ACTT

Service
Manual

Preventive Maintenance

AWE 00006 Rev. 005a

autocartruck.com
 Preventive Maintenance
Important Notice
This Service Manual has been prepared by Autocar Industries, LLC (“Autocar”) for reference and use
by technicians who have been trained to repair and service Autocar products.
Autocar has exercised reasonable care and diligence to present accurate, clear and complete
information and instructions regarding the techniques and tools required for maintaining, repairing
and servicing Autocar products. However, despite the care and effort taken in preparing this general
Service Manual, Autocar makes no representations or warranties that (a) the Service Manual or any
explanations, illustrations, information, techniques or tools described herein are either accurate,
complete or correct as applied to a specific Autocar product, or (b) any repairs or service of a
particular Autocar product will result in a properly functioning unit.
The vehicles and components referenced in this manual are under continuous 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 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.
Autocar is dedicated to protecting the environment. When servicing Autocar products, please dispose
of all removed material, oils and coolant in an environmentally responsible manner.

Autocar Industries, LLC

Hagerstown, Indiana, U.S.A.

Document Number: AWE 00192 Rev. 000

Copyright © 2018 Autocar Industries, LLC

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form by any means - electronic, mechanical, photocopying, recording or otherwise
- without the prior written consent of Autocar.
This page left blank intentionally.
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............................................................................................. 5
CNG/LNG Safety.................................................................................................................... 5
Welding and Hot Work Near CNG and LNG Trucks............................................................... 5
CNG Cylinders....................................................................................................................... 5
CNG 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 (150 Hours)........................................................................................... 10
Walk-Around Inspection....................................................................................................... 10
Fuel System......................................................................................................................... 13
Braking System.................................................................................................................... 15
Electrical System.................................................................................................................. 16
Electrical System.................................................................................................................. 16
Engine Compartment........................................................................................................... 17
Cooling System.................................................................................................................... 18
Intake Air Piping................................................................................................................... 19

AWE 00192 Rev. 000 877-973-3486 TOC-1

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.................................................................................................... 29
Walk-Around Inspection (300 Hours).................................................................................... 29
Cooling System Service......................................................................................................... 32
Coolant Drain and Fill Deaeration Procedure....................................................................... 32
Complete Cooling System Maintenance Procedures............................................................ 34
Fan Clutch Service................................................................................................................. 40
Fan Drive Inspection............................................................................................................. 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 (2,400 Hours)............................................................................. 46
Walk-Around Inspection (2,400 Hours)................................................................................. 47
Brake System........................................................................................................................ 47
Under Tractor Inspection (2,400 Hours)................................................................................ 47
Preventive Maintenance Intervals......................................................................................... 48
Special Torque Chart.............................................................................................................. 51
Lubricant and Fluid Requirements........................................................................................ 52
Chassis Lubrication Chart (Top View).................................................................................. 53
Chassis Lubrication Chart (Bottom View)............................................................................ 54

TOC-2 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
SAFETY DEFINITIONS SAFETY INFORMATION
The following safety indicators are used in this Ensure safe working conditions and
manual: procedures at all times. Read and understand
this entire manual before servicing the vehicle.
You must be thoroughly trained and familiar
DANGER with the vehicle before working on it. This
DANGER indicates a hazardous situation equipment can cause severe injury if not
which, if not avoided, will result in death properly used and maintained.
or serious injury or damage to equipment Safety procedures are for your protection. Do
or other property. not operate the vehicle until you have read and
understood the Operator Manual supplied with
WARNING the vehicle.
General Safety
WARNING indicates a hazardous situation
which, if not avoided, could result in There is no substitute for common sense and
death or serious injury or damage to careful practices in the workplace. Improper
equipment or other property. practices or carelessness can cause burns,
cuts, mutilation, asphyxiation, other bodily
injury or death. The sections that follow provide
CAUTION general safety precautions and guidelines.
Additional safety precautions are listed in
CAUTION indicates a hazardous situation
specific procedures when they apply. Read and
which, if not avoided, may result in
understand all of the safety precautions and
minor or moderate injury or damage to
guidelines before performing any repair.
equipment or other property.
The technician performing maintenance repairs
or service on Autocar products must (a) inspect
NOTICE the vehicle for abnormal wear and damage,
NOTICE is used to address practices not (b) choose a repair procedure which will not
related to physical injury which, if not endanger his/her safety, the safety of others,
complied with, may result in damage to the vehicle or the safe operation of the vehicle
equipment or other property. and (c) fully inspect and test the Autocar
product to ensure that the repair or service
SAFETY of the Autocar product has been properly
INSTRUCTIONS performed.
Safety instructions (or equivalent) Autocar is dedicated to protecting the
indicate specific safety-related environment. When servicing Autocar products,
instructions or procedures. please dispose of all removed material, oils
and coolant in an environmentally responsible
manner.

AWE 00192 Rev. 000 877-973-3486 3

ACTT Xspotter Service Manual
Refer to the “Antilock Braking System
WARNING Service Manual - AWE 00178 Rev. 000” for
information on disabling the ABS system.
NEVER service any part of the fuel
system while smoking or in the presence Pneumatic (Compressed Air)
of flames, sparks or hot surfaces. Components
Clean up fuel spills immediately. Fuel
leaked or spilled onto hot surfaces or DANGER
electrical components can cause a fire.
Pneumatic components such as air
Before working in or around the vehicle, reservoirs and park brake chambers
apply the parking brake, block the wheels store compressed air and can separate
and put the transmission in NEUTRAL. violently during disassembly or removal.
Before servicing any part of the
WARNING pneumatic (air) system, completely
release the compressed air from the
Immediately replace safety decals if they
entire system.
become damaged, unreadable or missing.
Contact Autocar for replacement decals Stay clear when inflating or deflating air
when required. bags. Drain ALL air reservoirs and ALL
air suspension components including
Lifting auxiliary, tag or pusher axle suspensions
Use a hoist or other assistance when lifting before working under or around a vehicle.
components that weigh 50 lb. (23 kg) or more.
Make sure all lifting devices such as chains, Hydraulic Components
hooks or slings are in good condition and have
the correct capacity. Make sure hooks are DANGER
positioned correctly. ALWAYS use a spreader
bar when necessary. The lifting hooks MUST Hydraulic systems and fuel injection
NOT be side loaded. systems can operate under extremely
high pressures and can remain
Jacking Up the Vehicle pressurized long after shutdown. Before
NEVER work under a vehicle supported only servicing any part of the hydraulic system
by jacks. Jacks can slip out from under the or fuel injection system, carefully relieve
vehicle or fall over. ALWAYS use jack stands the pressure completely. Escaping fluid
under the vehicle. Failure to do so can result in under high pressure can penetrate the
the vehicle falling. skin causing severe injury. NEVER check
for leaks using your hand.
The Antilock Brake System (ABS) MUST be
disabled on vehicles equipped with Automatic To pinpoint the origin of the leak use a
Traction Control (ATC) prior to jacking up the mirror, a piece of wood or cardboard held
vehicle and placing it on jack stands. If the ABS with long-nose pliers in the vicinity of the
is not disabled and one of the wheels starts to leak.
spin, the ATC will compensate and the vehicle
may come off the jack and/or jack stands.

4 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Working on CNG/LNG Trucks Attempting to operate or maintain any
CNG fuel system without proper training
SAFETY is dangerous. Complete training and
INSTRUCTIONS
consult instructional bulletins from the
If you store or dispense Compressed CNG system suppliers, such as Agility
Natural Gas (CNG) or Liquefied Natural Fuel Systems’ Field Service Bulletin:
Gas (LNG), or if you work on CNG or Safely Working on CNG Fuel Systems.
LNG trucks, your location must be CNG/LNG Safety
fully compliant with applicable codes,
regulations and standards, including
National Fire Protection Associate (NFPA) WARNING
codes, Society of Automotive Engineers
(SAE) standards, American National Welding and Hot Work Near CNG and
Standards Institute (ANSI) Natural Gas LNG Trucks
Vehicle (NGV) standards, the United Welding, grinding and other “hot work”
States Code of Federal Regulations (CFR) can be safely performed on or near a CNG
and your state and local fire and other or LNG vehicle, but certain precautions
applicable codes (including, for example, must be followed. Understand and
the California Code of Regulations and perform the necessary precautions
the Texas Administrative Code). provided by the CNG and LNG system
Contact your local fire department for suppliers, such as Agility Fuel Systems’
guidance and additional compliance Field Service Bulletin: Welding and Hot
information. Work Precautions Near CNG and LNG
Vehicles.
Technicians working on Autocar trucks
with CNG or LNG engines must be trained CNG Cylinders
in the proper repair of CNG and LNG
trucks and engines and the safe storage WARNING
and dispensing of CNG and LNG.
CNG fuel containers must meet Federal
Working on CNG Fuel Systems Motor Vehicle Safety Standard (FMVSS)
304 (Compressed Natural Gas Fuel
WARNING Container Integrity) and/or ANSI/
CSA NGV2 (Basic Requirements for
CNG fuel systems include a high pressure Compressed Natural Gas Vehicle Fuel
(3600 psi [24 820 kPa]) system for fuel Containers). Both standards specify a
storage and a low pressure system (125 detailed visual examination every three
psi [860 kPa]) for consumption by the years.
engine. Understanding the characteristics
of CNG and how the fuel system works Ensure that every truck owner completes
will prevent injury and damage to persons the required inspections, in accordance
and property. with the applicable standards and other
resources, such as the Clean Vehicle
Education Foundation and NGVAmerica’s
Compressed Natural Gas (CNG)
Container Visual Inspection Advisory.

