AUTOCAR ACTT Xspotter 2018 Service Manual
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AUTOCAR ACTT Xspotter 2018 Service Manual

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

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Summary of Contents for AUTOCAR ACTT Xspotter 2018

  • Page 1 ACTT Service Manual Preventive Maintenance autocartruck.com AWE 00006 Rev. 005a...
  • Page 3 Autocar products that have been modified after leaving Autocar’s factory. Autocar is not liable for any damage or failure of components added by a body builder or any other modification company not contracted by Autocar, or the failure of original components caused by any modification or alteration of the Autocar product.
  • Page 4 This page left blank intentionally.

  • Page 5: Table Of Contents

    Preventive Maintenance Table of Contents Safety Definitions ........................3 Safety Information ........................3 General Safety ........................3 Lifting ............................. 4 Jacking Up the Vehicle ......................4 Pneumatic (Compressed Air) Components ................4 Hydraulic Components ......................4 Working on CNG/LNG Trucks ....................5 Working on CNG Fuel Systems ....................
  • Page 6 ACTT Xspotter Service Manual Under Tractor Inspection (150 Hours).................. 19 Description ........................... 19 Lubrication ..........................20 Steering and Suspension ..................... 22 Interior and Instrumentation ....................23 Road Test (150 Hours) ......................27 Post Road Test Inspection (150 Hours) ................29 Inspection 300 Hrs Interval ....................

  • Page 7: Safety Definitions

    The technician performing maintenance repairs or service on Autocar products must (a) inspect NOTICE the vehicle for abnormal wear and damage, (b) choose a repair procedure which will not...

  • Page 8: Lifting

    Immediately replace safety decals if they entire system. become damaged, unreadable or missing. Stay clear when inflating or deflating air Contact Autocar for replacement decals bags. Drain ALL air reservoirs and ALL when required. air suspension components including Lifting...

  • Page 9: Working On Cng/Lng Trucks

    Field Service Bulletin: Welding and Hot guidance and additional compliance Work Precautions Near CNG and LNG information. Vehicles. Technicians working on Autocar trucks CNG Cylinders with CNG or LNG engines must be trained in the proper repair of CNG and LNG WARNING trucks and engines and the safe storage and dispensing of CNG and LNG.

  • Page 10: Cng Fuel Container Pressure Relief Devices (Prds)

    ACTT Xspotter Service Manual Eye, Ear and Skin Protection FMVSS 304 also requires that cylinders not be used after the end of life (EOL) date provided on the tank label. The WARNING EOL date is also displayed in the engine compartment and at the fueling ALWAYS wear appropriate eye protection connection of each truck.

  • Page 11: Road Testing The Vehicle

    Preventive Maintenance Road Testing the Vehicle WARNING When operating the vehicle on streets and highways while testing, ALWAYS have one DO NOT EXCEED 15 MPH (24 KM/H) person drive while another performs the test. WHEN TOWING TRAILERS. Failure to do so may cause a collision, which Operating at speeds in excess of 15 mph can result in serious injury or death.

  • Page 12: While Servicing The Vehicle

    ACTT Xspotter Service Manual LOCKOUT / TAGOUT PROCEDURES SAFETY INSTRUCTIONS WARNING Before driving the vehicle, be certain that you have read and understand the Before entering the vehicle or vehicle driving and handling information in the body, read and follow OSHA regulations Operator Manual.

  • Page 13: Introduction

    This inspection includes everything done shortening the interval between chassis during the A and B inspections, plus additional lubrication. Contact your authorized Autocar items requiring inspection at this interval. dealer to develop the Preventive Maintenance D Inspection Program that is best suited to your application.

  • Page 14: Inspection 150 Hrs Interval

    While conducting these inspections record the results using the Preventive Maintenance Wiper Blade and Arm Inspection form available from Autocar. • Check condition of wiper blade and arm for looseness, bends, tension, etc. Exhaust Stack • Check that the exhaust stack is not damaged and is securely mounted •...
  • Page 15 Preventive Maintenance Supply Lines and Wires • Check that all air lines, fuel lines, diesel exhaust fluid lines and electrical wires are properly routed and clamped securely. • Check the operation of cab tilt and cab latch mechanism Refer to the “Tilting the Cab”...
  • Page 16 ACTT Xspotter Service Manual Frame Rails and Crossmembers • Check the frame rails and crossmembers for cracks, damage or distortion. • Check the frame for loose bolts. Tighten any loose bolts to proper torque specification. • Check the condition of the paint and overall appearance of the tractor.

