Preventive Maintenance - Autocar, LLC

Service 

Manual 

Preventive Maintenance Manual 

AWE 00005 Rev. 001 

autocartruck.com

Preventive Maintenance 

Important Notice 

This Service Manual has been prepared by Autocar, 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, LLC 

Hagerstown, Indiana, U.S.A. 

Document Number: AWE 00005 Rev. 001 

Copyright © 2011 Autocar, 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.


ACX Service Manual 

Table of Contents 

Safety Definitions..................................................................................................................... 1 

General Safety Information...................................................................................................... 2 

General Safety........................................................................................................................ 2 

Lifting....................................................................................................................................... 2 

Pneumatic Components.......................................................................................................... 2 

Hydraulic Components............................................................................................................. 3 

General Safety........................................................................................................................ 3 

Safety Decals............................................................................................................................ 3 

Service of Natural Gas Engine Trucks (CNG / LNG).............................................................. 3 

Eye, Ear and Skin Protection................................................................................................... 3 

Testing the Equipment............................................................................................................. 4 

Road Testing the Vehicle......................................................................................................... 4 

While Servicing the Vehicle..................................................................................................... 4 

Ground Straps and Antistatic Mats.......................................................................................... 5 

Power Steering........................................................................................................................ 5 

Lockout / Tagout Procedures.................................................................................................. 5 

Introduction............................................................................................................................... 6 

Preventive Maintenance.......................................................................................................... 6 

Preventive Maintenance Program........................................................................................... 6 

Description and Operation...................................................................................................... 6 

Service Procedures................................................................................................................ 14 

Walk-Up / Walk-Around Inspection........................................................................................ 14 

Exterior.................................................................................................................................. 14 

Wheels and Tires.................................................................................................................. 15 

Fuel System.......................................................................................................................... 16 

Brake System........................................................................................................................ 18 

Electrical................................................................................................................................ 19 

Engine Compartment............................................................................................................ 21 

Under Truck Inspection / Lubrication..................................................................................... 25 

Tag and Pusher Axles........................................................................................................... 26 

Drive Axles............................................................................................................................ 26 

Steering and Suspension...................................................................................................... 27 

Torque Procedure (Reyco/Granning 102CC Single Axle Rear Suspension Only)................ 29 

All Other Suspensions........................................................................................................... 29 

Hendrickson PRIMAAX® Air Suspension.............................................................................. 30 

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877-973-3486 

TOC-1



Hendrickson Recommended Maintenance Intervals............................................................. 30 

Interior and Instrumentation Inspection................................................................................. 33 

Road Test.............................................................................................................................. 39 

After the Road Test................................................................................................................ 40 

Chassis Lubricants and Fluids.............................................................................................. 41 

Service Points....................................................................................................................... 41 

Chassis Lubrication Chart..................................................................................................... 42 

TOC-2 

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SAFETY DEFINITIONS 

The technician performing maintenance repairs 

or service on Autocar products must (a) inspect 

the vehicle for abnormal wear and damage, 

(b) choose a repair procedure which will not 

endanger his/her safety, the safety of others, 

the vehicle or the safe operation of the vehicle 

and (c) fully inspect and test the Autocar 

product to ensure that the repair or service 

of the Autocar product has been properly 

performed. 

This safety alert symbol appears 

with most safety statements. It means 

you should pay attention and be alert 

because your safety is involved! Read 

and abide by the message that follows 

the safety alert symbol. 

The safety messages that follow this 

heading indicate a hazardous situation 

which, if not avoided, will result in death 

or serious injury. 



which, if not avoided, could result in 

death or serious injury. 



which, if not avoided, may result in minor 

or moderate injury. 



which, if not avoided, may result in 

damage to the Autocar product or 

property damage. 

AWE 00005 Rev. 001 877-973-3486 

1



GENERAL SAFETY INFORMATION 

Follow safety and safe working procedures at 

all times. 

Read and understand this entire manual 

before operating, repairing or adjusting the 

vehicle. You must be thoroughly trained and 

familiar with the vehicle before working on it. 

This equipment can cause severe injury if not 

properly used and maintained. 

These safety procedures are for your own 

protection. Do not operate, service or up-fit the 

vehicle until you have read and understood 

the Operator’s Manual and service instructions 

supplied with the vehicle. 

General Safety 

There is no substitute for common sense and 

careful practices in the workplace. Improper 

practices or carelessness can cause burns, 

cuts, mutilation, asphyxiation, other bodily 

injury or death. Follow these general safety 

precautions and guidelines to reduce the 

risk to your personal safety. Special safety 

precautions are listed in specific procedures 

when they apply. Read and understand all of 

the safety precautions and guidelines before 

performing any repair. 

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. 

Lifting 

Use a hoist or other assistance when lifting 

components that weigh 50 lb. (23 kg) or more. 

Make sure all lifting devices such as chains, 

hooks or slings are in good condition and have 

the correct capacity. Make sure hooks are 

positioned correctly. ALWAYS use a spreader 

bar when necessary. The lifting hooks MUST 

NOT be side loaded. 

The Antilock Brake System (ABS) MUST be 

disabled prior to jacking up a vehicle that has 

a Traction Control System (TCS) and prior to 

placement of the jack stands. If the ABS is not 

disabled and one of the wheels starts to spin, 

the TCS will compensate and the vehicle may 

come off the jack and/or jack stands. 

The Automatic Traction Control (ATC) should 

be disabled by switching the ATC/OFF switch 

to the OFF position. NEVER work under a 

vehicle supported only by jacks. Jacks can slip 

out from under the truck or fall over. ALWAYS 

use jack stands under the truck. 

NEVER work under or around the truck unless 

it is supported on jack stands of adequate 

rating. Failure to do so can result in the vehicle 

falling. 

Pneumatic Components 

Pneumatic components such as air reservoirs 

and spring brake chambers store compressed 

air and can separate violently during 

disassembly or removal. Before servicing any 

part of the pneumatic (air) system, completely 

release the compressed air from the entire 

system including the lift and/or load suspension 

air bags. 

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877-973-3486 AWE 00005 Rev. 001



HYDRAULIC COMPONENTS 

SERVICE OF NATURAL GAS 

ENGINE TRUCKS (CNG / LNG) 

Hydraulic systems and fuel injection systems 

can operate under extremely high pressures 

which can remain long after shutdown. Before 

servicing any part of the hydraulic system 

or fuel injection system, carefully relieve the 

pressure completely. Escaping fluid under high 

pressure can penetrate the skin causing severe 

injury. NEVER check for leaks using your hand. 

Use instead a piece of wood or cardboard. 

General Safety 

Stay clear when suspension air is being 

energized or de-energized. The vehicle may 

move quickly and cause serious injury or death 

to anyone under or around the vehicle. 

NEVER service any part of the fuel system 

while smoking or in the presence of flames, 

sparks or hot surfaces. 

Clean up fuel spills immediately. Fuel leaked 

or spilled onto hot surfaces or electrical 

components can cause a fire. 

Before working in or around the vehicle, apply 

the parking brake, block the wheels and put the 

transmission in NEUTRAL. 

SAFETY DECALS 

Immediately replace safety decals if they 

become damaged, unreadable or missing. 

Contact Autocar for replacement decals when 

required. 

If you store or dispense Compressed Natural 

Gas (CNG) or Liquefied Natural Gas (LNG), 

or if you work on CNG or LNG trucks, your 

location must be fully compliant with applicable 

codes, regulations and standards, including 

National Fire Protection Associate (NFPA) 

codes, Society of Automotive Engineers (SAE) 

standards, American National Standards 

Institute (ANSI) Natural Gas Vehicle (NGV) 

standards, the United States Code of Federal 

Regulations (CFR) and your state and local 

fire and other application codes (including the 

California Code of Regulations and the Texas 

Administrative Code, as applicable). 

Contact your local fire department for guidance 

and additional compliance information. 

Technicians working on Autocar trucks with 

CNG or LNG engines must be trained in the 

proper repair of CNG and LNG engines and the 

safe storage and dispensing of CNG and LNG. 

EYE, EAR AND SKIN PROTECTION 

ALWAYS wear appropriate eye protection 

to prevent the risk of eye injury. Wear safety 

glasses to prevent eye contact with debris and 

fluids. Wear a welding face mask to protect 

eyes and face when welding. 

ALWAYS wear ear plugs when working around 

loud noises to prevent the risk of hearing loss 

and damage. 

ALWAYS wear appropriate gloves to protect 

the hands. Wear welding gloves to protect the 

hands when welding. Wear appropriate gloves 

when handling extremely hot or cold equipment 

and fluids. 

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TESTING THE EQUIPMENT 

Exhaust gases contain deadly poison. When 

testing a vehicle with the engine running, 

conduct the test outdoors or use a properly 

vented exhaust hose. 

Use caution when installing testing equipment. 

Keep away from hot engine or transmission 

components or fluids. A hot engine, 

transmission or fluids can permanently damage 

test equipment or can cause personal injury. 

If a vehicle is to be operated with testing 

equipment connected, take precautions 

to ensure that all equipment and related 

components are securely attached to prevent 

movement and interference. 

