arm Pinch Bolt 295 45 lb ft 400 60 N m Steering Gear Mounting Bolt 3 4 in 16 320 30 lb ft 414 41 N m Torque Ro...

Page 56: ...ust meet Cummins CES 20081 standards l Gas Chevron RPM Gas Engine Oil 15W40 Engine Coolant Coolant Reservoir Texaco Extended Life Coolant 50 50 mix or equivalent as required Do not mix different types of coolant Diesel Exhaust Fluid DEF Reservoir Fleetgaurd Air Shield Diesel Exhaust Fluid Refrigerant System Refrigerant R134a PAG 46 Transmission Transmission Filler Tube Castrol Transynd Transmissio...

Page 57: ...RICATION CHART TOP VIEW 1 2 2 3 4 5 1 1 4 1 Typical Chassis Lube and Fluids Actual component location varies by model 1 Chassis Grease 4 Castrol Transynd Transmission Fluid 2 Gear Oil as specified 5 Engine Oil as specified 3 Castrol Transynd Transmission Fluid Figure 45 ...

Page 58: ... 00192 Rev 000 54 ACTT Xspotter Service Manual CHASSIS LUBRICATION CHART BOTTOM VIEW 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Chassis Lube and Fluids Actual component location varies by model 1 Chassis Grease 2 Gear Oil Figure 46 ...

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Page 60: ...Printed In U S A Autocar Industries LLC 551 South Washington Street Hagerstown IN 47346 www autocartruck com Autocar Industries LLC 2018 AWE 00006 Rev 005a ...