AWE 00192 Rev. 000 877-973-3486 5

ACTT Xspotter Service Manual
FMVSS 304 also requires that cylinders Eye, Ear and Skin Protection
not be used after the end of life (EOL)
date provided on the tank label. The
EOL date is also displayed in the
WARNING
engine compartment and at the fueling ALWAYS wear appropriate eye protection
connection of each truck. If there is any to prevent the risk of eye injury. Wear
question as to proper decommissioning safety glasses to prevent eye contact
of a cylinder, contact the manufacturer, with debris and fluids. Wear a welding
whose name and address is also required face mask to protect eyes and face when
to be on the label. welding.
CNG Fuel Container Pressure Relief ALWAYS wear ear plugs when working
Devices (PRDs) around loud noises to prevent the risk of
hearing loss and damage.
WARNING ALWAYS wear appropriate gloves to
protect the hands. Wear welding gloves
PRDs must be properly maintained and to protect the hands when welding.
positioned for safe operation of a CNG Wear appropriate gloves when handling
fuel system. Missing vent caps can extremely hot or cold equipment and
allow moisture into PRDs and vent lines, fluids.
which can freeze and damage these
safety components. Debris which clogs Testing the Equipment
the PRDs and/or vent lines can prevent
proper function. WARNING
PRDs must be positioned to vent upward,
Exhaust gases contain deadly poison.
not outward, from a vehicle.
When testing a vehicle with the engine
Ensure that every truck owner completes running, conduct the test outdoors or use
periodic inspections of the PRDs and a properly vented exhaust hose.
vent lines and systems, in accordance
Use caution when installing testing
with guidance provided by the system
equipment. Keep away from hot engine
component suppliers.
or transmission components or fluids.
Alert First Responders to CNG A hot engine, transmission or fluids can
and LNG permanently damage test equipment and
can cause personal injury.

DANGER If a vehicle is to be operated with testing

equipment connected, take precautions
In the event of a fire or other emergency, to ensure that all equipment and related
alert first responders to the presence components are securely attached, to
and location of CNG fuel systems, prevent movement and interference.
tanks and dispensers. Ensure that All items within the cab must be secured
emergency personnel are aware of proper before the vehicle is serviced or driven.
precautions, such as those provided in
Agility’s First Responder Guide: CNG and
LNG Vehicle Fuel Systems.

6 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Road Testing the Vehicle
When operating the vehicle on streets and
WARNING
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
can result in serious injury or death. Operating at speeds in excess of 15 mph
(24 km/h) may lead to loss of vehicle
control. NEVER take turns at excessive
WARNING speeds, this may cause the vehicle and
trailer to roll over.
NEVER operate the starter without first
placing the transmission in NEUTRAL The majority of roll over accidents are
and applying the parking brake. Failure to caused by excessive cornering speed.
follow these instructions may result in the Roll over accidents may lead to serious
unintentional movement of the vehicle. injury or death.
NEVER release or drive a truck on the
road that has a brake defect – no matter WARNING
how minor – until it has been repaired or
corrected. Failure to repair brake defects Never tow trailers without BOTH the
can result in compromised braking and service and emergency brake lines
lead to loss of control of the vehicle. connected to the trailer.

NEVER drive the vehicle without power Never tow trailers without functioning
assisted steering. When the power assist service and emergency brake systems.
has failed, the effort required to turn the Operating the vehicle while towing
steering wheel is much greater, especially trailers without functioning trailer brake
in sharp turns or at low speeds. systems may lead to loss of control of the
vehicle, serious injury or death.
A speed retardation device (such as a
“Jake Brake®,” “C-Brake®” “Exhaust
Brake” or “Allison™ Retarder”) is not WARNING
intended to replace the service brake
Never tow a trailer above the minimum
system on the vehicle and cannot be
height required to clear the landing gear
relied on to bring the vehicle to a stop. A
from the ground. Lifting the fifth wheel
vehicle speed retardation device is only
and trailer too high drastically raises
intended to regulate the speed of the
the center of gravity of the trailer and
vehicle under certain conditions.
increases the chance of a roll over.

AWE 00192 Rev. 000 877-973-3486 7

ACTT Xspotter Service Manual
SAFETY LOCKOUT / TAGOUT PROCEDURES
INSTRUCTIONS

Before driving the vehicle, be certain WARNING

that you have read and understand the
driving and handling information in the Before entering the vehicle or vehicle
Operator Manual. Be certain that you body, read and follow OSHA regulations
fully understand and follow all safety concerning entry and working in
warnings. “CONFINED SPACE” OSHA 1910.146
and “LOCKOUT/TAGOUT” OSHA
While Servicing the Vehicle 1910.147. Follow OSHA regulations while
performing any work on the vehicle. The
CAUTION vehicle must be disabled by the following
steps before performing any work on the
Read and understand the precautions vehicle:
and guidelines in each component
1. Place the transmission in NEUTRAL.
manufacturer’s service information
before performing any service on the 2. Set the parking brake.
components. If you are not properly 3. Shut the engine OFF.
trained and certified in a procedure, ask 4. Lock the cab doors. Keep the key in your
your supervisor for training before you pocket. Block the wheels before entering
perform it. the body or performing any work on the
vehicle.
Ground Straps and Antistatic Mats 5. Turn the battery disconnect switch OFF, if
equipped, and lock it in that position.
SAFETY
INSTRUCTIONS 6. Completely drain the air from the
primary/A system and secondary/B
ALWAYS work with proper grounding system by opening the drain valves on
straps and antistatic mats around the air tanks themselves or by using the
electronic components. drain manifold if supplied. When draining
Power Steering the air tanks, do not look into the area
where air is draining. Dirt or sludge
SAFETY particles may be expelled in the air
INSTRUCTIONS stream and can cause eye injury.
Maintain cleanliness of the power 7. Place magnetic “DANGER” signs on both
steering hydraulic system at all times. cab doors before entering the body or
Clean the area around any component performing any work on the vehicle.
prior to disconnecting or connecting. 8. Take proper precautions before working
NEVER add used power steering fluid under the vehicle. Use ramps approved
to the system. Dirt in the power steering for the weight of your vehicle, or use floor
system can damage the pump or other jacks and stands. Never work under a
components. vehicle or auxiliary, tag or pusher axle
supported by jacks alone. Always use
jack stands to support the vehicle and
auxiliary, tag or pusher axles.

8 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
INTRODUCTION Major vehicle components such as engine,
transmission, axles and retarders, may
This manual has been designed to reflect have their own recommended preventive
a work-efficient approach to preventive maintenance intervals. Refer to each
maintenance. component’s maintenance manual for service
Periodic servicing, inspection, adjustment intervals and procedures. If no manufacturer
and maintenance are essential to the ongoing recommendation exists, follow the guidelines
dependability and efficiency of the vehicle. in the Preventive Maintenance Program in this
Vehicles that receive proper preventive Service Manual section.
maintenance operate more effectively and
economically. PREVENTIVE MAINTENANCE
One of the most important part of the vehicle’s
PROGRAM
maintenance is lubrication and oil changes. A Inspection
However, despite of the high quality of the Perform this inspection every 150 hours
lubricants and oils available today, natural wear of operation (maximum recommended
does occur necessitating adjustments and interval). This includes, but is not limited
repairs. to, basic inspection of the vehicle and may
A thorough Preventive Maintenance Program include engine oil and filter change, as well
can dramatically reduce breakdowns as complete chassis lubrication. Refer to
and increase service life. This Preventive manufacturer’s recommendations for further
Maintenance Program has been developed information.
to help prevent unexpected downtime and
B Inspection
continuously maintain the vehicle in good
operating condition. Following these guidelines Perform this inspection every 300 hours of
will also help ensure the vehicle meets all operation (maximum recommended interval).
federal, state, and local regulations, which is This inspection includes everything done
the responsibility of the owner. during the A inspection, plus additional items
requiring inspection at this interval.
This manual is intended as a general guide.
Individual users may need to alter these C Inspection
recommendations based upon the application Perform this inspection every 1,200 hours of
in which the truck will be used. For example, operation (maximum recommended interval).
more severe applications may require 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
Program that is best suited to your application. D Inspection
Perform this inspection every 2,400 hours of
The vehicle be serviced based on operating
operation or yearly (maximum recommended
hours. Maintenance intervals based on months
interval), whichever comes first.
or mileage do not take into consideration actual
operating hours.

AWE 00192 Rev. 000 877-973-3486 9

ACTT Xspotter Service Manual
EXTERIOR INSPECTION
NOTICE (150 HOURS)
For tractors that do not accumulate Walk-Around Inspection
2,400 hours per year, the D inspection Fluid Leaks
must be done annually to ensure proper Before beginning the actual inspection, check
maintenance of the vehicle. the ground under the tractor as you approach,
This inspection includes everything done looking for evidence of fluid leaks.
during the A, B and C inspections, plus Glass, Mirrors and Brackets
additional items requiring inspection at this
interval.
Use the Preventive Maintenance Inspection
Form when completing this inspection. Copies
of this form can be obtained through the
Autocar website (www.autocartruck.com).
Each service should follow the recommended
sequence: A-B-A-B-A-B-A-C-A-B-A-B-A-B-A-D,
etc. See “Preventive Maintenance Intervals”
Chart in this section.

INSPECTION 150 HRS INTERVAL

Perform this inspection every 150 hours of
operation (maximum recommended interval).
This includes, but is not limited to, basic Figure 1
inspection of the vehicle and may include, • Check windshields; must be free of
engine oil and filter change, as well as damage, hazing or discoloration within
complete chassis lubrication. certain guidelines.
Major vehicle components such as engine, • Check the windows, vents and back window
transmission and axles may have their for cracks.
own Preventive Maintenance Inspection • Check mirrors, they should be free of
procedures, and Autocar recommends damage, hazing and discoloration. Brackets
reviewing each component’s documentation for should be secure.
its recommended maintenance schedule. • If the mirrors are motorized, check the
While conducting these inspections record operation.
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
• Check all flex pipes
• Check all exhaust blankets..