When operating the vehicle on streets and 

highways while testing, ALWAYS have one 

person drive while another performs the test. 

Failure to do so may cause a collision, which 

can result in serious injury or death. 

Road Testing the Vehicle 

NEVER operate the starter without first placing 

the transmission in NEUTRAL and applying 

the parking brake. Failure to follow these 

instructions may result in the unintentional 

movement of the vehicle. 

NEVER release or drive a truck on the road 

that has a brake defect – no matter how 

minor – until it has been repaired or corrected. 

Failure to repair brake defects can result in 

compromised brake efficiency and lead to loss 

of control of the vehicle. 

NEVER drive the vehicle without power 

assisted steering. When the power assist has 

failed, the effort required to turn the steering 

wheel is much greater, especially in sharp turns 

or at low speeds. 

A speed retardation device (such as a “Jake 

Brake,” “C-Brake,” “Exhaust Brake,” “Telma 

Retarder” or “Allison Retarder”) is not intended 

to replace the service brake system on the 

vehicle, nor is it intended to bring the vehicle 

to a stop. A vehicle speed retardation device is 

only intended to retard the speed of the vehicle 

under certain conditions. 

Before driving the vehicle, be certain that you 

have read and that you fully understand each 

and every step of the driving and handling 

information in the Operator’s Manual. Be 

certain that you fully understand and follow all 

safety warnings. 

While Servicing the Vehicle 

You must read and understand the 

precautions and guidelines in each component 

manufacturer’s service information before 

performing any procedure. If you are not 

properly trained and certified in a procedure, 

ask your supervisor for training before you 

perform it. 

All items within the cab must be secured before 

the vehicle is serviced or driven. 

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877-973-3486 AWE 00005 Rev. 001



Ground Straps and Antistatic Mats 

LOCKOUT / TAGOUT 

PROCEDURES 

ALWAYS work with proper grounding 

straps and antistatic mats around electric 

components. 

Power Steering 

Maintain cleanliness of the power steering 

hydraulic system at all times. Clean the area 

around any component prior to disconnecting 

or connecting. NEVER add used power 

steering fluid to the system. Dirt in the power 

steering system can damage the pump or other 

components. 

Before entering the vehicle or vehicle 

body, read and follow OSHA regulations 

concerning entry and working in 

“CONFINED SPACE” OSHA 1910.146 

and “LOCKOUT/TAGOUT” OSHA 

1910.147 Follow OSHA regulations while 

performing any work on the vehicle. The 

vehicle must be disabled by the following 

steps before performing any work on the 

vehicle: 

1. Place the transmission in NEUTRAL. 

2. Set the parking brake. 

3. Shut the engine OFF. 

4. Lock the cab doors. Keep the key in your 

pocket. Block the wheels before entering 

the body or performing any work on the 

vehicle. 

5. Turn the battery disconnect switch OFF. 

6. Completely drain the air from the 

primary/A system and secondary/B 

system by opening the drain valves on 

the air tanks themselves or by using the 

drain manifold if supplied. When draining 

the air tanks, do not look into the area 

where air is draining. Dirt or sludge 

particles may be expelled in the air 

stream and can cause eye injury. 

7. Place magnetic “DANGER” signs on both 

cab doors before entering the body or 

performing any work on the vehicle. 

8. Take proper precautions before working 

under the vehicle. Use ramps approved 

for the weight of your vehicle, or use floor 

jacks and stands. Never work under a 

vehicle supported by jacks alone. Always 

use jack stands to support the vehicle. 

AWE 00005 Rev. 001 877-973-3486 

5



INTRODUCTION 


This manual has been designed to reflect 

a work-efficient approach to preventive 

maintenance. 

Periodic servicing, inspection, adjustment 

and maintenance are essential to the ongoing 

dependability and efficiency of the vehicle. 

Vehicles that receive proper preventive 

maintenance operate more effectively and 

economically. 

One of the most important parts of the vehicle’s 

maintenance is lubrication and oil changes. 

However, despite of the high quality of the 

lubricants and oils available today, natural wear 

does occur necessitating adjustments and 

repairs. 

A thorough Preventive Maintenance Program 

can dramatically reduce breakdowns 

and increase service life. This Preventive 

Maintenance Program has been developed 

to help prevent unexpected downtime and 

continuously maintain the vehicle in good 

operating condition. Following these guidelines 

will also help ensure the vehicle meets all 

federal, state, and local regulations, which is 

the responsibility of the owner. 

This manual is intended as a general guide. 

Individual users may need to alter these 

recommendations based upon the application 

in which the truck will be used. For example, 

more severe applications may require 

shortening the interval between chassis 

lubrication. Contact your authorized Autocar 

dealer to develop the Preventive Maintenance 

Program that is best suited to your application. 

The vehicle should be serviced based on 

operating hours. Maintenance intervals 

based on months or mileage do not take into 

consideration actual operating hours. 

Major vehicle components such as engine, 

transmission, axles and retarders, may 

have their own recommended preventive 

maintenance intervals. Refer to each 

component’s maintenance manual for service 

intervals and procedures. If no manufacturer 

recommendation exists, follow the guidelines 

in the Preventive Maintenance Program in this 

Service Manual section. 

PREVENTIVE MAINTENANCE 

PROGRAM 

Description and Operation 

A Inspection 

Perform this inspection every 150 hours 

of operation (maximum recommended 

interval). This includes, but is not limited 

to, basic inspection of the vehicle and may 

include engine oil and filter change, as well 

as complete chassis lubrication. Refer to 

manufacturer’s recommendations for further 

information. 

B Inspection 

Perform this inspection every 300 hours of 

operation (maximum recommended interval). 

This inspection includes everything done 

during the A inspection, plus additional items 

requiring inspection at this interval. 

C Inspection 


operation (maximum recommended interval). 


during the A and B inspections, plus additional 

items requiring inspection at this interval. 

D Inspection 


operation or yearly (maximum recommended 

interval), whichever comes first. This is 

commonly referred to as an annual inspection 

for single shift trucks. 

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877-973-3486 AWE 00005 Rev. 001



For trucks that do not accumulate 2,400 

hours per year, the D inspection must 

be done annually to ensure proper 

maintenance of the vehicle. 


during the A, B and C inspections, plus 

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. 

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Interval 

(1) Walk-up/ 

Walkaround 

Inspection 

Exterior 

Wheels and Tires 

Fuel / DEF System 

Check glass, mirrors, mirror mounting. 

Check condition of wiper blades. 

Check exhaust stack condition and mounting. 

Check routing and clamping of all air lines, fuel lines, 

electrical wires. 

Check cab mounting hardware, tilt, latch mechanisms. 

Check and lubricate cab hinges. 

Check condition of frame rails and crossmembers; check for 

cracks and loose fasteners. 

Check paint/finish, overall appearance. 

Check condition of cab steps and grab handles. 

Check mud flaps, brackets, hardware. 

Torque inner and outer wheel nuts. 

Inspect wheels for cracks, rust, elongated holes. 

Inspect tires for abnormal wear, cuts, foreign objects, air 

pressure. 

Record tread depth of all tires. 

Check valve stems and extensions for damage or leaks. 

Check dual matching. 

Check fuel tank(s) for damage, secure mounting, leaks, rust. 

Drain water and sludge from tanks. 

Drain and clean fuel/water separator. 

Replace fuel filter element. 

Inspect fuel lines for wear/damage, routing and clamping. 

Check DEF reservoir for damage, secure mounting, and 

leaks. 

Inspect DEF and DEF heater lines for wear/damage, routing 

and clamping. 

Replace DEF filter. 

Check air line routing and clamping. 

A 

150 

hrs 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

B 

300 

hrs 

x 

x 

C 

1200 

hrs 

D 

2400 

hrs or 

Annually 

x 

Check for damaged/leaking air lines. 

x 

Check condition of air brake hoses. 

x 

Check air dryer: 

Inspect air dryer mounting, connections, wiring. 

x 

Check operation (see mfg. documentation). 

x 

Brake System 

Check heater element if equipped. 

Change air dryer desiccant. 

Drain moisture from air tanks. 

Check dual air brake system operation. 

Check slack adjusters for operation and adjustment. Check 

brake adjuster angle. Check and record brake adjuster push 

rod travel. Inspect brake adjuster pin for free movement and 

proper lubrication 

x 

x 

x 

x 

Refer to the equipment 

manufacturer’s 

documentation for service 

intervals, procedures, and 

specifications. 

x 

Check condition of S-cams and brake chambers. 

Remove chamber plug and inspect for hung-up caging 

plate. Install new plug. 

Check brake lining for wear, cracks, drum-to-lining clearance. 

Record brake lining thickness. 

x 

x 

x 

x 

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Interval 

(1) Walk-up/ 

Walkaround 

Inspection 

(continued) 

(2) Under 

Truck 

Inspection/ 

Lubrication 

Brake System 

(continued) 

Engine 

Compartment 

Lubrication 

A 

150 

hrs 

B 

300 

hrs 

If equipped with disc brakes, check to ensure all 

calipers are free-floating and that no excessive caliper x 

to pad clearance is present. 