  • Page 17: Fuel System

    • Using a tire tread depth gauge, check the tread depth in the center of the tread. Record the tread depth in 1/32s of an inch. Autocar recommends that front (steering axle) tires with less than 4/32 in. tread depth should be replaced, and rear (drive) tires with less than 2/32 in.
  • Page 18 ACTT Xspotter Service Manual Diesel Exhaust Fluid (DEF) System (On- Highway Models Only) 1. Inspect 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.

  • Page 19: Braking System

    Preventive Maintenance Braking System Air Reservoirs WARNING DANGER When draining the air tanks, do not look NEVER release a vehicle that has a into the area of the escaping air. Dirt or defect in the brake system – no matter sludge particles may be expelled and how minor the defect.

  • Page 20: Electrical System

    ACTT Xspotter Service Manual Electrical System • Apply the brakes. Ensure that there is an application of the slack adjusters for the Battery Hold-Down Hardware rear brakes. • Inspect the battery hold-down hardware and Slack Adjuster fasteners for proper placement. Ensure the batteries are secure and free of corrosion •...

  • Page 21: Engine Compartment

    Preventive Maintenance Engine Compartment WARNING General Inspection • Check for evidence of fluid leaks. NEVER remove the coolant surge tank cap or radiator cap when the engine is • Inspect all hoses for cracking, cuts, secure warm. The explosive escape of scalding installation, proper routing and clamping, coolant or steam will result.

  • Page 22: Cooling System

    ACTT Xspotter Service Manual • Check windshield washer fluid level • Check the power steering/hydraulic fluid (Figure 15 [Item 1)]. level (Figure 16). The fluid level may be checked with the engine running or not. The • Check washer reservoir mounting. Check fifth wheel must be completely lowered to condition of washer hoses.

  • Page 23: Intake Air Piping

    Preventive Maintenance 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 material.

  • Page 24: Lubrication

    ACTT Xspotter Service Manual Lubrication Starter • Inspect for secure mounting and evidence Driveline Lubrication of cracks. Note: Refer to the axle manufacturers’ • Check routing and clamping of cables documentation for recommended (Figure 19). lubricants, change intervals and service specifications.
  • Page 25 Preventive Maintenance Slip Joint Lubrication Procedure • Change the engine oil per engine manufacturer’s recommendation. Remove 1. Loosen the dust cap nut at the rear end of and replace full-flow and bypass filters. the slip yoke one full turn (Figure 20, Check crankcase capacity and fill to proper Item [3]).

  • Page 26: Steering And Suspension

    (see manufacturers’ documentation for interval, procedure and specifications). Rear Suspension • Check the rear suspension for cracks and secure mounting. Refer to the manufacturer’s service literature, or the appropriate Autocar suspension service manual for service procedures. 877-973-3486 AWE 00192 Rev. 000...

  • Page 27: Interior And Instrumentation

    Preventive Maintenance INTERIOR AND Seat • Check the seat suspension and adjustment INSTRUMENTATION mechanisms. • Lubricate the seat adjustment mechanism. CAUTION • Examine the seat belt for condition, function NEVER use fuel tanks (unless nonslip of retractor, latch, adjusting hardware, steps are part of the tank) or the tops and interface with cab panels or hardware of the battery boxes as steps.
  • Page 28 ACTT Xspotter Service Manual Exterior Lights Instrument and Dash Lighting • Turn the key to the ON position (Figure 24). Note: This procedure may require the help of an assistant. • Check operation and condition of all exterior lights: emergency flashers, turn signals (front and rear), brake lights, parking lights, headlights (low and high beam), marker and clearance lights, taillights, reverse lights,...
  • Page 29 Preventive Maintenance Starting The Engine • Check for evidence of intake air restriction as follows: • Ensure that the starter solenoid engages and disengages properly. The starter motor • If the tractor is equipped with an engine- should turn over without any abnormal mounted air restriction gauge, run the noise or drag.
  • Page 30 ACTT Xspotter Service Manual Governor Test Air System Test the air compressor governor cut-in/cutout • Check the operation of the low air pressure as follows: warning light (Figure 28) and audible alarm. • Pump the brake pedal until the pressure drops to 30 psi (207 kPa).

  • Page 31: Road Test (150 Hours)

    Preventive Maintenance Road Test (150 Hours) on the in-cab monitor, if equipped. Radio WARNING • Check the operation of the AM/FM and two- way radios, if equipped. DO NOT EXCEED 15 MPH (24 KM/H) WHEN Steering TOWING TRAILERS. • Check the steering wheel for excessive play Operating at speeds in excess of 15 mph (free movement not to exceed a maximum (24 km/h) may lead to loss of vehicle...
  • Page 32 ACTT Xspotter Service Manual • Using the dash oil pressure gauge CAUTION (Figure 33), check and record high and low oil pressure. NEVER exceed the manufacturer’s recommended maximum engine speed. If the oil pressure gauge indicates a sudden drop in oil pressure, stop the engine immediately.