10 877-973-3486 AWE 00192 Rev. 000

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.
Cab
• Check the operation of cab tilt and cab
latch mechanism Refer to the “Tilting the
Cab” section in the Operators Manual for
complete procedures and warning for tilting
the cab.

WARNING
Close and securely 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. Check air suspension
components for condition, proper mounting,
and operation. Check for rust or cracks
around mounts (Figure 2). Figure 2
• Check latches for adequate tension.
• Check the cab hinges (Figure 3).

Figure 3

AWE 00192 Rev. 000 877-973-3486 11

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. Note any
damage, rust or corrosion.
• Check the condition of the cab access
steps, platforms and grab handles. They Figure 5
should be secure, undamaged and free
from slick spots (Figure 4). DANGER
Failure to properly torque-tighten the
wheel nuts can result in breakage of the
wheel studs and the subsequent loss
of the wheels. Loss of vehicle control
resulting in serious injury or death may
occur.
• Inspect the wheels for elongated or
distorted mounting holes. Examine the inner
and outer wheels for cracks and for rust
streaks around the lug nuts.
• Examine each tire for unusual or uneven
wear patterns.
Figure 4
• Check the valve stems and extensions on
Wheels and Tires
each wheel for leaks.
• Check for the presence and condition of
mudguards or flaps. Inspect the condition 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.

12 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
• Check and record pressure in each tire. The Fuel System
tire inflation pressure is specified by a decal Fuel Tank(s)
located near each tire. If there is no decal,
• Inspect fuel tank for damage, leaks or
refer to the air pressure as indicated on
rust (Figure 7).
each tire.
• 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. tread depth
should be replaced (Figure 6).
Note: The tires should be rotated
periodically to maximize tire life. Typically,
rear drive axle tires will wear more rapidly
than front drive axle tires, due to them
Figure 7
travelling on the outside of the turning
circle. No specific interval can be given, • Examine the mounting straps for cracks,
as the requirement changes depending on and ensure that the rubber insulators are
operational conditions. secure.
• Ensure that the tanks have not rotated in
their mounts.
1/8 in. 1/16 in,
• Inspect and clean the vent in each tank.
(3 mm) (6 mm)
• Inspect the operation of the shutoff valves.
• Drain water and sludge from all fuel tanks.
• Place a container under the fuel tank and
loosen the drain plug until water begins to
runout.
• Allow the fuel tank to drain until the water
and sludge are gone and only fuel is
draining. Install and tighten the drain plug.
Steer Drive Fuel Filters
Tire Tire • B Inspection: Change engine fuel filter.
Figure 6 • Drain the fuel filter/water separator and
clean the outside of the unit (Figure 8 or
Figure 9)
• Inspect all fuel lines for wear, damage and
secure clamping.

AWE 00192 Rev. 000 877-973-3486 13

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.
2. Inspect all DEF and DEF heater lines for
wear, damage and secure clamping.

Figure 8

Figure 10
3. D Inspection or annually - Replace DEF
system filter (Figure 11).

Figure 11
Figure 9

14 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Braking System Air Reservoirs

DANGER WARNING
NEVER release a vehicle that has a When draining the air tanks, do not look
defect in the brake system – no matter into the area of the escaping air. Dirt or
how minor the defect. Failure to repair sludge particles may be expelled and
brake system discrepancies can result cause eye injury.
in compromised brake efficiency leading • Open petcocks or pull drain cables on air
to loss of control, resulting in severe reservoirs to drain-off moisture If excessive
personal injury or death. oil or water comes from the tank, make a
Air Lines and Hoses note on the inspection form for follow-up
• Inspect all air lines and hoses for routing, (Figure 12).
secure clamping, chafing, cracks and
Note: As shown in Figure 12, some tanks
evidence of air leaks.
may be equipped with remote drains.
• Inspect air brake hoses for cracks or
damage.
• Inspect all air fittings to ensure that they are
tight.
• Check all valves for secure mounting and
listen for audible air leaks.

WARNING
Before beginning any service work on
any part of the air system, be certain
that the air pressure has been released.
Failure to do so may cause a component
to violently separate, which can result in
Figure 12
serious personal injury.
Dual Air Brake System
Air Dryer
• Apply full air brake pressure to the air brake
• “D” inspection or annually: Change system and verify there is no more than two
desiccant cartridge. psi (20 kPa) pressure loss per minute.
Note: Desiccant may require more frequent • Charge both A and B air systems.
service in humid climate operation. • Drain the air tank for the A system.
• Check mounting, wiring and connections. • Apply the brakes. Ensure that there is an
• Check operation per equipment application of the slack adjusters for the
manufacturer’s recommendation. front brakes.
• Check heater element, if equipped. Refer • Charge both A and B air systems again.
to manufacturer’s recommendation for • Drain the air tank for the B system.
inspection procedures. • Verify gauge reading.

AWE 00192 Rev. 000 877-973-3486 15

ACTT Xspotter Service Manual
• Apply the brakes. Ensure that there is an Electrical System
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
• Inspect the slack adjuster operation, batteries are secure and free of corrosion
mounting and adjustment (Refer to (Figure 13, Item [2]).
equipment manufacturer’s documentation
for service intervals, procedures and
specifications).
Chamber Plug
• Remove chamber plug and discard, then
inspect for hung-up caging plate. After
inspection is complete, install new chamber
plug.
S-Cams and Springs
• Examine S-cams, springs and
miscellaneous braking components for wear
and general condition.
Figure 13
Brake Lining
• Measure and record the brake lining Electrical System
thickness. Replace lining and shoe Batteries and Cables
assembly if 0.250 in. (6.35 mm) or less • Inspect the cables for proper length and
remains at the middle of the shoe. Check broken insulation or strands. Check the
the brake lining for cracks. Check and cables for chafing and proper routing.
note drum-to-lining clearance. Maximum Check that the terminal ends are secure
acceptable clearance is 0.063 in. (1.60 and free of cracks (Figure 13, Item [1]).
mm). • Remove any corrosion from the cable ends
and battery posts. After thorough cleaning,
Note: For a complete listing of preventive
spray the area with a corrosion-preventive
measures and their intervals refer to the
compound.
“Preventive Maintenance Schedule” in this
manual. • Ensure that all ground connections are
clean, free of corrosion and secure. Check
the terminal connections.

16 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Engine Compartment
General Inspection
WARNING
• Check for evidence of fluid leaks. NEVER remove the coolant surge tank
• Inspect all hoses for cracking, cuts, secure cap or radiator cap when the engine is
installation, proper routing and clamping, warm. The explosive escape of scalding
chafing and evidence of leaks. Inspect coolant or steam will result.
steel-braided lines for wear and rust. • Coolant level should be visible in the
Inspect clamps to ensure that they are sight glass (Figure 14). If level is low, add
installed securely. Texaco® Extended Life Coolant 50/50
Fluid Levels mix, or equivalent as required. Do not mix
• Check all fluid levels; fill as necessary: different types of coolant.
• Engine oil level must be between full and • Do not overfill: Level must be visible is sight
add marks of dipstick. glass. No coolant seen through the sight
glass is an underfill condition and a full
sight glass (no air line visible) is an overfill
NOTICE condition. Both low and overfill situations
Add oil as required. Oil used in the could cause damage to the cooling system
on-road B6.7 engine must meet the and/or its components.
Cummins® CES 20086 standard. Oil • Pressure test radiator cap.
used in the off-road QSB T4F must meet
Cummins® CES 20081 standards. 1
• Perform “Cold Check” on transmission
fluid in accordance with the transmission
manufacturer’s operator’s manual.
Use Castrol® Transynd® or equivalent
transmission oil ONLY.
• Assess the oil for evidence of overheating
(burned smell or discoloration).
2
Note: The transmission fluid level must be
checked when the transmission is at normal
operating temperature (160 – 200˚F [71 –
93˚C]), and the engine is idling in neutral.
1 Coolant Reservoir Pressure Cap
The oil level in Allison transmissions can be
2 Coolant Reservoir Sight Glass
checked using push-button or bump-shift
selector, if equipped with an oil level sensor Figure 14
(refer to the manufacturer’s documentation • Test block heater and inspect cord for
for more information). evidence of damaged insulation. Verify
the cord is properly routed and clamped
securely.
• Install new coolant filter, if applicable. Refer
to engine manufacturer’s documentation
for service interval, procedures and
specifications.
AWE 00192 Rev. 000 877-973-3486 17
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
• Check washer reservoir mounting. Check checked with the engine running or not. The
condition of washer hoses. fifth wheel must be completely lowered to
check fluid level. Add Castol® Transynd®
1 or equivalent as required. Do not overfill the
reservoir.

3
2 2
1
3

1 Windshield Washer Reservoir 3 Air Filter

2 Automatic Lubrication System (Optional)
1 ADD Sight Glass 3 One-Piece Sight Glass
Figure 15 2 FULL Sight Glass
Front Hubs Figure 16
• Check the oil level of the front axle hubs.
Use Chevron® Delo™ Gear Lubricant SAE Cooling System
80W-90 or synthetic Chevron® Delo™ Radiator, Charge Air Cooler and Condenser
Syn-Gear HD SAE 75W-90, or equivalent. • Check grille and behind grille area for clear
DO NOT MIX DIFFERENT TYPES OF airflow.
LUBRICANTS. • Check that radiator core is clear and not
damaged. Check the area between Charge
Air Cooler (CAC) and radiator for debris
build-up. This area is prone to trapping
debris and can affect engine cooling. Clean
as required.
• Check the rubber CAC expansion bushings
(Figure 17). Replace as required.

18 877-973-3486 AWE 00192 Rev. 000

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. If deposits are found,
find and repair the source of the leak. Clean
the pipes thoroughly and reassemble.
• Inspect air filter and housing.