Replace fuel filters 

x 

Replace power steering filter (No more than 2,400 hrs 

or annually) 

Drain and replace power steering fluid 

Intake air piping: 

Check connections and mounting 

x 

Check air filter, housing, and air restriction gauge 

Check inside of pipes and charge air cooler to buildup 

of foreign material 

x 

Replace air filter 

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) Band Clamps, 

Heat Shield, and mounting fasteners. Add any attaching 

x 

hardware necessary. 

Transmission mounts / fasteners: 

Check torque 

x 

Check for cracks 

x 

Air conditioning: 

Check compressor mounting 

x 

Inspect for leaks 

x 

Check sight glass for moisture. Change A/C drier as 

necessary 

Pressure test system for proper level of refrigerant 

Air compressor: 

Check mounting and connections 

Alternator: 

Check mounting 

x 

Check harness routing, clamping and connections 

x 

Starter: 

Check for secure mounting 

x 

Check cable routing and connections 

x 

Lubricate chassis per Chassis Lubrication Chart (Figure 

32 at the back of this Service Manual section) 

x 

Lubricate driveline 

x 

Check for looseness of components 

x 

Slip joints 

x 

U-joints x* 

Carrier bearings - Check for looseness and end play x 

Engine: 

Replace engine oil and filter 

Check all engine mounting fasteners for proper torque 

Transmission: 

Check for loose rear transmission bearing (driveshaft 

yoke) 

Check oil level 

C 

1200 

hrs 

x 

x 

x 

x 

x 

D 

2400 

hrs or 

Annually 

Refer to the engine manufacturer’s 

documentation for procedures, 

specifications and service intervals. 

x 

x 

x 

x 

x 

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Interval 

A 

150 

hrs 

B 

300 

hrs 

C 

1200 

hrs 

D 

2400 

hrs or 

Annually 

Under Truck 

Inspection/ 

Lubrication 

(continued) 

Lubrication 

(continued) 

Steering and 

Suspension 

Replace fluid and filter 

Lubricate PTO linkages and shafts, if equipped 

Tag/pusher axles: 

Check wheel hub oil level; Inspect for leaks 

Rear drive axles: 

Check torque rods for looseness 

Check oil level 

Check and clean breather 

Replace oil and filter 

See component manufacturers’s service 

documentation for procedure and specifications. Oil 

change interval varies based on the type of oil used. 

Inspect input and output bearings for free play* 

Inspect wheel seal and axle are for leaks 

Check Telma retarder mounting bolts, if equipped 

Check carrier bearing mounting bolt torque 

Inspect front suspension: 

Springs 

Shackles 

Check spring hanger bolt torque 

Mounting hardware, mounts, and U-bolts 

Check steering. Note: On dual steer trucks, check 

components on both sides 

Check steering for excessive play 

Check for secure steering gear mounting 

Steering drag 

Coupler 

U-joints 

Slip joints 

On dual-steer trucks check 90° steering boxes, both 

slip joints, and all U-joints 

On dual-steer trucks lubricate the grease fitting and 

check lubricant level on the 90° steering boxes. 

Check steering column for secure mounting and 

bearing smoothness 

Drag link* 

Tie rod ends* 

Tighten draw key nut to specification 

Check steering arm bolt torque 

Pitman arm and nut 

Check steering assist cylinder and hoses for leaks 

and damage 

Check steering knuckle vertical play 

Check and record king pin movement 

Lubricate steering and front suspension 

Refer to the transmission 

manufacturer’s documentation for 

procedures, specifications and service 

intervals. 

x 

x 

x 

x 

x 

Refer to axle manufacturer’s 

documentation for further information. 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

Refer to steer axle manufacturer’s 


specification, and service interval. 

x 

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Interval 

A 

150 

hrs 

B 

300 

hrs 

C 

1200 

hrs 

D 

2400 

hrs or 

Annually 

Under Truck 

Inspection/ 

Lubrication 

(continued) 

(3) Interior and 

Instrumentation 

Steering and 

Suspension 

continued) 

Check front and rear wheel bearings 

Check front wheel alignment 

Check steering stop settings 

Check tandem alignment 

Inspect rear suspension 

Springs 

Shackles 

Mounting hardware and U-bolts 

Reyco 102CC suspension - retorque rear axle 

U-bolts** 

Check torque arm bushings and mounts 

Inspect air suspension, if equipped 

Inspect shock absorbers 

Mounting 

Damage or leakage 

Note: Check both driver stations on dual station cab 

Check window and door operation 

Strikers and latches 

Seals 

Hinges 

Window operation 

Check general condition of floor, seats, panel, visors, 

and loose items 

Inspect seat cushions 

Check seat mounting and suspension 

Lubricate window rollers and tracks 

Check seat belt operation 

Check seat belt latches and tensioners 

Check all exterior light operation, flashers, directional 

signals, high and low beams, parking lights, clearance 

and marker lights, reflectors, tail lights, brake lights, and 

reverse lights. Check instruments and dash lights. 

Key switch ON, engine NOT running 

Check tail lamps and indicators 

Check all gauges with key ON and engine NOT 

running 

If equipped, verify camera image(s) are displayed on 

the cab monitor 

Start engine 

Check starter operation 

Check all gauges with engine running 

Check for smoke, surging, misfire, excessive noise 

Check accelerator pedal, mounting and operation 

(including sensor wiring and pivot) 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

** ** See note 

x 

x 

x 

x 

x 

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Interval 

Interior and Instrumentation 

(continued) 

(4) Road Test 

(5) After Road Test 

Air system: 

Check low air pressure light and alarm 

Test air compressor cut-in/cut-out 

Test air replenishment 

Perform dynamic air pressure test 

Check reservoir check valve operation 

Check primary circuit low-pressure warning 

Check emergency brake spring operation 

Check interior lights and switches 

Test horns and backup alarm 

Check wiper blades/washer condition and operation 

Check heater, defroster, and AC operation 

Check work station power, if equipped 

Check operation of lift axles and auto-lift in reverse, if 

equipped 

Inspect safety equipment provided by Autocar 

Record fire extinguisher expiration date on inspection 

form 

Check Telma lights, if equipped (truck must be moving 

at least three mph) 

Check engine controls and performance. Record 

engine idle; high ______; low ______ 

Check for smoke surging misfire, excess noise 

Check service brake operation 

Parking brake operation. Check operation (see FMVSS 

documentation) 

Check park brake valve function* 

Check ABS system* 

Check transmission operation 

Check differential lock, (if equipped) 

Check for abnormal vibration and noise 

Check steering system 

Check for fluid leaks 

Record the date and type of the last inspection 

Complete inspection form and install new sticker 

* Refer to component manufacturer’s service documentation for procedures, intervals, and specifications. 

**Reyco/Granning 102CC Single Axle Rear Suspension 

A 

150 

hrs 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

x 

B 

300 

hrs 

x 

x 

C 

1200 

hrs 

D 

2400 

hrs or 

Annually 

It is extremely important that the rear axle U-bolts be retorqued at Pre-Delivery Inspection (PDI) or BEFORE placing the vehicle in 

service. Once the vehicle is placed in service, retorque the U-bolts after the first 50 hours of operation, and with each 300 hours 

of operation thereafter. Follow all of the bolt/nut tightening recommendations included in this document. The U-bolts MUST BE 

replaced after retorquing three times, as they will have lost their elasticity. The retorque at PDI is the second time. If any movement 

of the nut is detected at the 50 hour check, make a note in the vehicle service record to replace the bolt(s) the next time any 

movement of the nut occurs during a torque check. Failure to do so may result in U-bolt failure. 

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Engine Mount Bolts 

Transmission Mount Bolts 

Frame Bolts 

Pitman Arm Pinch Bolt 

Special Torque Chart 

Item Size Specification 

Front Spring Hanger-to-Frame Bolt 

Front Axle U-Bolt 

Rear Axle U-Bolt 

Torque Rod Bolt 

Torque Rod Flange Nut 

Steering Gear Mounting Bolt 

M12 flange head 

M16 

63 ± 11 ft-lb (85 ± 15 N·m) 

163 ± 26 ft-lb (221 ± 355 N·m) 

1/2" - 13 105± 10 ft-lb (142 ± 13 N·m) 

1/2" - 20 90 ± 9 ft-lb (122 ± 12 N·m) 

9/16" - 18 168 ± 11 ft-lb (227 ± 11 N·m) 

5/8" - 11 200 ± 20 ft-lb (227 ± 11 N·m) 

1/2" hex head 80 ± 5 ft-lb (108 ± 6.8 N·m) 

1/2" flange head 105 ± 10 ft-lb (142 ± 13.5 N·m) 

9/16" 139 ± 6 ft-lb (188 ± 8 N·m) 

5/8" 200 ± 20 ft-lb (271 ± 27 N·m) 

3/4" 280 ± 15 ft-lb (380 ± 20 N·m) 

1/2" 105 ± 10 ft-lb (142 ± 13.5 N·m) 

5/8" 200 ± 20 ft-lb (271 ± 27 N·m) 

3/4" 300 ± 30 ft-lb (414 ± 41 N·m) 

295 ± 45 ft-lb (400 ± 60 N·m) 

1/2" 105 ± 10 ft-lb (142 ± 13.5 N·m) 

5/8" 200 ± 20 ft-lb (271 ± 27 N·m) 

3/4" 305 ± 30 ft-lb (414 ± 41 N·m) 

M20 

305 ± 30 ft-lb (414 ± 41 N·m) 

7/8" 500 ± 50 ft-lb (678 ± 68 N·m) 

3/4" 305 ± 30 ft-lb (414 ± 41 N·m) 

M20 

369 ± 55 ft-lb (500 ± 75 N·m) 

7/8" Reyco 102CC Suspension Only 400 - 425 ft-lb (545 - 580 N·m) 

7/8" 425 ± 42 ft-lb (576 ± 57 N·m) 

M24 

**Reyco/Granning 102CC Single Axle Rear Suspension 

486 ± 55 ft-lb (659 ± 57 N·m) 

See equipment manufacturers’s service 

documentation for specification. 