  • Page 33: Post Road Test Inspection (150 Hours)

    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. Figure 34 Fuel Water Separator Filter 877-973-3486 AWE 00192 Rev. 000...
  • Page 34 ACTT Xspotter Service Manual Slack Adjuster • Replace fuel/water separator filter (Figure 35 or Figure 36). Fill new filter(s) • Inspect the slack adjuster operation, with clean fuel prior to installation to reduce mounting and adjustment (Refer to air in fuel system (refer to manufacturers’ equipment manufacturer’s documentation documentation for procedure).
  • Page 35 Preventive Maintenance Electrical System Batteries and Cables Figure 38 Alternator • Test the alternator as follows: • Remove the surface charge — connect a carbon pile and load the batteries at 25% of their total CCA rating for 15 seconds. Or, turn the headlights on high beam for Figure 37 two to three minutes per battery.

  • Page 36: Cooling System Service

    ACTT Xspotter Service Manual COOLING SYSTEM SERVICE • With a carbon pile, apply a current load equal to 75% of rated output capacity of the Coolant Drain and Fill Deaeration alternator for 10 seconds. Procedure • Test voltage at the alternator terminals using a volt meter.
  • Page 37 Preventive Maintenance Note: If coolant is being changed or the WARNING cooling system is being flushed, it is desirable to leave the coolant flow valves Do not stand near the surge tank or to the equipment heating systems open, in radiator while operating the engine with order to completely drain the system.

  • Page 38: Complete Cooling System Maintenance Procedures

    ACTT Xspotter Service Manual Complete Cooling System 5. Check for damaged hoses and loose or damaged hose clamps. Replace as Maintenance Procedures required. 6. Check the radiator for leaks, damage, NOTICE and buildup of dirt. Clean and replace as required. The following information is provided 7.
  • Page 39 Preventive Maintenance NOTICE NOTICE Operation of the EGR system without Do not allow the engine speed to sufficient coolant will damage the exceed 2,000 rpm while the EGR valve is EGR cooler. The EGR valve MUST be disconnected. Operation at higher rpm in disconnected prior to the fill procedure this mode can result in engine damage.
  • Page 40 ACTT Xspotter Service Manual WARNING WARNING Do not remove the pressure cap from Do not stand near the surge tank or radiator while operating engine with a hot engine. Wait until the coolant the pressure cap off. If the vehicle is temperature is below 120°F (50°C) before removing the pressure cap.
  • Page 41 Preventive Maintenance 13. Turn the engine OFF and verify that 23. With the pressure cap off: coolant is visible in the sight glass on - Operate the engine at LOW idle for two the coolant reservoir and add coolant, if minutes.
  • Page 42 ACTT Xspotter Service Manual NOTICE NOTICE Operation of the EGR system without Be sure to open the petcock on the sufficient coolant will damage the aftercooler, if equipped. Wait two to three EGR cooler. The EGR valve must be minutes to allow the air to be vented; then disconnected prior to the fill procedure add the mixture to bring the coolant level in order to protect the EGR cooler from...
  • Page 43 Preventive Maintenance 10. Turn the HVAC temperature control knob NOTICE fully clockwise to select maximum heat allowing maximum coolant flow through The cooling system must be filled slowly the heater core. The blower motor must to prevent airlocks. During filling, air be turned ON to activate the water control must be vented from the engine coolant valve.

  • Page 44: Fan Clutch Service

    ACTT Xspotter Service Manual 15. The freeze point protection must be 2. Refer to Figure 39 and inspect for air checked if coolant is added to the cooling leaks at the points shown. system. • Check for air leaks around the fan drive while applying air to the fan drive.
  • Page 45 Preventive Maintenance Area between Measure this distance to determine wear drive pulley and fan drive Fan Drive Drive Pulley Aluminum Friction Check for Spring Liner discolorization or Housing other signs Figure 41 of overheating Figure 40 6. Check the electrical wiring at the air- conditioning trinary pressure switch and 4.

  • Page 46: Additional Checks For Two-Speed Fan Drives

    ACTT Xspotter Service Manual Additional Checks for Two-Speed Fan Under Tractor Inspection (300 Hours) Drives Note: Any fastener or driveline component Check the Two-Speed Mechanism, (while air with a shiny, metallic appearance, or having is applied to the fan drive) by rotating the fan rust streaks, indicates a loose or broken and clutch pack in both directions (independent part.

  • Page 47: Road Test (300 Hours)

    Preventive Maintenance Steering and Suspension Interior and Instrumentation Steering CAUTION • With front axle elevated, turn the steering wheel from side to side. There should be NEVER use fuel tanks (unless nonslip slight drag at the center point. If no drag steps are part of the tank) or the tops can be felt, adjustment is required.