UNDER TRACTOR INSPECTION

(150 HOURS)
Description
Figure 17 Inspect all of the following items paying special
Fan Blade and Shroud attention to all wiring, hoses and fasteners.
• Inspect fan shroud for secure installation.
Inspect for cracks or damage. Check Note: Any fastener or driveline component
for adequate clearance between the with a shiny, metallic appearance, or having
fan and the fan shroud, or other engine rust streaks, indicates a loose or broken
compartment components, in both the part.
engaged and disengaged mode. Repair if Engine
the clearance is inadequate. • Check the condition of all engine mounting
• Check the fan for looseness and damage, hardware and isolators (Figure 18).
such as bent, cracked or missing blades, • Check the torque on all engine mount
loose rivets, or missing weights. Re-torque fasteners.
if loose, replace if damaged.
• Inspect drive belts for cuts, wear,
weathering, proper tension and alignment.
• Check fan clutch for looseness or leakage.
Drain air filter, if equipped. If moisture or
contamination is detected, the filter must be
disassembled and flushed thoroughly with
clean parts solvent. Dry thoroughly before
reassembly. The cause of the moisture
or contamination must be determined
and action must be taken to correct the
condition.

Figure 18

AWE 00192 Rev. 000 877-973-3486 19

ACTT Xspotter Service Manual
Starter Lubrication
• Inspect for secure mounting and evidence Driveline Lubrication
of cracks.
• Check routing and clamping of cables Note: Refer to the axle manufacturers’
(Figure 19). documentation for recommended
lubricants, change intervals and service
specifications.

WARNING
To rotate the driveline, the drive wheels
must be elevated, the transmission in
neutral and the parking brake released.
Ensure front wheels are securely
Figure 19 chocked before elevating the drive
Transmission Mounts wheels. ABS must be deactivated before
• Check the transmission mounts for cracks. lifting/rotating wheels.
Check that all fasteners are tightened • Perform chassis lubrication per the
to proper torque. Refer to the “Special “Chassis Lubrication Chart” in this
Torque Chart” in this manual. manual. For chassis lubrication use Delo
Exhaust System Grease EP NLGI 1 and 2 (minimum) or
equivalent. Be sure that grease fittings
• Check exhaust system condition and
are clean and free from debris prior to
mounting.
application of grease. Ensure that each
• Verify all exhaust insulation blankets are grease fitting fills with grease when
in condition and installed correctly, (if lubricated. Remove excess grease from
equipped). fittings, spring shackles and other surfaces.
Inspect fittings for evidence of leaks.
• Lubricate boom lift cylinder pivot pins.
• Lubricate the upper fifth wheel surface.
• Lubricate U-joints, slip yokes and carrier
bearings (Figure 20).

Note: When greasing U-joints, enough

grease should be applied so that the old
grease and impurities are forced out past
the seals. If grease does not squeeze out
of a seal, press the shaft toward the seal
and apply grease at full pressure. Ensure
grease is expelled from all four trunnions
before proceeding.

20 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Slip Joint Lubrication Procedure • Change the engine oil per engine
1. Loosen the dust cap nut at the rear end of manufacturer’s recommendation. Remove
the slip yoke one full turn (Figure 20, and replace full-flow and bypass filters.
Item [3]). Check crankcase capacity and fill to proper
2. Attach grease gun to the Zerk fitting on level using oil recommended by the engine
the slip yoke (Figure 20, Item [2]). manufacturer.
3. Fill the slip joint until fresh grease comes Transmission
out the bleed hole in the yoke (Figure 20, • Change the transmission fluid and replace
Item [1]). the filter per transmission manufacturer’s
4. Cover the hole with your finger and recommendation. Inspect magnetic drain
continue greasing until fresh lube appears plug for excess metal filings. Assess the oil
at the rear end of the slip yoke splines. for evidence of overheating (burned smell
5. Tighten the slip yoke dust cap nut. or discoloration).
6. Clean up excess grease before • Check and lubricate the PTO linkages and
continuing. shafts (if equipped).

Note: Follow the transmission

2 3 4 5
manufacturers’ recommendations for drain
intervals .

1 Note: All ACTT’s are factory-filled with

Castrol Transynd synthetic fluid.
Drive Axles
• Check the oil level of the rear axle
1 Bleed Hole 4 Seal Washer (Figure 21). Use Chevron® Delo™ Gear
2 Grease Zerk 5 Backup Washer Lubricant SAE 80W-90 or synthetic
3 Dust Cap Nut Chevron® Delo™ Syn-Gear HD SAE
Figure 20 75W-90, or equivalent. DO NOT MIX
DIFFERENT TYPES OF LUBRICANTS.
Ensure the breather is clear and not
NOTICE damaged.
If grease is not expelled in Step 4 above,
remove the driveshaft and remove the
slip yoke from the splines to determine
the cause.

WARNING
Always use new bolts when reinstalling
any u-joint. DO NOT reuse old fasteners.

AWE 00192 Rev. 000 877-973-3486 21

ACTT Xspotter Service Manual
Steering and Suspension
Front Suspension
• Check front springs, shackles, mounts,
mount bolts and U-bolts. Check the spring
hangers, mounts and all brackets for cracks
and proper bolt torque.
• Check for broken or cracked leaf springs.
• Inspect spring hangers for cracks.
• Tighten the spring hanger to frame bolts to
specification.
• Check center bolt and springs for shifting on
1 Oil level must be even with bottom of fill plug hole
the axle.
2 Temperature Indicator Plug - DO NOT REMOVE • Check U-bolts for proper torque and to
3 Fill Plug ensure that the bolts have not shifted. Refer
Figure 21 to the Special Torque Chart in this Service
Manual section.
Note: When steam cleaning the axle or • Check spring eyes and pins for wear and
within the axle area, the axle breather cracks. Wear must not exceed 0.125 in.
cap must be covered to prevent moisture (3.18 mm).
and contaminants from entering the axle
Steering
housing.
• Check the steering gear box for secure
• Check the rear axle. See axle mounting.
manufacturers’ documentation for • Check steering column for secure mounting
procedures and specifications. and smoothness of bearings.
• Inspect the pinion shaft bearing for possible • Inspect power steering hoses for damage or
wear. leakage, and routing or clamping.
• Check pinion bearing wear.
• Inspect the wheel seals and axle area for Note: Refer to the steer axle manufacturers’
evidence of leakage. documentation for procedures,
specifications, and service intervals.
• Lubricate steering and front 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.

22 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
INTERIOR AND Seat
INSTRUMENTATION • Check the seat suspension and adjustment
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. Always (Figure 22).
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 foot, or one hand and both feet,
in contact with the grab handles/steps at
all times.
Doors and Windows
• Check operation of all doors and windows.
• Inspect both doors for ease of operation
and 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. Figure 22
• Check interior sheet metal for cracks Note: Record any needed corrections on
around doors, back panel and flooring. inspection form for follow-up.

AWE 00192 Rev. 000 877-973-3486 23

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,
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 24
• Check that all applicable telltale indicator
lamps illuminate, and that all instruments
respond appropriately. The indicator on all
gauges should sweep and return to zero
(Figure 25).

Figure 25

Note: Depending on the options and

configuration of the tractor, some telltale
indicator lamps may not be used.
Figure 23

24 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Starting The Engine • Check for evidence of intake air restriction
• Ensure that the starter solenoid engages as follows:
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. engine at maximum rated speed. Observe
• Verify all gauges and all telltale indicator and record the reading on the gauge.
lamps respond appropriately after the Replace the air filter if the reading is 25
engine has started. inch WC or less, or if the gauge indicates
• Check the engine for excessive smoke, that the filter needs replacing. After filter
surging, misfiring and noise indicating a replacement, check and record air cleaner
malfunction. restriction gauge reading.
Air Restriction Warning • If the tractor is not equipped with an air
• All tractors are equipped with an air restriction gauge on the intake piping, run
restriction warning light in the tell tale the engine at maximum rated speed. If the
indicator section of the instrument panel air restriction indicator light comes on, the
(Figure 26). Some engines may also have air filter should be replaced.
an air restriction gauge on the air intake
piping (Figure 27). NOTICE
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. Failure to follow these
AIR guidelines may result in major engine
FILTER
damage.
Figure 26
• When installing a new air filter, clean the
filter housing thoroughly and install a new
gasket or seal. Record the installation date
on the air cleaner cover with a grease
pencil.

Note: If equipped with filter minder be sure

to reset after each air cleaner element
installation.

Figure 27

AWE 00192 Rev. 000 877-973-3486 25

ACTT Xspotter Service Manual
Air System Governor Test
• Check the operation of the low air pressure Test the air compressor governor cut-in/cutout
warning light (Figure 28) and audible alarm. 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).
BRAKE Windshield Wiper and Washer
PRESSURE • Check windshield wiper and washer/wiper
Figure 28 operation (Figure 30). With the windshield
wet, turn on the wipers and check the
• Pump the brakes to bring the air pressure following:
down to activate the low air pressure
• Washer fluid output.
warning system. Alarm should activate at 60
psi (414 kPa) (Figure 29). • Blades and wipers for wear and contact.
• Operation at each speed setting.
• Blades and wipers operate evenly.