ACX, ACXR, and ACX Dual Steer -- 

7/8" - 9 bolts 460 ± 45 ft-lb (624 ± 61 N·m) 

7/8" - 14 bolts 500 ± 50 ft-lb (678 ± 68 N·m) 

7/8" - 14 bolts 305 ± 30 ft-lb (413 ± 41 N·m) 

It is extremely important that the rear axle U-bolts be retorqued at Pre-Delivery Inspection (PDI) or BEFORE placing the vehicle in 

service. Once the vehicle is placed in service, retorque the U-bolts after the first 50 hours of operation, and with each 300 hours 

of operation thereafter. Follow all of the bolt/nut tightening recommendations included in this document. The U-bolts MUST BE 

replaced after retorquing three times, as they will have lost their elasticity. The retorque at PDI is the second time. If any movement 

of the nut is detected at the 50 hour check, make a note in the vehicle service record to replace the bolt(s) the next time any 

movement of the nut occurs during a torque check. Failure to do so may result in U-bolt failure. 

AWE 00005 Rev. 001 877-973-3486 

13



SERVICE PROCEDURES 

Walk-Up / Walk-Around Inspection 

Exterior 

1. Check the ground under the truck as you 

approach, looking for evidence of fluid 

leaks. 

2. Check all glass, mirrors and brackets. 

• Windshields must be free of damage, 

hazing or discoloration within certain 

guidelines. Refer to current federal, 

state and local regulations for full 

requirements. 

• Check the windows, (front and back) 

for cracks. 

• Mirrors should be free of damage, 

hazing and discoloration. Brackets 

should be secure. 

• If the mirrors are motorized, check the 

operation. 

3. Check condition of wiper blades and 

arms. Check for looseness, bends, 

tension, etc. 

4. Check that the exhaust stack is not 

damaged and is securely mounted. 

5. Check that all air lines, fuel lines and 

electrical wires are properly routed and 

clamped securely. 

• Verify that air line routing has not been 

modified by the body manufacturer. 

• Autocar recommends that air lines, fuel 

lines and electrical wires are secured 

adequately. 

6. Check the operation of cab tilt pump 

(Figure 1). 

Figure 1 

7. Check cab mounting: 

• Check that cab mounts are securely 

bolted to the frame. 

• Check the rubber cushions for 

deterioration. 

• Check for rust or cracks around mounts. 

• Check and lubricate the cab hinges. 

• Check latches for adequate tension 

and alignment adjusting as necessary 

(Figure 2). 

Figure 2 

8. Check the frame rails and crossmembers 

for cracks, damage or distortion. 

14 

877-973-3486 AWE 00005 Rev. 001



9. Check the frame for loose bolts. Tighten 

any loose bolts to specification. Refer 

to Special Torque Chart in this Service 

Manual section. 

10. Check the condition of the paint and 

overall appearance of the vehicle. Note 

any damage, rust or corrosion. 

Failure to properly torque 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. 

Figure 4 

Figure 3 

11. Check the condition of the cab access 

steps, platforms and grab handles. They 

should be secure, undamaged and free 

from slick spots (Figure 3). 

Wheels and Tires 

1. Check for the presence and condition of 

mudguards or flaps. Inspect the condition 

of the mounting brackets and hardware. 

2. Tighten the wheel nuts to the proper 

torque (Figure 4). All disc wheels used on 

the Xpeditor® series require a torque of 

450 ft-lb (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 

manufacturer’s specification. 

3. Inspect the wheels for elongated or 

distorted mounting holes. Examine the 

wheels for cracks and for rust streaks 

around the lug nuts. 

4. Examine each tire for unusual or uneven 

wear patterns. 

5. Check the valve stems and extensions on 

each wheel for leaks. 

6. Check and record pressure in each tire. 

The tire inflation pressure is specified by 

a decal located near each tire. If there 

is no decal, refer to the air pressure as 

indicated on each tire. 

AWE 00005 Rev. 001 877-973-3486 

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Figure 5 

7. Using a tire tread depth gauge, check 

the tread depth in the center of the 

tread (Figure 5). Record the tread depth 

in 1/32s (0.79 mm) of an inch on the 

inspection form. Autocar recommends 

that front (steering axle) tires with less 

than 1/8 in. (3 mm) tread depth should be 

replaced, and rear (drive) tires with less 

than 1/16 in. (1.5 mm) tread depth should 

be replaced. 

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 traveling 

on the outside of the turning circle. No 

specific interval can be given, as the 

requirement changes depending on 

vocation. 

Fuel System 

Figure 6 

1. Inspect fuel tanks for damage, leaks or 

rust (Figure 6): 

• Examine the mounting straps for cracks, 

and ensure that the rubber insulators 

are secure. 

• Ensure that the tanks have not rotated 

in their mounts. 

• Inspect and clean the vent in each tank. 

• Inspect the operation of the shutoff 

valves. 

2. Drain water and sludge from all fuel tanks 

(if applicable): 

• Place a container under each fuel tank 

and loosen the drain plug until water 

begins to run out. 

• Allow the fuel tank to drain until the 

water and sludge are gone and only fuel 

is draining. Install and tighten the drain 

plug. 

To prevent fuel leaks you must address 

any problem with the fuel system 

immediately. 

16 

877-973-3486 AWE 00005 Rev. 001



Diesel Exhaust Fluid (DEF) System 

1. Inspect DEF reservoir (Figure 8) 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 7 

3. Drain the fuel filter/water separator and 

clean the outside of the unit (Figure 7). 

• B Inspection: Replace fuel filter(s). 

Fill new filter(s) with clean fuel prior to 

installation to reduce air in fuel system 

(refer to manufacturer’s documentation 

for procedure). 

Note: Different model fuel/water separators 

may be installed on the vehicle based on 

customer specifications. 

4. Inspect all fuel lines for wear, damage 

and secure clamping. 

Figure 8 

AWE 00005 Rev. 001 877-973-3486 

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3. D Inspection - Replace DEF system filter 

(Figure 9). 

Brake System 

Figure 9 

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 

serious personal injury. 

2. Air dryer: 

• Check mounting, wiring and 

connections. 

• Check operation per equipment 

manufacturer’s recommendation. 

• Check heater element (if equipped) 

per equipment manufacturer’s 

recommendation. 

• D Inspection: Replace the air dryer 

desiccant per manufacturer’s 

guidelines. 

NEVER release a vehicle that has a 

defect in the brake system – no matter 

how minor the defect. Failure to repair 

brake system discrepancies can result 

in compromised brake efficiency leading 

to loss of control, resulting in severe 

personal injury or death. 

1. Inspect all air lines and hoses for routing, 

secure clamping, chafing, cracks and 

evidence of air leaks. 

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. 

Figure 10 

When draining the air tanks, do not look 

into the area of the escaping air. Dirt or 

sludge particles may be expelled and 

cause eye injury. 

3. Open petcocks on air tanks to drain 

moisture (Figure 10). If excessive oil or 

water comes from the tank, make a note 

on the inspection form for follow-up. 

18 

877-973-3486 AWE 00005 Rev. 001



Note: Tank shown is equipped with remote 

drains. 

4. Inspect the dual air brake system as 

follows, to ensure that it is operating 

properly: 

• Apply full air brake pressure to the air 

brake system and verify there is no 

more than two psi (13.8 kPa) pressure 

loss per minute. 

• Charge both A and B air systems. 

• Drain the air tank for the A system. 

• Apply the brakes. Ensure that there is 

an application of the slack adjusters for 

the front brakes. 

• Charge both A and B air systems again. 

• Drain the air tank for the B system. 

• Apply the brakes. Ensure that there is 

an application of the slack adjusters for 

the rear brakes. 

5. Inspect the slack adjuster operation, 

mounting and adjustment. Refer to 

brake manufacturer’s documentation for 

procedures and specifications. 

6. Remove chamber plug and inspect for 

hung-up caging plate. Install new plug 

when finished. 

7. Examine S-cams, springs and 

miscellaneous braking components for 

wear and general condition. 

8. Measure and record the brake lining 

thickness. Replace lining and shoe 

assembly if 0.250 in. (6.35 mm) or less 

remains at the middle of the shoe. Check 

the brake lining for cracks. Check and 

note drum-to-lining clearance. Maximum 

acceptable clearance is 0.063 in. (1.60 

mm). 

Electrical 

Always wear the appropriate safety gear 

when working near the vehicle batteries. 

