SERVICE PROGRAM

SERVICE PROGRAMSP 2-202-001DECEMBER 2007LOCKOUT/TAGOUT PROCEDURESBefore entering the vehicle or vehicle body, readand follow OSHA regulations concerning entry andworking in “CONFINED SPACE” OSHA 1910.146and “LOCKOUT/TAGOUT” OSHA 1910.147.Follow OSHA regulations while performing anywork on the vehicle.The vehicle must be disabled by the followingsteps before performing any work on the vehicle:1. Place the transmission in PARK.2. Set the parking brake.3. Shut the engine OFF.4. Turn the battery disconnect switch OFF.5. Lock cab doors, keep the key in your pocket,and block the wheels before entering the bodyor performing any work on the vehicle.6. Place magnetic “DANGER” signs on both cabdoors before entering the body or performingany work on the vehicle.GENERAL SAFETY NOTICESWARNINGTo prevent eye injury, always wear eyeprotection when performing vehiclemaintenance, service, or inspection.DANGERBefore working on a vehicle, turn the engine to off,set the parking brake, place the transmission inneutral and block the wheels. Failure to do so canresult in unexpected vehicle movement, resultingin serious personal injury or death.REPAIR PROCEDURESTEP 1: Raise the cab●●●●WARNINGDue to the danger of sustaining personal injuryand/or damage to the vehicle, never attempt toraise the cab outdoors under extremely windyconditions. The strong wind conditions couldforce the cab beyond the normal limits of its travel.Remove or secure all loose articles andclose all doors before raising the cab. Thearea above and ahead of the cab must beclear from obstructions. Place front wheelsin a straight ahead position.Remove the pump handle from its storage onthe inside wall of the driver or passenger sidedoor.Place the selector lever on the hydraulicpump in the RAISE position. Insert thepump handle into the pump and operatethe handle in an up and down motion. Thehydraulic cab latches will open, then thehydraulic cylinders will lift the cab until themidpoint (top) is reached.Once the cab has reached its midpoint, thecab will free fall forward to the fully openposition. The safety pin in the cab tilt lockdevice must be installed when the holes lineup in the sliding bar.DANGERNever rely on the hydraulic pressure to hold thecab in an open position. Always use the safety pinin the cab tilt lock tube to prevent serious personalinjury or death.CAUTIONRemove the pump handle when not in use. It maystick out and could cause injury to passersby.Questions? Visit the Autocar website atwww.autocartruck.com and click the Web-Link Directicon to request emergency service assistance.3 of 6AC-SP-263-0712-P54

SERVICE PROGRAMSP 2-202-001DECEMBER 2007STEP 2: Detach the left-side stay rod●Using a 15/16” box wrench, remove the stayrod adjusting nut to disconnect the stay rodfrom the stay rod bracket (Figure 1). Savethe hex nut, as it will be reused.STEP 3: Remove the stay rod bracket●NOTE:Using a 3/4” box wrench and 3/4” socket,remove and discard the (2) 1/2” flanged hexnuts and (2) 1/2” hex head flange screwsattaching the bracket to the bracket support(Figure 2).On some vehicles, the stay rod bracket mayhave been attached using Huck fasteners.If so, a Huck removal tool must be used toremove the fasteners.Figure 1STEP 4: Install the replacement stay rod bracket●●●●●●●Align the hole in the replacement bracketwith the threaded end of the stay rod.Slide the bracket on to the stay rod.Thread the hex nut on to the threaded endof the stay rod.Using a 15/16” box wrench, torque the stayrod adjusting nut so that there is no free playwhen attempting to move the stay rod in thestay rod bracket.Align the (2) holes in the bracket with thecorresponding holes in the bracket support.Install the (2) new hex head cap screws andhex nuts to secure the bracket to the bracketsupport. Thread the hex nuts onto the hexhead cap screws.Using a 3/4” box wrench, 3/4” socket, andtorque wrench, torque the 1/2” threadedfasteners to 105 ft-lbs (±11 ft-lbs).Figure 24 of 6AC-SP-263-0712-P54Questions? Visit the Autocar website atwww.autocartruck.com and click the Web Link-Directicon to request emergency service assistance.

SERVICE PROGRAMSP 2-202-001DECEMBER 2007STEP 5: Check for clearance between the stay rodand the fan ring●●●●●●●Visually check for proper clearance betweenthe radiator stay and fan ring. With thevehicle parked on a level surface, thereshould be 1” of clearance between the stayrod and nearest point on the fan ring (Figure3).Using a hydraulic floor jack, raise the frontleftcorner of the chassis 6” and visuallycheck for proper clearance between theradiator stay rod and fan ring. With onecorner of the chassis raised 6”, the stay rodshould not contact the fan ring.Lower the front-left corner of the chassis.Using a hydraulic floor jack, raise the frontrightcorner of the chassis 6” and visuallycheck for proper clearance between theradiator stay rod and fan ring. With onecorner of the chassis raised 6”, the stay rodshould not contact the fan ring.Lower the front-right corner of the chassis.If there is not proper clearance between thestay rod and fan ring, proceed to Step 6.If there is proper clearance between the stayrod and fan ring, skip Step 6 and proceed toStep 7.1”1”1”Figure 3STEP 6: Adjust for proper clearance (if necessary)● Remove the (2) 1/2” flanged hex nuts, (2)1/2” hex head flange screws, and (1) stayrod adjusting nut.●●●●Remove the stay rod bracket.Using a grinder, remove enough materialfrom the fan ring to allow adequateclearance between the stay rod and fan ring.Re-install the stay rod bracket, as directed inStep 4.Repeat Step 5 to check for proper clearancebetween the stay rod and fan ring.Questions? Visit the Autocar website atwww.autocartruck.com and click the Web-Link Directicon to request emergency service assistance.5 of 6AC-SP-263-0712-P54

SERVICE PROGRAMSP 2-202-001DECEMBER 2007STEP 7: Lower the cab●●●Remove the safety pin in the sliding cab tiltlock bar. Place the selector lever on thehydraulic pump to the LOWER position.Insert the pump handle into the pump andoperate the handle in an up and downmotion. The hydraulic cylinders then lowerthe cab until the midpoint (top) is reached.Once the cab has reached its midpoint, stoppumping and the cab will free fall rearwardto the fully lowered position. When the cabis lowered, the hydraulic cab latches willautomatically close, securing the cab to theframe.CAUTIONRemove the pump handle when not in use. It maystick out and could cause injury to passersby.Please direct all questions regarding this serviceprogram to: info@autocartruck.com or call the servicehotline at 877-973-3486 (extension 6062).6 of 6AC-SP-263-0712-P54Questions? Visit the Autocar website atwww.autocartruck.com and click the Web Link-Directicon to request emergency service assistance.