  • Page 48: Post Road Test Inspection (300 Hours)

    Preventive Maintenance Inspection procedures, and Autocar recommends reviewing each component’s documentation for its’ recommended maintenance schedule. While conducting these inspections record Figure 42 the results using the Preventive Maintenance Inspection form available from Autocar. 877-973-3486 AWE 00192 Rev. 000...

  • Page 49: Walk-Around Inspection (1,200 Hours)

    Preventive Maintenance Walk-Around Inspection Brake System (1,200 Hours) Slack Adjuster Fuel System • Inspect the slack adjuster operation, mounting and adjustment (Refer to Fuel Filter equipment manufacturer’s documentation • Replace fuel filter(s). Fill new filter(s) with for service intervals, procedures and clean fuel prior to installation to reduce specifications).

  • Page 50: Inspection 2,400 Hours Interval

    • Check center bolt and springs, if equipped. Major vehicle components such as engine, Note: Autocar sets axle stops to provide transmission and axles may have their maximum turn angle. Clearance of 3/8 own Preventive Maintenance Inspection inch (9.5 mm) should be observed on full...

  • Page 51: Walk-Around Inspection (2,400 Hours)

    Preventive Maintenance Walk-Around Inspection (2,400 Hydraulic and Power Steering System Hours) Hydraulic and Power Steering Reservoir Emissions System • Drain and replace hydraulic oil. DEF Filter • Replace hydraulic filter. • Change the DEF Doser Unit Filter Under Tractor Inspection (2,400 (Figure 44).

  • Page 52: Preventive Maintenance Intervals

    ACTT Xspotter Service Manual PREVENTIVE MAINTENANCE INTERVALS Interval 1200 2400 hrs or Annually Inspect battery hold-down hardware. Inspect batteries and cables. Electrical System Remove any corrosion from battery terminals. Ensure all ground connections are clean and tight. Check for all fluid levels and check for leaks. Inspect all hoses for damage and correct routing.
  • Page 53 Preventive Maintenance Interval 1200 2400 hrs or Annually Air conditioning: Check compressor mounting. Inspect for leaks. Check sight glass for moisture. Change A/C drier as necessary. (1) Walk-up/ Engine Walkaround Pressure test system for proper level of refrigerant. Compartment Inspection (continued) Air compressor: (continued)
  • Page 54 ACTT Xspotter Service Manual Interval 1200 2400 hrs or Annually Inspect front suspension: Springs. Shackles. Check spring hanger bolt torque. Mounting hardware, mounts, and U-bolts. Check steering: Check steering for excessive play. Check for secure steering gear mounting. Inspect drag link. Inspect coupler.

  • Page 55: Special Torque Chart

    Preventive Maintenance SPECIAL TORQUE CHART 5/8” 190 ± 10 lb.ft (258 ± 14 N·m) Axle Flange Nuts 3/4” 275 ± 25 lb.ft (373 ± 34 N·m) M12 X 1.75 65 ± 5 lb.ft (88 ± 7 N·m) Engine Mount Bolts 9/16 in.

  • Page 56: Lubricant And Fluid Requirements

    ACTT Xspotter Service Manual Lubricant and Fluid Requirements System Service Locations Required Lubricant/Fluid Front Spring Hangers Tie Rod Ends and Drag Link King Pins Front Axle & Steering EP NLGI 1 or 2 Steering Shaft U-Joints Steering Gear Output Shaft Grease Fitting Brake S-Cams and Slack Adjusters Front Wheel Bearings Front Hub Bearings...

  • Page 57: Chassis Lubrication Chart (Top View)

    Preventive Maintenance CHASSIS LUBRICATION CHART (TOP VIEW) Typical Chassis Lube and Fluids (Actual component location varies by model) Castrol Transynd ® ® Chassis Grease Transmission Fluid Engine Oil (as Gear Oil (as specified) specified) Castrol Transynd Transmission Fluid ® ® Figure 45 877-973-3486 AWE 00192 Rev.

  • Page 58: Chassis Lubrication Chart (Bottom View)

    ACTT Xspotter Service Manual CHASSIS LUBRICATION CHART (BOTTOM VIEW) 1 1 1 1 1 2 Chassis Lube and Fluids (Actual component location varies by model) Chassis Grease Gear Oil Figure 46 877-973-3486 AWE 00192 Rev. 000...
  • Page 60 Autocar Industries, LLC 551 South Washington Street Hagerstown, IN 47346 www.autocartruck.com © Autocar Industries, LLC 2018 Printed In U.S.A. AWE 00006 Rev. 005a...

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