Never smoke or use a spark producing 

device near the batteries as gases could 

be present. 

Figure 11 

1. Inspect the battery hold-down hardware 

and fasteners for proper placement, 

making sure that it is secure and free of 

corrosion (Figure 11). Inspect the cables 

for proper length and broken insulation 

or strands. Inspect the positive (+) 

battery cables throughout the chassis 

for chafing and proper routing. Inspect 

all connections at the starter. Check that 

the terminal ends are secure and free of 

cracks. 

2. Remove any corrosion from the cable 

ends and battery posts. After thorough 

cleaning, spray the area with a corrosionpreventive 

compound. 

3. B Inspection: Clean and seal the 

terminals on the battery disconnect switch 

(if equipped) in the same manner as the 

battery terminals. 

AWE 00005 Rev. 001 877-973-3486 

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4. Ensure that all ground connections are 

clean, free of corrosion and secure. 

Check the terminal connections. 

5. B Inspection: Test the batteries. 

• Inspect the batteries for secure 

mounting, cracks, and corroded 

terminals. 

• Check the specific gravity of 

maintenance-type batteries. 

• Attach a carbon pile and load-test the 

batteries as instructed by the load tester 

manufacturer. Replace any batteries 

that fail the test. 

6. B Inspection: Check the starter as follows: 

• Perform current draw test using tool 

VAT40. See the appropriate engine 

service documentation for procedure 

and specifications. 

• Inspect the starter to verify secure 

mounting, and inspect for cracks around 

the mounting flanges. 

• Check cables for wear and ensure 

connections are clean, tight and free of 

corrosion. 

• Ensure that the wiring is properly 

routed and securely clamped to prevent 

chafing. 

7. B Inspection: Test the alternator as 

follows: 

• Remove the surface charge as follows: 

- 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 

2-3 minutes per battery. 

- Allow the batteries to recover for 30 

seconds, then check the voltage 

using a voltmeter. If the reading is less 

than 12.40 volts, charge or replace the 

batteries before proceeding. 

• Voltage Output Test: 

Note: Most Leece Neville alternators have 

isolated round rectification. Always connect 

tester/volt meter directly to the negative 

output terminal of alternator or your test 

will be inaccurate. Ensure all electrical 

accessories are off and there is no load on 

the batteries. 

- Connect a DC voltmeter to the positive 

and negative output terminals at the 

alternator. Measure the voltage at the 

batteries. The reading must be within 

1.0 volts of the reading taken at the 

alternator. Correct any problems before 

proceeding. 

- Start engine and increase speed to 

1500 rpm: The voltmeter should now 

indicate alternator output voltage has 

increased to a range from 13.8 volts to 

14.2 volts. 

If voltage increases, but is out of range, 

inspect to see if alternator has an 

adjustable regulator. If so, reduce 

engine speed to idle. Adjust voltage to a 

setting of 14.0 volts. 

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 the alternator incorporates an 

ignition/“IGN” terminal, this terminal 

must have battery voltage present 

above 12.4 volts. If not, inspect circuit 

for open and repair. 

20 

877-973-3486 AWE 00005 Rev. 001



Additionally, if the alternator 

incorporates a DUVAC/Remote Sense 

“S” terminal, inspect to see that this 

terminal also has voltage of 12.40 volts 

or above present. If not, inspect circuit 

for open and repair. If all is verified and 

alternator voltage has not increased or 

is out of range, replace alternator. 

If within range, perform Current Output 

Test. 

• B Inspection: Current Output Test: 

- With a carbon pile, apply a current 

load equal to 75% of rated output 

capacity of the alternator for 10 

seconds. 

- Test voltage at the alternator terminals 

using a voltmeter. The voltage should 

not decrease more than 0.50 volts. 

If voltage drops more than 0.50 volts, 

the alternator is defective and must be 

replaced. 

Check the amperage against the 

specified maximum. Readings within 

10% are considered acceptable. 

• Inspect the alternator pulley and drive 

pulley for correct alignment. 

• Ensure that the alternator mounting 

bolts are torqued properly on the 

alternator mounting bracket. 

Engine Compartment 

1. Check for evidence of fluid leaks. 

2. Inspect all hoses for cracking, cuts, 

secure installation, proper routing and 

clamping, chafing and evidence of leaks. 

Inspect steel braided lines for wear and 

rust. Inspect clamps to ensure that they 

are installed securely. 

3. Check all fluid levels; fill as necessary: 

• Engine oil level must be between “full” 

and “add” marks of dipstick. DO NOT 

overfill. DO NOT MIX DIFFERENT 

TYPES OF OILS. For oil type, refer to 

engine manufacturer’s specifications. 

• Transmission oil level (refer to 

manufacturer’s documentation). Assess 

the oil for evidence of overheating 

(burned smell or discoloration). DO NOT 

MIX DIFFERENT TYPES OF OILS. To 

ensure compliance with the Autocar/ 

Allison four-year warranty requirements, 

use Castrol TranSynd transmission oil 

only. 

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. 

Note: The oil level in Allison transmissions 

should be checked using push-button or 

lever shift selector. 

• D Inspection: Power steering fluid level 

must be between “full” and “add” marks 

of dipstick. DO NOT overfill. 

• C Inspection: Hydraulic oil level. 

• Cab tilt hydraulic oil level. 

NEVER remove the coolant surge tank 

cap or radiator cap when the engine is 

warm. The explosive escape of scalding 

coolant or steam will result. 

AWE 00005 Rev. 001 877-973-3486 

21



Figure 12 

• Coolant level should be visible in the 

sight glass (Figure 12). If level is low, 

add 50/50 antifreeze/water mix. DO 

NOT MIX DIFFERENT TYPES OF 

COOLANT. Use Texaco Extended Life 

coolant #20358716 or etheleyne glycol 

base standard coolant #20469513. 

• Windshield washer fluid level. 

• Check washer reservoir mounting. 

Check condition of washer hoses. 

4. Check grille and behind grille area for 

clear air flow. 

Also check that radiator core is clear and 

not damaged. Check the area between 

Charge Air Cooler (CAC) and radiator 

for debris buildup. This area is prone to 

trapping debris and can affect engine 

cooling. Clean as required. Check the 

CAC expansion bushings (Figure 13). 

Replace as required. 

Figure 13 

5. Inspect fan shroud for secure installation. 

Inspect for cracks or damage. Check 

for adequate clearance between the fan 

and the fan shroud (minimum 1/4 in. 

(6.5 mm), or other engine compartment 

components, in both the engaged and 

disengaged mode. Repair if the clearance 

is inadequate. 

6. Check the fan for looseness and damage, 

such as bent, cracked or missing blades, 

loose rivets, or missing weights. Retorque 

if loose, replace if damaged. 

7. Inspect drive belts for cuts, wear, 

weathering, proper tension and 

alignment. 

22 

877-973-3486 AWE 00005 Rev. 001



8. 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. 

A contaminated air supply may damage 

the fan clutch assembly. Anytime system 

contamination is present take the 

necessary steps to correct the situation 

and purge the air lines. 

9. B Inspection: Check water pump, fan and 

idler pulley. See engine manufacturer’s 

documentation for procedures and 


• Loosen belts and rotate water pump 

pulley, checking for smoothness of 

water pump bearing operation and 

proper end play. 

• Inspect water pump shaft for wobble 

and evidence of leaks. 

• Inspect idler pulley for cracks. Check 

bearing for smooth, quiet operation. 

10. B Inspection: Inspect torsional vibration 

damper for evidence of dents, fluid loss, 

wobble, swelling and deformation. 

11. Inspect the front engine mount for isolator 

bushing wear or damage (Figure 14). 

Check mount bolts for proper torque. 

Figure 14 

NEVER remove the coolant surge tank 

cap or radiator cap when the engine is 

warm. The explosive escape of scalding 

coolant or steam will result. 

12. Cooling system: 

• Check coolant concentration. See 

engine manufacturer’s documentation 

for service interval, procedures and 


• B Inspection: Pressure test the cooling 

system: 

- Attach pressure tester at filler neck, 

ensuring that pressure is equal to 

normal operating pressure (with heater 

controls open). Leave the system 

under normal operating pressure for 

5-10 minutes. 

- Check top and bottom radiator tanks 

for leakage. 

AWE 00005 Rev. 001 877-973-3486 

23



- Remove the pressure tester and 

check the cap seal area and flange 

for distortion. While the test is running, 

check all coolant hoses and clamps for 

wear, cracking, distortion and leakage. 

Replace as necessary. 

• Pressure test radiator cap. 

• Test block heater and inspect cord for 

evidence of damaged insulation. Verify 

the cord is properly routed and clamped 

securely. 

• Install new coolant filter, if applicable. 

See engine manufacturer’s 

documentation for service interval, 


• Drain and refill cooling system. See 




13. Adjust valves and fuel injectors. See 




14. Replace crankcase vent filter. See engine 

manufacturer’s documentation for service 

interval, procedures and specifications. 

15. CNG engines: 

Note: See engine manufacturer’s 

documentation for recommended service 

intervals. 

• Replace crankcase filter. 

• Replace spark plugs and boots. 