Figure 29
• Test air replenishment. Figure 30
• Perform dynamic air pressure test. Climate Control
• Perform static air pressure test. • Check the operation of the heater, defroster
and air conditioner (if equipped) as follows:
• Check primary circuit low pressure warning.
• Operate heater/air conditioner fan through
• Check secondary circuit low pressure all ranges, checking for vibration and
warning. excessive noise.
• Check operation of all in-cab controls.
In-Cab Monitor
• Verify that the camera images are displayed

26 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
on the in-cab monitor, if equipped. Road Test (150 Hours)
Radio
• Check the operation of the AM/FM and two- WARNING
way radios, if equipped.
DO NOT EXCEED 15 MPH (24 KM/H) WHEN
Steering
TOWING TRAILERS.
• Check the steering wheel for excessive play
(free movement not to exceed a maximum Operating at speeds in excess of 15 mph
of three degrees of rotation, or one inch (24 km/h) may lead to loss of vehicle
(25.4 mm). control. NEVER take turns at excessive
• Check steering column integrity. speeds, this may cause the vehicle and
trailer to roll over.
Other Inspection Areas
• Test the horn (s) for clear, audible sound. The majority of roll over accidents are
caused by excessive cornering speed.
• Check workstation power, if equipped. Roll over accidents may lead to serious
injury or death.
Note: This procedure may require the help
of an assistant.
• Check the backup alarm. WARNING
• Check that all safety equipment, such as Never tow trailers without BOTH the
fire extinguishers, triangle reflectors and service and emergency brake lines
flares, if equipped, are present and in connected to the trailer.
usable condition (Figure 31).
Never tow trailers without functioning
service and emergency brake systems.
Operating the vehicle while towing
trailers without functioning trailer brake
systems may lead to loss of control of the
vehicle, serious injury or death.

WARNING
Never tow a trailer above the minimum
height required to clear the landing gear
from the ground. Lifting the fifth wheel
Figure 31 and trailer too high drastically raises
the center of gravity of the trailer and
Note: Your vehicle may not be equipped increases the chance of a roll over.
with all of the safety devices shown in
Figure 31.

AWE 00192 Rev. 000 877-973-3486 27

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. Failure to follow these
guidelines may result in major engine
damage.
• Check the engine controls and
performance.
• Using the dash tachometer, check and
record high and low engine idle speed (rpm)
Figure 33
(Figure 32).
• 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 gears sequentially and
smoothly.
• Listen for unusual noises. Make sure that
the vehicle is riding smoothly, free from
roughness or excessive vibration.
• Ensure that there is no excessive play
Figure 32
in the steering wheel. Turning operation
should be smooth and free of rough spots.
Check for vibration in the steering wheel or
column.

28 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Post Road Test Inspection Walk-Around Inspection (300 Hours)
(150 Hours) Wheels and Tires
Major Components • Check dual matching
• Check all major components for fluid leaks. Air Filter
Engine, transmission, cooling system, fuel Replace the air filter element every 300 hours
system, power steering system, and rear or when the restriction indicator reaches 25 in.
axles WC, whichever comes first.
Record Keeping • If the tractor is not equipped with an air
• Check and record the date of the last restriction gauge on the intake piping, check
inspection and inspection interval every 150 for restriction by running the engine at
hours. maximum rated speed. If the air restriction
• Complete inspection form and apply new indicator light comes on, the air filter should
sticker. be replaced.
• When installing a new air filter, clean the
INSPECTION 300 HRS INTERVAL filter housing thoroughly and install a new
Perform this inspection every 300 hours of gasket or seal. Record the installation date
operation (maximum recommended interval). on the air cleaner cover with a grease
pencil.
NOTICE Fuel System
Fuel Filter
This inspection includes everything done
during the 150 hour inspection, PLUS • Replace fuel filter (Figure 34). Fill new
additional items requiring inspection at filter(s) with clean fuel prior to installation
this interval. to reduce air in fuel system (refer to
manufacturers’ documentation for
Major vehicle components such as engine, procedure).
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.

Figure 34
Fuel Water Separator Filter

AWE 00192 Rev. 000 877-973-3486 29

ACTT Xspotter Service Manual
• Replace fuel/water separator filter Slack Adjuster
(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). for service intervals, procedures and
specifications).

Figure 35

Figure 36
Brake System

30 877-973-3486 AWE 00192 Rev. 000

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. Allow the
• Load test the batteries (Figure 37). batteries to recover for 30 seconds, then
• Inspect the batteries for secure mounting, check the voltage using a voltmeter. If the
cracks, and corroded terminals. reading is less than 12.40 volts, charge or
replace the batteries before proceeding.
• Check the specific gravity of maintenance-
type batteries. Voltage Output Test
• Check cables for wear and ensure • Connect a DC voltmeter to the positive and
connections are clean, tight and free of negative output terminals at the alternator.
corrosion. Measure the voltage at the batteries. The
• Ensure that the wiring is properly routed reading must be within 1.0 volts of the
and securely clamped. reading taken at the alternator. Correct any
problems before proceeding.
• Clean and seal the terminals on the battery
disconnect switch, if equipped, in the same • Start engine and increase speed to 1500
manner as the battery terminals. rpm: The volt meter should now indicate
alternator output voltage has increased to a
Starter
range from 13.8 volts to 14.2 volts.
• Perform current draw test. See the If voltage increases, but is out of range,
appropriate engine service documentation inspect to see if alternator has an
for procedure and specifications. adjustable regulator. If so: reduce engine
• Inspect the starter to verify secure speed to idle. Adjust voltage to a setting of
mounting,and inspect for cracks around the 14.0 volts.
mounting flanges (Figure 38). • If voltage is higher than 14.7 volts and
cannot be adjusted below 14.25 volts, or if
voltage is lower than 13.8 volts and cannot
be adjusted into range; replace alternator.
• If within range, perform Current Output Test.
Current Output Test

AWE 00192 Rev. 000 877-973-3486 31

ACTT Xspotter Service Manual
• With a carbon pile, apply a current load COOLING SYSTEM SERVICE
equal to 75% of rated output capacity of the
alternator for 10 seconds. Coolant Drain and Fill Deaeration
• Test voltage at the alternator terminals Procedure
using a volt meter. The voltage should not
decrease more than 0.50 volts. NOTICE
• If voltage drops more than 0.50 volts,
the alternator is defective and must be The following information is provided
replaced. courtesy of Cummins® Engine Company.
To avoid costly repairs that may not be
• Check the amperage against the specified covered by the engine manufacturer’s
maximum. Readings within 10% are warranty always follow these steps when
considered acceptable. servicing the cooling system.
• Inspect the alternator pulley and drive
pulley for correct alignment. Draining the system
• Ensure that the alternator mounting bolts
are torqued properly on the alternator WARNING
mounting bracket.
Do not remove the pressure cap from
Engine Compartment a hot engine. Wait until the coolant
Water Pump, Fan and Idler Pulley. temperature is below 120°F (50°C) before
removing the pressure cap. Heated
• Check water pump, fan and idler pulley
coolant spray or steam can cause
(see engine manufacturer’s documentation
personal injury.
for procedures and specifications).
• Loosen belts and rotate water pump pulley,
checking for smoothness of water pump WARNING
bearing operation and proper end play.
Coolant is toxic. Keep away from children
• Inspect water pump shaft for wobble and
and pets. If not reused, dispose of in
evidence of leaks.
accordance with local environmental
• Inspect idler pulley for cracks. Check regulations.
bearing for smooth, quiet operation.
1. Isolate the engine from the vehicle
Torsional Vibration Damper cooling system by closing all coolant flow
• Inspect torsional vibration damper for valves to the heater before initiating the
evidence of dents, fluid loss, wobble, repair. This will prevent the heater circuit
swelling and deformation. from draining, minimizing the chance for
air pockets to be present during the fill
process.

32 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Note: If coolant is being changed or the
cooling system is being flushed, it is WARNING
desirable to leave the coolant flow valves
to the equipment heating systems open, in Do not stand near the surge tank or
order to completely drain the system. radiator while operating the engine with
the radiator pressure cap removed. If the
vehicle is equipped with a fill door on
WARNING the side of the surge tank, keep the door
closed due to coolant expansion.
Do not remove the pressure cap from
a hot engine. Wait until the coolant 7. Operate the engine at LOW idle for two
temperature is below 120°F (50°C) before minutes with the radiator pressure cap
removing the pressure cap. Heated removed.
coolant spray or steam can cause 8. Turn off the engine and add coolant to
personal injury. bring the coolant level back to FULL,
using a 50/50 mixture of water and
Filling the System
antifreeze.
1. Remove the pressure cap. 9. Operate the engine, with the radiator
2. Fill the cooling system until coolant is pressure cap off, at LOW idle for one
visible in the sight glass on the coolant minute to allow adequate oil pressure
reservoir with a mixture of 50 percent throughout the engine. Run the engine at
water and 50 percent ethylene glycol or HIGH idle until the thermostat opens. Run
propylene glycol antifreeze. the engine at idle for two minutes before
3. Open all coolant flow valves to the heater, shutting it down. This allows adequate
if equipped. cool down of the pistons, cylinders,
4. Wait two to three minutes, without starting bearings, and turbocharger components.
the engine, to allow the coolant level to 10. Turn off the engine and check the coolant
stabilize. level to ensure coolant is visible in the
5. Add a 50/50 mixture of water and sight glass on the coolant reservoir. Add
antifreeze to bring the coolant level back a 50/50 mixture of water and antifreeze,
to FULL. if necessary, to bring the cooling system
6. Turn the HVAC temperature control knob back to the proper level. Install the
fully clockwise to select maximum heat pressure cap.
allowing maximum coolant flow through
the heater core. The blower motor must
be turned ON to activate the water control
valve.