• Check ignition coils. 

• Check catalytic converter. 

For trucks that do not accumulate 2,400 

hours per year, this inspection must 

be done annually to ensure proper 

maintenance of the vehicle. 

17. 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. 

18. B Inspection: Visually inspect exhaust 

system for signs of leakage at all 

connections. Examine all clamps and 

fittings for cracks and to ensure secure 

mounting. Repair any leaks or damage 

before returning truck to service. 

19. Check the transmission mounts for 

cracks. Check that all fasteners are 

tightened to proper torque. Refer to 

Special Torque Chart in this Service 


20. B Inspection: Check engine mounts for 

cracks. Check that all fasteners are 

tightened to proper torque. Refer to 



16. D Inspection: Change power steering fluid 

and filter. 

24 

877-973-3486 AWE 00005 Rev. 001



21. Air conditioning: 

• Refrigerant capacity: 

Note: For refrigerant capacities, refer to the 

decal on the side of the radiator near the air 

conditioning compressor. 

• B Inspection: Inspect air conditioner 

compressor base and mounting for 

proper attachment, cracks and evidence 

of leaks. 

• B Inspection: Check all air conditioning 

system lines, hoses and connections for 

evidence of leakage. Current production 

trucks use a fluorescent dye in the 

refrigerant. Use a black light to look for 

leaks. 

• C Inspection: Inspect the sight glass to 

determine if moisture is present. If the 

sight glass shows a blue indicator, the 

A/C dryer is in good working condition. 

If the sight glass shows a pink indicator, 

the A/C dryer must be replaced. 

Change air conditioning system dryer as 

required. 

22. C Inspection: Air Compressor: 

• Inspect the air compressor mounting for 

proper attachment, cracks and evidence 

of leaks. 

• Check that connections are tight. 

23. Alternator: 

• Check for secure mounting. 

• Check wire routing, clamping and 

connections. 

Under Truck Inspection / Lubrication 

Note: Any fastener or driveline component 

with a shiny, metallic appearance, or having 

rust streaks, indicates a loose or broken 

part. 

1. Check exhaust system condition and 

mounting. 

2. Starter: 

• Inspect for secure mounting and 

evidence of cracks. 

• Check routing and clamping of cables. 

Lubrication 

To rotate the driveline, the drive wheels 

must be elevated, the transmission in 

NEUTRAL and the parking brake released. 

Ensure front wheels are securely blocked 

before elevating the drive wheels. 

Note: Refer to the axle manufacturer’s 

documentation for recommended 

lubricants, change intervals and service 


1. Perform chassis lubrication per the 

Chassis Lubrication Chart (Figure 32) in 

this Service Manual section. For chassis 

lubrication use Delo Grease EP NLGI 1 

or 2 or equivalent. Be sure that grease 

fittings are clean and free from debris 

prior to application of grease. Ensure 

that each grease fitting fills with grease 

when lubricated. Remove excess grease 

from fittings, spring shackles and other 

surfaces. Inspect fittings for evidence of 

leaks. 

• Lubricate U-joints and slip yokes with 

EP NLG 12. 

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. 

AWE 00005 Rev. 001 877-973-3486 

25



2. Check U-joints, slip yokes and center 

bearings or free play during lubrication 

procedure. Inspect driveline for loose 

bolts. Rotate driveline, checking for 

excessive play in U-joints (not to exceed 

0.063 in. [1.60 mm]). Check all driveline 

fasteners for looseness. Any shiny area, 

or rust stains in the driveline indicate that 

there is a loose driveline part. Inspect 

center bearings for leaks and free play 

(not to exceed 0.063 in. [1.60 mm]). 

Push and pull shaft, checking for run-out 

at splines (should be between 0.063 in. 

(1.60 mm) and 0.125 in. [3.18 mm]). 

3. Change the engine oil per engine 


Remove and replace full-flow and bypass 

filters. Check crankcase capacity and fill 

to proper level using oil recommended by 

the engine manufacturer. 

4. Transmission: 

• B Inspection: Check the transmission 

output bearing (driveshaft yoke) 

for movement. See transmission 


procedure and specifications. 

• Change the transmission fluid and 

replace the filter per transmission 


Inspect magnetic drain plug for excess 

metal filings. Assess the oil for evidence 

of overheating (burned smell or 

discoloration). 

• Check and lubricate the PTO linkages 

and shafts (if equipped). 

Note: For all ACX models the correct factory 

fill is Castrol Transynd Synthetic fluid. 

5. Check the rear suspension torque rods 

and fasteners for looseness. Torque 

rods periodically need to be replaced 

as normal maintenance items, and are 

therefore not covered under warranty. 

Tag and Pusher Axles 

Check the oil level in wheel hubs and look for 

evidence of leaks. Inspect the wheel seals for 

evidence of leakage. 

Note: Refer to the axle manufacturer’s 

documentation for recommended 

lubricants, change intervals, and service 


• Check air bags for damage and cuts. 

Replace if required. 

• Check routing and clamping for brake 

and air ride hoses. 

• Grease kingpins and tie rods. 

• Check pivot bushings for wear. 

Drive Axles 

1. Check the oil level of each rear axle 

(Figure 15). If necessary, top up with 

the axle manufacturer’s recommended 

lubricant. DO NOT MIX DIFFERENT 

TYPES OF LUBRICANT. Use Rear axle 

lubricant 75W90 or Synthetic rear axle 

lubricant 75W90 or equivalent. Ensure 

the breather is clear and not damaged. 

Temperature Indicator Plug 

- DO NOT REMOVE 

Figure 15 

Oil Level must be 

even with the bottom 

of the fill plug hole. 

Fill Plug 

26 

877-973-3486 AWE 00005 Rev. 001



Note: When steam cleaning the axle or 

within the axle area, the axle breather 

cap must be covered to prevent moisture 

and contaminants from entering the axle 

housing. 

2. C Inspection: Replace axle lubricant 

and filter. Inspect magnetic drain plug 

for excess metal filings. Clean the drain 

plug and reinstall. Clean the breather and 

replace the filter, if applicable. Fill with 

manufacturer’s recommended lubricant, 

until lubricant is level with the fill hole. 

Note: The rear axle may be filled with a 

synthetic “extended drain” lubricant. This 

is sometimes indicated by a metal tag 

or decal located near the drain plug. The 

drain intervals for synthetic lubricants 

usually differ from that of petroleum-based 

lubricants. Follow the axle manufacturer’s 

recommendations for drain intervals. 

3. Check the rear axle. See axle 



• Inspect the input and output bearings 

for free play. Inspect the pinion shaft 

bearing for possible wear. 

• Check the axle flange nut torque. 

• Check the torque on the carrier bearing 

assembly mounting bolts. 

• Check pinion bearing wear. 

4. Inspect the wheel seals and axle area for 

evidence of leakage. 

Steering and Suspension 

1. 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. 

• A Inspection: Tighten the spring hangerto-frame 

bolts to specification. Refer 

to Special Torque Chart in this Service 


• Check center bolt and springs for 

shifting on the axle. 

• Check U-bolts for proper torque and to 

ensure that the bolts have not shifted. 

Refer to Special Torque Chart in this 

Service Manual section. 

• Check spring eyes and pins for wear 

and cracks. Wear must not exceed 

0.125 in. (3.18 mm). 

2. Check the steering as follows: 

• Check the steering gear box for secure 

mounting. 

• B Inspection: With front axle elevated, 

turn the steering wheel from side to 

side. There should be slight drag at 

the center point. If no drag can be felt, 

adjustment is required. Note on the form 

for follow-up. 

• B Inspection: Check the steering shaft 

coupler for security. 

• B Inspection: Check U-joints for 

looseness. Lubricate all U-joints. 

• B Inspection: Check slip joints for 

looseness. Lubricate all slip joints. 

• B Inspection: On dual-steer trucks, 

check 90° steering gear box, both slip 

joints and all U-joints. 

• Check steering column for secure 

mounting and smoothness of bearings. 

• B Inspection: Check the drag link and 

tie-rod ends. There must be no free 

play or wear in these components 

See manufacturer’s documentation for 

procedure. 

• B Inspection: Tighten draw key nut 

to specification. See manufacturer’s 

documentation for procedure and 

specification. 

AWE 00005 Rev. 001 877-973-3486 

27



• B Inspection: Inspect the pitman arm 

and check the nut torque. Refer to 



• Inspect steering assist cylinder and 

hoses for damage or leakage, and 

routing or clamping. 

• Refer to the steer axle manufacturer’s 


specifications, and service intervals. 

• Lubricate steering and front suspension. 

See manufacturer’s documentation for 

interval, procedure and specifications. 

• D Inspection: Tighten steering arm bolts 

to specification. See manufacturer’s 

documentation for procedure and 

specification. 

3. C Inspection: Check the front and rear 

wheel bearings. Refer to the Autocar 

Wheel Bearing Adjustment Manual for the 

complete inspection procedure for wheel 

bearings. 

4. C Inspection: Check the front wheel 

alignment and steering stop adjustment. 

Refer to the front axle manufacturer’s 

service documentation for the complete 

inspection and adjustment procedure. 

Note: Autocar sets axle stops to provide 

maximum turn angle. Clearance of 3/8 

in. (8.25 mm should be observed on full 

lock between stub axle and steering stop 

adjusting bolt. 

6. Check the rear suspension, springs, 

shackles, mounts and U-bolts. Refer to 

the manufacturer’s service literature, 

or the appropriate Autocar suspension 

service manual for service procedures. 

• Pre-Delivery Inspection (Reyco/ 

Granning 102CC Single Axle Rear 

Suspension Only): It is extremely 

important that the rear axle U-bolts be 

retorqued at Pre-Delivery Inspection 

(PDI) or BEFORE placing the vehicle in 

service. 

- Once the vehicle is placed in service 

retorque the U-bolts after the first 50 

hours of operation, and with each 

300 hours of operation thereafter. 

Follow all of the bolt/nut tightening 

recommendations. 

- These U-bolts MUST BE replaced 

after retorquing three times as they 

will have lost their elasticity. The 

retorque at PDI is the second time, 

therefore if any movement of the 

nut is detected at the 50 hour check 

make a note in the vehicle service 

record to replace the bolt(s) the next 

time any movement of the nut occurs 

during a torque check. Failure to do 

so may result in U-bolt failure. 

5. D Inspection: Check the tandem 

alignment. Place the vehicle (loaded, 

if possible) on a level surface. 

Follow instructions in the appropriate 

manufacturer’s service manual. There is 

no specific rule as to how much variation 

will cause misalignment wear. Variations 

of 1/4 in. (6.5 mm) are generally 

acceptable. If no other defects are found 

to explain wear, errors in parallelism and 

symmetry should be considered and 

corrected. 

28 

877-973-3486 AWE 00005 Rev. 001



Failure to replace the U-bolts when they 

have reached their elastic limit could 

result in U-bolt failure and axle separation 

from the vehicle. 

Torque Procedure (Reyco/Granning 

102CC Single Axle Rear Suspension 

Only) 

NEVER use air impact tools to tighten the 

U-bolts as they will most likely be overtorqued 

and destroy the U-bolt. 

Torque Specification is 400-425 ft. lbs. 

(545-580 N·m). 

Gradually tighten locknuts in a diagonal 

pattern, in 100 ft. lb. (135 N·m) increments, 

while making sure springs remain square to the 

axle. U-bolts should be perpendicular to bottom 

seat and parallel to one another for proper 

installation. If this is not the case the torque 

will not apply the proper clamp load and may 

cause the joint to loosen. 

All Other Suspensions 

• C Inspection: Check for broken or 

cracked leaf springs. 

• C Inspection: Check center bolt and 

springs for shifting on the axle. 

• C Inspection: Check U-bolts for proper 

torque and to ensure that the bolts have 

not shifted. 

• C Inspection: Check spring eyes and 

pins for wear and cracks. Wear must 

not exceed 1/8 in. (3.2 mm). 

• C Inspection: Inspect the spring 

hangers, mounts, and all brackets for 

cracks and secure mounting. 

• B Inspection: Check torque arm 

bushings and mounts. 

7. B Inspection: Check the condition of the 

air springs, if equipped. 

8. B Inspection: Check the upper and lower 

shock absorber mounting and brackets. 

Ensure the fasteners are secure. Check 

the shock absorbers for evidence of 

leaks. 

AWE 00005 Rev. 001 877-973-3486 

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Hendrickson PRIMAAX® Air 

Suspension 

Introduction 

Following appropriate inspection procedures 

is important to help ensure the proper 

maintenance and operation of the suspension 

system and component parts. Hendrickson 

recommends the PRIMAAX® heavy-duty rear 

suspension is inspected at pre-delivery, the first 

1,000 miles (1,600 km) of service and at the 

regular preventive maintenance intervals. 

Off-highway and severe service operating 

conditions require more frequent inspections 

than on-highway service operation. 

Following appropriate inspection procedures 

is important to help ensure the proper 

maintenance and operation of the PRIMAAX® 

suspension system and component parts 

function to their highest efficiency. 

Note: Torque values shown in this 

publication apply only if Hendrickson 

supplied fasteners are used. 

The inspection must include the following 

components: 

• Air springs 

• Air supply and fittings 

• Clamp group 

• Top pad 

• U-bolt locknuts 

• Cross brace 

• End cap hex bolts 

• All fasteners 

• Frame hanger bracket 

• Height control valve 

• QUIK-ALIGN® connections 

• S-cam support tube bracket 

• Shock absorbers 

• Support beam assembly 

• Tire wear 

• Torque rods 

– Transverse 

– Longitudinal 

• Suspension wear and damage 

Hendrickson Recommended 

Maintenance Intervals 

Pre-Delivery Inspection 

1. Visually inspect the suspension for proper 

assembly. 

2. Verify the lateral alignment of the 

drive axles are within the vehicle 

manufacturer’s tolerances, contact the 

vehicle manufacturer for the correct 

lateral alignment instructions. 

3. Check all fasteners for proper torque 

with special attention to the following 

suspension connections: 

a. QUIK-ALIGN® fasteners (Figure 16 - 

View A). 

b. End cap fasteners (Figure 16 - View B). 

c. Clamp group fasteners (U-bolts) 

(Figure 16 - View C). 

d. Top pad to torque rod fasteners (Figure 

16 - View D). 

4. Verify that the ride height is correct. Ride 

height is measured from the bottom of the 

frame rail to the center line of the axle. 

There are different ride heights for the 

various PRIMAAX® suspensions, contact 

the vehicle manufacturer for the correct 

ride height dimension. 

5. Verify the transverse torque rod(s) is 

perpendicular to the frame rail (0° ± 1.5°) 

and parallel to the ground (+5° / - 0°). 

30 

877-973-3486 AWE 00005 Rev. 001



Inspection at 1,000 Miles (1,600 km) 

1. Visually inspect suspension components. 

Check for: 

• Proper suspension function. 

• Any signs of unusual movement, loose 

or missing components. 

• Any signs of abrasive or adverse 

contact with other components. 

• Any damaged, bent or cracked parts. 

• Proper air springs and support beam 

assembly. 



suspension connections, (Figure 16 - 

View A through D). 

a. QUIK-ALIGN® fasteners 

b. End cap fasteners 


d. Top pad to torque rod fasteners 


• Off highway and severe service – 

Every 25,000 miles (40,000 km) or six 

months, whichever comes first. 

• 100% On-highway – Every 50,000 

miles 80,000 km) or 12 months, 

whichever comes first. 

1. Visually inspect suspension components. 

Check for: 

• Proper suspension function. 

• Any signs of unusual movement, loose 

or missing components. 

• Any signs of abrasive or adverse 

contact with other components. 

• Any damaged, bent or cracked parts. 

• Proper air springs and support beam 

assembly. 



suspension connections, (Figure 16 - 

View A through D). 

a. QUIK-ALIGN® fasteners 

b. End cap fasteners 


d. Top pad to torque rod fasteners 

3. Verify that the lateral alignment of 

the drive axles is within the vehicle 

manufacturer’s tolerances. Refer to the 

Steering Linkage and Wheel Alignment 

section of the Autocar Service Manual for 

the correct lateral alignment instructions. 

AWE 00005 Rev. 001 877-973-3486 

31



View A 

View B 

View C 

View D 

Figure 16 

32 

877-973-3486 AWE 00005 Rev. 001



Interior and Instrumentation 

Inspection 

NEVER use fuel tanks or the tops of the 

battery boxes as steps. Always face the 

cab when entering or exiting the cab. 

NEVER exit the cab “face first.” Use a 

“3-point mounting” approach to enter 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. 

On dual-steer models, all in-cab 

inspections and operational checks must 

be performed from both driver stations. 

1. 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 vent windows for correct fit, 

bushing tension and latch operation. 

2. Check condition of cab interior, floor, 

seats and panels. 

• Visually check the condition of the floor 

mats, panels and visors. 

• Check interior sheet metal for cracks 

around doors, back panel and flooring. 

• Inspect the seat upholstery condition. 

• Check the seat suspension and 

adjustment mechanisms. 

• Lubricate the seat adjustment 

mechanism. 

• Remove any loose items and trash. 

Figure 17 

3. Examine the seat belt for condition, 

function of retractor, latch, adjusting 

hardware, and interface with cab panels 

or hardware (Figure 17). Note any 

needed corrections on inspection form for 

follow-up. 

Figure 18 

AWE 00005 Rev. 001 877-973-3486 

33



4. Check operation and condition of all 

exterior lights (Figure 18). 

Note: This procedure will require the help of 

an assistant. 

• Emergency flashers 

• Turn signals (front and rear) 

• Brake lights 

• Parking lights 

• Headlights (low and high beam) 

• Marker and clearance lights 

• Taillights 

• Reverse lights 

• Verify all instrument and dash lights 

operate properly. 

• Check that all reflectors are secure and 

not damaged. 

5. Turn the key to the IGN position (Figure 

19). Check that all applicable telltale 

indicator lamps illuminate (Figure 20), and 

that all instruments respond appropriately. 

The indicators on all gauges should 

sweep and return to zero. 

6. If equipped, verify that the camera images 

are displayed on the in-cab monitor. 