AWE 00192 Rev. 000 877-973-3486 33

ACTT Xspotter Service Manual
Complete Cooling System 5. Check for damaged hoses and loose
Maintenance Procedures or damaged hose clamps. Replace as
required.
6. Check the radiator for leaks, damage,
NOTICE and buildup of dirt. Clean and replace as
The following information is provided required.
courtesy of Cummins® Engine Company. 7. Check the engine coolant level sensor for
To avoid costly repairs that may not be proper operation.
covered by the engine manufacturer’s Flush Cooling System
warranty always follow these steps when
Fleetguard® Restore™
servicing the cooling system.
Fleetguard® Restore™ is a heavy-duty cooling
Draining Coolant
system cleaner that removes corrosion, silica
gel, and other deposits. The performance of
WARNING Fleetguard® Restore™ is dependent on time,
temperature, and concentration levels. An
Do not remove the pressure cap from extremely scaled or flow-restricted system, for
a hot engine. Wait until the coolant example, can require higher concentrations of
temperature is below 120°F (50°C) before cleaners, higher temperatures, longer cleaning
removing the pressure cap. Heated times, or the use of Restore Plus™.
coolant spray or steam can cause
personal injury. Up to twice the recommended concentration
levels of Fleetguard® Restore™ can be used
1. Remove the pressure cap. safely. Fleetguard® Restore Plus™ must be
2. Drain the cooling system by opening used only at its recommended concentration
the drain valve on the radiator and by level.
opening the drain valve on the bottom of
Extremely scaled or fouled systems can require
the engine oil cooler housing. A drain pan
more than one cleaning.
with a capacity of 15 gallons (57 liters) is
adequate in most applications. 1. Disconnect the electrical connection from
3. After the cooling system is completely the EGR valve.
drained, close the drain valves.
Note: Disconnecting the EGR valve will
cause Fault Code 2272 to become active.
WARNING Disregard indications of Fault Code 2272
during this procedure.
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in Note: Operation at high idle with the EGR
accordance with local environmental valve disconnected may cause misfire
regulations. faults to become active when no misfire is
4. Connect a pressure tester to the radiator actually occurring.
cap, pressurize to the rated pressure and
verify operation. Repeat this test four
more times. If the cap fails any of the
tests, replace with a new one.

34 877-973-3486 AWE 00192 Rev. 000

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.
in order to protect the EGR cooler from
3. If applicable, open the manual bleed
thermal damage.
valve before filling the cooling system.
4. Once filled, close the manual bleed valve.
NOTICE
Fleetguard® Restore™ contains no NOTICE
antifreeze. Do not allow the cooling
system to freeze during the cleaning The system has a designed fill rate of up
operation. to five gallons (19 liters) per minute.

Note: Monitor the coolant temperature

NOTICE with INSITE™ electronic service tool. If
the thermostat does not open before the
The system must be filled properly to coolant temperature reaches 195° F (90° C),
prevent air locks or serious engine discontinue the flush operation, inspect the
damage can result. During filling, air thermostat, and replace it if necessary.
must be purged from the engine coolant
passages. Make sure to open the petcock Note: The performance of Restore™ is
on the aftercooler for aftercooled dependent on time, temperature, and
engines. Wait two to three minutes to concentration levels. An extremely scaled
allow the air to be vented; then add the or flow-restricted system, for example, will
mixture to bring the coolant level to the require higher concentrations of cleaners,
top. higher temperatures, longer cleaning times,
2. Connect INSITE™ electronic service tool. or the use of Restore Plus™.
Record the current value of the Maximum Restore™ can safely be used up to twice the
Engine Speed without Vehicle Speed recommended concentration levels.
Source parameter located in the Vehicle
Restore Plus™ must be used only at its
Speed Source section of Features and
recommended concentration level.
Parameters. If the current value is higher
than 2,000 rpm, adjust the Maximum Extremely scaled or fouled systems will require
Engine Speed without Vehicle Speed more than one cleaning.
Source parameter to 2,000 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.

AWE 00192 Rev. 000 877-973-3486 35

ACTT Xspotter Service Manual

WARNING WARNING
Do not remove the pressure cap from Do not stand near the surge tank or
a hot engine. Wait until the coolant radiator while operating engine with
temperature is below 120°F (50°C) before the pressure cap off. If the vehicle is
removing the pressure cap. Heated equipped with a fill door on the side of
coolant spray or steam can cause the surge tank, keep it closed.
personal injury.
8. Open all coolant flow valves to the heater,
5. Drain the cooling system. Do not allow if equipped. Wait two to three minutes,
the cooling system to dry out. Restore™ without starting the engine, to allow the
will not be effective if the cooling system coolant level to stabilize.
is allowed to dry out. 9. Turn the HVAC temperature control knob
fully clockwise to select maximum heat
allowing maximum coolant flow through
WARNING the heater core. The blower motor must
Coolant is toxic. Keep away from children be turned ON to activate the water control
and pets. If not reused, dispose of in valve.
accordance with local environmental 10. With the pressure cap off:
regulations. - Operate the engine at LOW idle for two
minutes.
6. Immediately add one gallon (3.8 liters) of - Turn engine OFF and add plain water to
Fleetguard™ Restore™, Restore Plus™, bring the level back to FULL.
or equivalent for each 10-15 gallons (38
to 57 liters) of cooling system capacity, 11. With the pressure cap off:
and fill the system with plain water. - Operate the engine at LOW idle for one
minute to allow adequate oil pressure to
build throughout the engine.
NOTICE - Operate the engine at HIGH idle but
no more than 2,000 rpm until the
Fleetguard® Restore™ contains no
thermostat opens.
antifreeze. Do not allow the cooling
system to freeze during the cleaning Note: Monitor the coolant temperature
operation. with INSITE™ electronic service tool. If
the thermostat does not open before the
7. Fill the cooling system until coolant is
coolant temperature reaches 195°F (90° C),
visible in the sight glass on the coolant
discontinue the flush operation, inspect the
reservoir with plain water.
thermostat, and replace it if necessary.
12. Operate the engine at low idle for two
minutes before shutting it down. This
allows adequate cool down of pistons,
cylinders, bearings, and turbocharger
components.

36 877-973-3486 AWE 00192 Rev. 000

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.
necessary, to bring it back to the FULL - Turn engine OFF and add plain water to
level. bring the level back to FULL.
14. Install the pressure cap.
24. With the pressure cap off:
15. Operate the engine at normal operating - Operate the engine at LOW idle for one
temperatures, at least 185°F (85°C), for minute to allow adequate oil pressure to
one to one and one-half hours. build throughout the engine.
16. Turn the engine OFF and allow to cool - Operate the engine at HIGH idle until the
to 122°F (50°C), and drain the cooling thermostat opens.
system.
25. Continue to operate the engine at HIGH
WARNING idle for five minutes with the coolant
temperature above 185°F (85°C).
Do not remove the pressure cap from 26. Allow the engine to idle for two minutes
a hot engine. Wait until the coolant
before shutting it down. This allows
temperature is below 120°F (50°C) before
removing the pressure cap. Heated adequate cool down of pistons, cylinders,
coolant spray or steam can cause bearings, and turbocharger components.
personal injury.
17. Remove the pressure cap. WARNING
18. Fill the cooling system with plain water Do not remove the pressure cap from
until coolant is visible in the sight glass on a hot engine. Wait until the coolant
the coolant reservoir. temperature is below 120°F (50°C) before
19. Open all coolant flow valves to the heater, removing the pressure cap. Heated
if equipped. coolant spray or steam can cause
personal injury.
WARNING 27. Turn engine OFF and allow to cool to
Do not stand near the surge tank or 122°F (50°C), and drain the cooling
radiator while operating the engine with system. If the water being drained is still
the pressure cap off. dirty, the system must be flushed again,
until the drained water is clean.
20. Wait two to three minutes, without starting
Fill the System
the engine, to allow the coolant level to
stabilize. 1. Disconnect the electrical connection for
21. Add plain water to bring the level back to the EGR valve.
FULL.
22. Turn the HVAC temperature control knob Note: Monitor the coolant temperature
fully clockwise to select maximum heat with INSITE™ electronic service tool. If
allowing maximum coolant flow through the thermostat does not open before the
the heater core. The blower motor must coolant temperature reaches 195° F (90° C),
be turned ON to activate the water control discontinue the fill operation, inspect the
valve. thermostat, and replace it if necessary.

AWE 00192 Rev. 000 877-973-3486 37

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 to the top.
thermal damage.
2. Connect INSITE™ electronic service tool. NOTICE
3. Record the current value of the Maximum
Engine Speed without Vehicle Speed During all coolant fill procedures, all
Source parameter located in the Vehicle coolant flow valves to equipment heating
Speed Source section of Features and systems must be opened in order to
Parameters. purge air from those systems as well as
4. If the current value is higher than 2,000 from the base engine cooling system.
rpm, adjust the Maximum Engine Speed These valves must remain open during
without Vehicle Speed Source parameter the engine cooling system deaeration
to 2,000 rpm. process. Make sure adequate coolant
levels are maintained in the coolant
Note: Some applications can have a manual reservoir during the entire fill procedure.
bleed valve that is required to be opened to Special care must be taken when filling
properly fill the system. The upper radiator EGR cooler equipped engines to make
pipe is a common location for bleed valves. sure all air is purged from the cooling
system or serious engine damage can
NOTICE result.

Opening the manual bleed valve on Note: A 50/50 mixture of antifreeze and
applicable installations is critical. Failure water must be premixed before filling the
to do so can result in engine damage. cooling system. The ability of antifreeze to
remove heat from the engine is not as good
5. If applicable, open the manual bleed as water, so pouring antifreeze into the
valve before filling the cooling system. engine first can contribute to an overheated
6. Once filled, close the manual bleed valve. condition before the liquids completely
intermix.
NOTICE
NOTICE
The system must be filled properly to
prevent air locks or serious engine Never use water alone for coolant. This
damage can result. During filling, air can result in damage from corrosion.
must be purged from the engine coolant
Close all drain valves and fill the cooling
passages.
system. Use a 50 percent water and 50 percent
antifreeze mixture to provide freeze protection
to -33°F (-36°C).