Figure 19 

34 

877-973-3486 AWE 00005 Rev. 001



Figure 20 

NEVER breathe engine exhaust gas. It 

contains carbon monoxide which has 

no color or odor. Carbon monoxide 

is a dangerous gas which can cause 

unconsciousness or death. 

NEVER start the engine without first 

ensuring the transmission is in NEUTRAL 

and the park brake is engaged. Failure 

to do so may result in the unintentional 

movement of the vehicle, resulting in 

property damage, personal injury or 

death. 

Chock the wheels to prevent unexpected 

movement of the truck. NEVER leave the 

cab unless the wheels are chocked and 

the parking brake is engaged. 

7. Start the engine: 

• Ensure that the starter solenoid 

engages and disengages properly. The 

starter motor should turn over without 

any abnormal noise or drag. 

• Verify all gauges and all telltale indicator 

lamps respond appropriately after the 

engine has started. 

• Check the engine for excessive smoke, 

surging, misfiring and noise indicating a 

malfunction. 

• B Inspection: Verify the accelerator 

pedal operates properly, and the engine 

responds accordingly. 

AWE 00005 Rev. 001 877-973-3486 

35



8. All trucks are equipped with an air 

restriction warning light in the telltale 

indicator section of the instrument panel 

(Figure 21). Some engines may also have 

an air restriction gauge on the air intake 

piping (Figure 22). Check for evidence of 

intake air restriction as follows: 

Figure 21 

Figure 22 

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. 

• If the truck is equipped with an engine 

mounted air restriction gauge, run the 

engine at maximum rpm. Observe 

and record the reading on the gauge. 

Replace the air filter if the reading is 25 

in. WC or less, or if the gauge indicates 

that the filter needs replacing. After 

filter replacement, check and record air 

cleaner restriction gauge reading. 

• If the truck is not equipped with an air 

restriction gauge on the intake piping, 

run the engine at maximum rpm. If the 

air restriction indicator light comes on, 

the air filter should be replaced. 

• 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 a filter minder be 

sure to reset after each air cleaner element 

installation. 

36 

877-973-3486 AWE 00005 Rev. 001



9. Air system: 

a. Check the operation of the low air 

pressure warning light and audible 

alarm as follows: 

Figure 23 

b. Pump the brakes to bring the air 

pressure down to activate the low air 

pressure warning system (Figure 23). 

Alarm should activate at 60 psi (415 

kPa) (Figure 24). 

• Test the air compressor governor cut-in/ 

cutout as follows: 

a. Pump the brake pedal until the 

pressure drops to 30 psi (206 kPa). 

The parking brake will be applied if 

the pressure falls to between 20 and 

45 psi (138 and 210 kPa). It should 

release after the pressure goes 

above 45-60 psi (310 - 410 kPa). At 

idle, it should take approximately 1 

minute to restore pressure to 100 psi 

(690 kPa). 

b. Test air replenishment. 

c. Perform dynamic air pressure test. 

d. Perform static air pressure test. 

e. B Inspection: Check reservoir check 

valve operation. 

f. Check primary circuit low pressure 

warning. 

g. Check emergency brake spring 

operation. 

10. Check the operation of all interior lights 

and switches. 

11. Test the horn(s) for clear, audible sound. 

See Figure 25 and Figure 26. 

Figure 24 

Figure 25 

AWE 00005 Rev. 001 877-973-3486 

37



Figure 26 

Note: This procedure will require the help of 

an assistant. 

12. Check the backup alarm. 

13. Check windshield wiper and washer/wiper 

operation (Figure 27). With the windshield 

wet, turn on the wipers and check the 

following: 

• Washer fluid output 

• Wiper blades for wear and contact 

• Operation at each speed setting 

• Wipers operate evenly 

Figure 28 

14. Check the operation of the heater, 

defroster and air conditioner as follows: 

• Operate heater/air conditioner fan 

through all ranges, checking for 

vibration and excessive noise. 

• Check operation of controls (Figure 28). 

15. Check the steering wheel for excessive 

play free movement not to exceed a 

maximum of 3 in. (76.2 mm) of rotation, or 

1 in. (25.4 mm). Check steering column 

integrity. 

16. Check the operation of the two-way radio, 

if equipped. 

17. Check workstation power, if equipped. 

18. Check the operation of lift axles (and 

auto-lift in reverse if equipped). 

19. Check that all safety equipment, such as 

fire extinguishers, triangle reflectors and 

flares are present and in usable condition 

(Figure 29). 

Figure 27 

38 

877-973-3486 AWE 00005 Rev. 001



Note: Your vehicle may not be equipped 

with all of the safety devices shown in 

Figure 29 

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. 

2. Using the dash tachometer (Figure 30), 

check and record high and low engine 

idle rpm. 

Figure 29 

20. Check Telma lights if equipped (Note: 

Truck must be moving at least three mph 

[five kmh]). 

Road Test 

1. Check the engine controls and 

performance. 

Figure 30 

Figure 31 

3. Using the dash oil pressure gauge (Figure 

31), check and record high and low oil 

pressure. 

4. Check the engine for excessive smoke, 

surging, misfiring and noise indicating a 

malfunction. 

5. Verify that the parking brake operation 

meets federal, state, and local 

regulations. 

6. While in motion, apply the brakes to 

check for even lockup and release. Check 

the ABS system, if equipped. 

AWE 00005 Rev. 001 877-973-3486 

39



7. 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. 

8. B Inspection: If equipped, check 

differential lock operation. Listen for 

differential lock engagement and 

disengagement. Check that dashboard 

indicator light illuminates. 

9. Listen for unusual noises. Make sure that 

the vehicle is riding smoothly, free from 

roughness or excessive vibration. 

10. Ensure that there is no excessive play 

in the steering wheel. Turning operation 

should be smooth and free of rough 

spots. Check for vibration in the steering 

wheel or column. 

After the Road Test 

1. Check all major components for fluid 

leaks. 

• Engine 

• Transmission 

• Cooling system 

• Fuel system 

• Power steering system 

• Rear axles 

2. Check and record the date of the last 

inspection and inspection type (A, B, C, 

D). 

40 

877-973-3486 AWE 00005 Rev. 001



CHASSIS LUBRICANTS AND FLUIDS 

Service Points 

Front Axle & Steering 

Steering Miter Boxes 

System Service Locations Required Lubricant/Fluid 

Front Wheel Bearings 

Front and Rear Spring Hangers 

Tie Rod Ends 

Drag Link 

King Pins 

Steering Gear Output Shaft 

Steering Shaft U-Joints 

Steering Gear Output Shaft Grease Fitting 

Steering Miter Boxes (Input Shaft Grease 

Fitting) 

Brake S-Cams and Slack Adjusters 

EP NLGI 1 or 2 

Input Shaft Grease Fitting EP NLGI 1 or 2 

Lubricant Fill 

Front Hub Bearings 

AGMA 5 EP Oil 

75W90 Gear Lube (Synthetic or Standard 

Depending On Customer Specification) 

Windshield Washer Washer Fluid Reservoir Standard Washer Fluid 

Engine Oil 

Diesel 

Gas 

Ursa Plus EC CJ4 Low Ash 15W40 Engine Oil 

Chevron RPM Gas Engine Oil 15W40 

Engine Coolant Coolant Reservoir Chevron ELA 50/50 coolant (Extended Life) 

Diesel Exhaust Fluid DEF Reservoir Fleetgaurd Air Shield Diesel Exhaust Fluid 

Refrigerant System 

Refrigerant 

Refrigerant Oil 

R134a 

PAG SP-15 (Sanden Compressor) 

PAG-46 (Que Compressor) 

Transmission Transmission Filler Tube Transynd Transmission Oil 

Driveshafts 

U-Joints EP NLG 12 

Slip Yokes EP NLG 12 

Cab Jack Cab Jack Pump Reservoir 5606A Hydraulic Oil 

Power Steering Power Steering Reservoir Dexron ATF 

Drive Axle(s) 

Auxiliary Axle(s) 

Filler Plugs and Axle Housing(s) 

Brake S-Cams and Slack Adjusters EP NLGI 1 or 2 

Wheel Bearings 

Brake S-Cams and Slack Adjusters EP NLGI 1 or 2 





AWE 00005 Rev. 001 877-973-3486 

41



Chassis Lubrication Chart 

Chassis Lube and Fluids 

1 Chassis Grease 5 Engine Oil 

2 Gear Oil 6 Cab Jack Oil 

3 Transmission Fluid 7 Washer Fluid 

4 Power Steering Fluid 8 Refrigerant Oil 

9 Cab Jack Oil 

Figure 32 

42 

877-973-3486 AWE 00005 Rev. 001



HENDRICKSON HAULMAAX ® SUSPENSION PREVENTIVE 

MAINTENANCE BULLETIN 

AWE 00005 Rev. 001 877-973-3486 

43



Notes: 

44 

877-973-3486 AWE 00005 Rev. 001

Autocar, LLC 

551 South Washington Street 

Hagerstown, IN 47346 

www.autocartruck.com 

© Autocar, LLC 2011 

AWE 00005 Rev. 001 

Printed In U.S.A.

Preventive Maintenance - Autocar, LLC

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