38 877-973-3486 AWE 00192 Rev. 000

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.
passages. Wait two to three minutes to
allow air to be vented, then add mixture to
bring the level to the top. WARNING
Do not stand near the surge tank or
NOTICE radiator while operating the engine with
the pressure cap off. If the vehicle is
Do not allow the engine speed to equipped with a fill door on the side of
exceed 2,000 rpm while the EGR valve is the surge tank, keep it closed.
disconnected. Operation at higher rpm in
this mode can result in engine damage. 11. With the pressure cap off:
- Operate the engine at LOW idle for two
Low silicate antifreeze must be mixed with minutes.
quality water at a 50/50 ratio (40 to 60 percent - Turn engine OFF and add coolant to
working range). A 50/50 mixture of antifreeze bring the level back to FULL, using a
and water gives a -33°F (-36°C) freeze point 50/50 mixture.
and a boiling point of 228°F (109°C).
12. With the pressure cap off:
The actual lowest freeze point of ethylene - Operate the engine at LOW idle for one
glycol antifreezes is at 68 percent, The use of minute to allow adequate oil pressure to
higher concentrations of antifreeze will raise build throughout the engine.
the freeze point of the solution and increase - Operate the engine at HIGH idle until the
the possibility of a silicate gel problem. thermostat opens.
7. Remove the pressure cap. Fill the
cooling system until coolant is visible in Note: Monitor the coolant temperature
the sight glass on the coolant reservoir with INSITE™ electronic service tool. If
with a mixture of 50 percent water and the thermostat does not open before the
50 percent ethylene glycol or propylene coolant temperature reaches 90° C [195°F],
glycol antifreeze. discontinue the flush operation, inspect the
8. Open all coolant flow valves to the heater, thermostat, and replace it if necessary.
if equipped. 13. Allow the engine to idle for two minutes
9. Wait two to three minutes, without starting before shutting it down. This allows
the engine, to allow the coolant level to adequate cool down of pistons, cylinders,
stabilize. Add a 50/50 mixture to bring the bearings, and turbocharger components.
coolant level back to FULL. 14. Turn the engine OFF and verify that
coolant is visible in the sight glass on
the coolant reservoir and add coolant, if
necessary, to bring it back to the FULL
level.

AWE 00192 Rev. 000 877-973-3486 39

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
Final Step while applying air to the fan drive.
• Listen for leaks at the solenoid valve
1. Install the pressure cap.
and in the air hoses and fittings.
2. Operate the engine until the coolant
• Feel for a leak with a wet finger or by
temperature reaches 180°F (82°C), and
applying soapy water and looking for
check for coolant leaks.
bubbles.
3. Connect the electrical connection to the
EGR valve. Connect INSITE™ electronic Note: Most fan drive failures are caused by
service tool. air leaks.
4. Restore the Maximum Engine Speed
without Vehicle Speed Source parameter
to its original value as required.
5. Troubleshoot any active fault codes.
6. Clear all inactive fault codes.

FAN CLUTCH SERVICE

Fan Drive Inspection

WARNING
Before performing work on the fan drive,
be sure to follow good shop safety
practices. Turn the vehicle’s ignition off,
apply the vehicle’s parking brake and
block the vehicle’s wheels.
1. Start the vehicle’s engine and build air
pressure in excess of 90 psi (621 kPa). Figure 39
• Manually engage and disengage the fan 3. Check the fan drive for discoloration or
drive by disconnecting and reconnecting any other signs of slipping or overheating,
the harness connector from the solenoid Figure 40. The fan drive may slip if
valve. incoming air pressure is below 90 psi
• Observe the fan and fan drive from a (621 kPa) or if an air leak exists inside
distance. Look for vibration, fan blade the fan drive. Never let a leak remain
contact, fan drive slippage and fan drive unattended.
operation.

40 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Area between Measure this distance
drive pulley to determine wear
and fan drive

Fan Drive

Drive
Pulley

Aluminum
Check for Friction
Spring
discolorization or Liner
Housing
other signs
of overheating Figure 41
Figure 40 6. Check the electrical wiring at the air-
4. Check the fan drive bearing. conditioning trinary pressure switch and
• Turn the fan blade in both directions the solenoid valve. Ensure there are no
and feel for worn hub bearing. loose wires or connections.
• If the fan belts can be easily removed, 7. Check the fan drive for proper
remove the belts and check for worn engagement and disengagement. Turn
sheave bearing. on the ignition switch but do not start the
• Turn the sheave in both directions. If engine.
either the hub or sheave bearing is • Be certain at least 90 psi (621 kPa) of
worn, repair or replace the fan drive. air pressure is available in the vehicle
reservoirs.
5. Check the fan drive friction facing for • Manually engage and disengage the fan
wear by measuring the thickness of the drive by disconnecting and reconnecting
friction material, Figure 41. A new facing the harness connector from the solenoid
is 11/32” (8.51 mm) thick. Replace the valve.
friction material if it has worn to less than • Check fan clutch for looseness or
1/4” (6.35 mm). leakage. If moisture or contamination
is detected, the clutch must be
disassembled and flushed thoroughly
with clean parts solvent. Dry thoroughly
before reassembly. The cause of the
moisture or contamination must be
determined and action must be taken to
correct the condition.

AWE 00192 Rev. 000 877-973-3486 41

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.
from the pulley).
Driveline
• Check for damaged or broken magnets
• Check U-joints and slip yokes for free
and for interference between the magnet
play during lubrication procedure. Inspect
assembly and fan mounting disc. If
driveline for loose bolts. Rotate driveline,
damaged or broken, repair the fan drive
checking for excessive play in U-joints (not
with the appropriate repair kit, or replace as
to exceed 0.063 in. [1.60 mm]). Check all
needed.
driveline fasteners for looseness. Any shiny
area, or rust stains in the driveline indicate
NOTICE that there is a loose driveline part. Inspect
center bearings for leaks and free play
A contaminated air supply may damage (0.063 in. [1.60 mm]). Push and pull shaft,
the fan clutch assembly. Anytime system checking for run-out at splines (should be
contamination is present take the between 0.063 in. [1.60 mm]).
necessary steps to correct the situation
Engine
and purge the air lines.
• Check engine mounts for cracks and
Air Conditioning Refrigerant deterioration.
• Verify air conditioning refrigerant charge is • Verify all engine mounting fasteners are
at the correct level and the system operates tightened to the correct torque.
correctly.
Transmission
• Capacity 2.4lb +/- .25lb.
• Check the transmission output bearing
Compressor (driveshaft yoke) for movement (Refer to
• Inspect air conditioner compressor base transmission manufacturer’s documentation
and mounting for proper attachment, cracks for procedure and specifications).
and evidence of leaks.
System Lines, Hoses and Connections
• 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.

42 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Steering and Suspension Interior and Instrumentation
Steering
• With front axle elevated, turn the steering CAUTION
wheel from side to side. There should be
slight drag at the center point. If no drag NEVER use fuel tanks (unless nonslip
can be felt, adjustment is required. Note on steps are part of the tank) or the tops
the form for follow-up. of the battery boxes as steps. Always
face the cab when entering or exiting the
• Check the steering shaft coupler for cab. NEVER exit the cab “face first.” Use
security. a “three-point mounting” approach to
• Check U-joints for looseness. Lubricate all enter/exit the cab. Always have two hands
U-joints. and one foot, or one hand and both feet,
• Check slip joints for looseness. Lubricate all in contact with the grab handles/steps at
slip joints. all times.
• Check the drag link and tie-rod ends. Accelerator Pedal
There must be no free play or wear in
• Start the engine and verify that the
these components. See manufacturer’s
accelerator pedal operates properly, and
documentation for procedure.
the engine responds accordingly.
• Tighten draw key nut to specification.
Air System
See manufacturers’ documentation for
procedure and specification. • Check A/B reservoir check valve operation
• Inspect the pitman arm and check the nut as follows,
torque. Refer to “Special Torque Chart” in • Drain wet tank while monitoring pressures
this manual. in the A & B tank. If wet tank drains and A
• Check the upper and lower shock absorber & B tanks stay full, check that valves are
mounting and brackets. Ensure the operating properly.
fasteners are secure. Check the shock Road Test (300 Hours)
absorbers for evidence of leaks.
Rear Axle Mounting WARNING
• Inspect all axle mounting hardware and
verify all fasteners are tightened to the DO NOT EXCEED 15 MPH (24 KM/H) WHEN
TOWING TRAILERS.
correct torque.
Operating at speeds in excess of 15 mph
• Check torque arm bushings and mounts, if
(24 km/h) may lead to loss of vehicle
equipped.
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.

AWE 00192 Rev. 000 877-973-3486 43

ACTT Xspotter Service Manual
Post Road Test Inspection
WARNING (300 Hours)
Never tow trailers without BOTH the Major Components
service and emergency brake lines • Check all major components for fluid leaks
connected to the trailer. (engine, transmission, cooling system, fuel
Never tow trailers without functioning system, power steering system, and rear
service and emergency brake systems. axles).
Operating the vehicle while towing Record Keeping
trailers without functioning trailer brake • Check and record the date of the last
systems may lead to loss of control of the inspection and inspection interval every 150
vehicle, serious injury or death. hours.
• Complete inspection form and apply new
WARNING sticker.

Never tow a trailer above the minimum INSPECTION 1,200 HOURS

height required to clear the landing gear INTERVAL
from the ground. Lifting the fifth wheel
and trailer too high drastically raises Description and Operation
the center of gravity of the trailer and (1,200 Hours)
increases the chance of a roll over. Perform this inspection every 1,200 hours of
• Check axle lock operation, if equipped operation (maximum recommended interval).
(Figure 42). Listen for differential lock
engagement and disengagement. Check NOTICE
that dashboard indicator light illuminates.
This inspection includes everything done
during the 150 and 300 hour inspections,
plus additional items requiring inspection
at this interval.
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
Figure 42 the results using the Preventive Maintenance
Inspection form available from Autocar.

44 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Walk-Around Inspection Brake System
(1,200 Hours) Slack Adjuster
Fuel System • Inspect the slack adjuster operation,
Fuel Filter mounting and adjustment (Refer to
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).
air in fuel system (refer to manufacturers’
documentation for procedure). Cab Tilt Pump
DEF System • Check cab tilt hydraulic oil level.
DEF Tank Filter Air Conditioning
• Remove and inspect the DEF tank filter and • Inspect the sight glass to determine if
inspect (Figure 43). Replace if necessary. moisture is present. If the sight glass shows
a blue indicator, the A/C dryer is in good
• Refer to “Diesel Engine and Emissions
working condition. If the sight glass shows
Service Manual AWE 00193” for detailed
a pink indicator, the A/C dryer must be
information on servicing this filter.
replaced.
• Change air conditioning system dryer as
required.
Air Compressor
• Inspect the air compressor mounting for
proper attachment, cracks and evidence of
leaks.
• Check that all air and coolant connections
are tight and leak free.
Under Tractor Inspection
(1,200 Hours)
Rear Axle
• Replace axle lubricant and filter. Inspect
magnetic drain plug for excess metal
particles.
• Clean the drain plug and reinstall.
• Clean the breather.
• Inspect wheel seals for leakage.

Figure 43

AWE 00192 Rev. 000 877-973-3486 45

ACTT Xspotter Service Manual
Steering and Suspension INSPECTION 2,400 HOURS
• Check the front wheel bearings. Refer to INTERVAL
the Autocar Wheel End Assembly Service
Manual for the complete inspection Description and Operation
procedure for wheel bearings. (2,400 Hours)
• Inspect front wheel seals for leakage. Perform this inspection every 2,400 hours of
• Check the front wheel alignment and operation or yearly (maximum recommended
steering stop adjustment. Refer to the front interval), whichever comes first. This is
axle manufacturers’ service documentation commonly referred to as an annual inspection
for the complete inspection and adjustment for single shift tractors.
procedure.
• Check center bolt and springs. NOTICE
Rear Axle Mounting This inspection includes everything
• Inspect rear axle mounting for loose done during the 150, 300 and 1,200
fasteners or cracks. hour inspections, plus additional items
• Check center bolt and springs, if equipped. requiring inspection at this interval.

Note: Autocar sets axle stops to provide Major vehicle components such as engine,
maximum turn angle. Clearance of 3/8 transmission and axles may have their
inch (9.5 mm) should be observed on full own Preventive Maintenance Inspection
lock between stub axle and steering stop procedures, and Autocar recommends
adjusting bolt. 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.

46 877-973-3486 AWE 00192 Rev. 000

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).
Hours)
• Replace the DEF Tank Filter (Figure 43). Steering and Suspension
• Refer to “Diesel Engine and Emissions • Tighten steering arm bolts to specification.
Service Manual AWE 00193” for detailed See manufacturers’ documentation for
information on servicing this filter. procedure and specification.

Figure 44
Axle Flange Nuts
Inspect the axle flange nuts. If any axle flange
nuts or wheel lug nuts are missing, 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.

AWE 00192 Rev. 000 877-973-3486 47

ACTT Xspotter Service Manual
PREVENTIVE MAINTENANCE INTERVALS
Interval A B C D
150 300 1200 2400
hrs hrs hrs hrs or
Annually
Inspect battery hold-down hardware. x
Electrical Inspect batteries and cables. x
System Remove any corrosion from battery terminals. x
Ensure all ground connections are clean and tight. x
Check for all fluid levels and check for leaks. x
Inspect all hoses for damage and correct routing. x
Inspect cooling system.
Check grille and behind for clear airflow. x
Inspect CAC expansion bushings for wear or damage. x
Inspect fan blade and shroud. x
Check fan clutch. x
Listen for leaks at the solenoid valve, filter assembly and in
the air hoses and fittings. Repair as required
x
Check the fan drive for discoloration or any other signs of
slipping or overheating
x
Check the 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
(1) Walk-up/
Walkaround Test coolant concentration. x
Inspection
(continued) Pressure test pressure cap. x
Engine Test block heater, if equipped. x
Compartment
Install new coolant filter, if equipped. Refer to engine manufacturer’s service
intervals.
Drain and refill coolant system. Refer to engine manufacturer’s service
intervals.
Intake air piping:
Check connections and mounting. x
Check air filter, housing, and air restriction gauge. x
Check inside of pipes and charge air cooler for buildup of
foreign material.
x
Replace air filter. x
Starter:
Check for secure mounting. x
Check cable routing and connections. x
Check transmission mounts and fastener torque. x
Check exhaust system for leaks and secure mounting.
Add any attaching hardware necessary and correct or x
repair any source of exhaust gas leakage.
Check the DPF (Diesel Particulate Filter) System x
Inspect the DEF tank filter. x
Replace the DEF tank Filter x
Replace the DEF dosing unit filter x

48 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
Interval A B C D
150 300 1200 2400
hrs hrs hrs hrs or
Annually
Air conditioning:
Check compressor mounting. x
Inspect for leaks. x
Check sight glass for moisture. Change A/C drier as
necessary.
x
(1) Walk-up/ Engine
Walkaround Pressure test system for proper level of refrigerant. x
Inspection Compartment
(continued) (continued) Air compressor:
Check mounting and connections. x
Alternator:
Check mounting. x
Check harness routing, clamping and connections. x
Lubricate chassis per Chassis Lubrication Charts in this x
Service Manual section).
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:
(2) Under Check for loose rear transmission bearing (driveshaft yoke). x
Truck Lubrication Check oil level. x
Inspection/
Lubrication Replace fluid and filter. Refer to the Allison™ documentation for
procedures, specifications and service
intervals.
Hydraulic/power steering fluid reservoir
Check fluid level. x
Replace fluid and filter. x
Rear drive axle:
Check lubricant level x
Check and clean breather. x
Replace oil and filter. Refer to axle manufacturer’s
documentation for further information.
Inspect input bearing for free play. x
Inspect wheel seal and axle are for leaks. x

AWE 00192 Rev. 000 877-973-3486 49

ACTT Xspotter Service Manual
Interval A B C D
150 300 1200 2400
hrs hrs hrs hrs or
Annually
Inspect front suspension:
Springs. x
Shackles. x
Check spring hanger bolt torque. x
Mounting hardware, mounts, and U-bolts. x
Check steering:
Check steering for excessive play. x
Check for secure steering gear mounting. x
Inspect drag link. x
Inspect coupler. x
Inspect U-joints. x
(2) Under Inspect Slip joints. x
Truck Check steering column for secure mounting and bearing
Steering and x
Inspection/ smoothness.
Suspension
Lubrication
(continued) 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
Check and record king pin movement. documentation for procedures,
Lubricate steering and front suspension. specification, and service interval.

Check front and rear wheel bearings. x

Check front wheel alignment. x
Check steering stop settings. x
Inspect rear axle mounting. x
Inspect shock absorbers. x
Check for fluid leaks. x
(5) After Road Test Record the date and type of the last inspection. x
Complete inspection form and install new sticker. x

50 877-973-3486 AWE 00192 Rev. 000

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. - 12 127± 10 lb.ft (172 ± 14 N·m)
3/4 in. - 14 280 ± 20 lb.ft (380 ± 27 N·m)
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)
Transmission Mount Bolts 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)
1/2 in. 105 ± 10 lb.ft (142 ± 13.5 N·m)
Frame Bolts 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 Rod Bolt See equipment manufacturers’ service
documentation for specification.
Torque Rod Flange Nut

AWE 00192 Rev. 000 877-973-3486 51

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 Use Chevron® Delo™ Gear Lubricant SAE
80W-90 or synthetic Chevron® Delo™ Syn-Gear
HD SAE 75W-90, or equivalent. DO NOT MIX
DIFFERENT TYPES OF LUBRICANTS
Windshield Washer Washer Fluid Reservoir Standard Washer Fluid
Diesel Oil used in the on-road B6.7 engine must meet
the Cummins® CES 20086 standard. Oil used in
Engine Oil the off-road QSB T4F must meet Cummins® CES
20081 standards. l
Gas Chevron RPM Gas Engine Oil 15W40
Coolant Reservoir Texaco® Extended Life Coolant 50/50 mix, or
Engine Coolant equivalent as required. Do not mix different types
of coolant
Diesel Exhaust Fluid DEF Reservoir Fleetgaurd Air Shield™ Diesel Exhaust Fluid
Refrigerant R134a
Refrigerant System
PAG-46
Transmission Filler Tube Castrol®Transynd™ Transmission Oil, or
Transmission equivalent
U-Joints EP NLG 12
Driveshafts
Slip Yokes EP NLG 12
Cab Jack Cab Jack Pump Reservoir Dexron ATF
Boom Lift and Power Hydraulic Reservoir Castrol®Transynd™ Transmission Oil, or
Steering equivalent
75W90 Gear Lube (Synthetic or Standard
Filler Plugs and Axle Housing(s)
Drive Axle(s) Depending On Customer Specification)
Brake S-Cams and Slack Adjusters EP NLGI 1 or 2
Fifth Wheel Lift Boom All Pivot Pins and Cylinder Eye Bushings EP NLGI 1 or 2
Fifth Wheel Top Plate Surface and Locking Jaws EP NLGI 1 or 2

52 877-973-3486 AWE 00192 Rev. 000

Preventive Maintenance
CHASSIS LUBRICATION CHART (TOP VIEW)
2
4

1
1
3 1

1
5

2 4

Typical Chassis Lube and Fluids

(Actual component location varies by model)
Castrol® Transynd®
1 Chassis Grease 4 Transmission Fluid
Engine Oil (as
2 Gear Oil (as specified) 5 specified)
3 Castrol® Transynd® Transmission Fluid
Figure 45

AWE 00192 Rev. 000 877-973-3486 53

ACTT Xspotter Service Manual
CHASSIS LUBRICATION CHART (BOTTOM VIEW)

1 1

1
1

1
1

1
1
2
1

Chassis Lube and Fluids

(Actual component location varies by model)
1 Chassis Grease 2 Gear Oil
Figure 46

54 877-973-3486 AWE 00192 Rev. 000

Autocar Industries, LLC

551 South Washington Street

Hagerstown, IN 47346
www.autocartruck.com

© Autocar Industries, LLC 2018

AWE 00006 Rev. 005a Printed In U.S.A.