SP 8-600-001

SP 8-600-001
SERVICE PROGRAM
July, 2014
ATTENTION:
SERVICE RESPONSIBILITY:
Service Managers / Parts Managers
Service Programs are performed on eligible
vehicles at no charge to the owner until the
expiration date listed above.
SUBJECT:
Autocar Xpert HVAC Performance Upgrade
DESCRIPTION OF SERVICE
PROGRAM:
This Service Program provides instructions to
upgrade the HVAC on certain Xpert vehicles.
PROGRAM EXPIRES:
July 31, 2015
VEHICLES AFFECTED:
There are 32 affected vehicles with serial
numbers in the range 213783 through
214181. Refer to the VIN list beginning on
Page 31.
SERVICE PROGRAM
INFORMATION:
Service Programs are product modifications
and/or product improvements that Autocar
has determined will enhance the operation
of the truck. In a continuing effort to inform
our customers of potential service issues
and avoid unnecessary down time, Autocar
has identified the following operation as
recommended preventive maintenance.
This Service Program should be added to
your preventive maintenance and service
manuals.
While being committed to continuous
product improvement, Autocar is not liable
for updating existing chassis after they have
been placed in service.
Questions regarding this Service Program
should be directed to Autocar Technical
Support at 888-218-3611.
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 1 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
REQUIRED PARTS:
(1) S5704001K001 HVAC Upgrade kit
(1) A5700040-001
IP moulding
(1) A5700041-001
IP trim
(1) A5700042-001
IP moulding, L/LH
(1) A5700043-001
IP moulding, L/RH
(1) A5700044-001
IP moulding, L/C
(1) A5700045-001
Cup-holder, LH
(1) A5700046-001
Cup-holder, RH
(2) A5700048-001
Bracket, IP LH
(14) A5700058-001
Plug, IP screw
(10) A5700067-001
Switch, edge
(11) A5700068-001
Switch, center
(1) A5700069-001
Panel, IP LH
(2) A5941003-001
Cigar lighter
(1) A8220015-001
Starter switch
(3) A6000088-001
Vent, angled port
(1) A6000089-001
Vent, straight port
(6) A6000062-001
Vent, windshield
(2) A6000082-001
Vent, LH foot-well
(1) A6220043-001
Switch, LH mirror
(1) A6220079-001
Switch, RH mirror
(1) GZ120017-001 Switch, regen
(1) GZ120017-003 Switch, CC on/off
(1) GZ120017-004 Switch, CC set/res
(1) GZ120017-005 Switch, DD
(1) GZ120017-010 Switch, DS axle
(1) GZ120017-017 Switch, rear-view
					mirror heating
(15) GZ120017-020 Cover
(1) A5700070-001
Bracket
(15) A5700071-001
Nutsert, IP
(2) A5710022-001
Cluster cover
(1) A6000060-001
Duct, defrost LH
(1) A6000061-001
Duct, defrost RH
(1) A6000064-001
Duct, connector
(1) A6000075-001
Duct, LH IN vent
(1) A6000076-001
Duct, RH INT vent
Page 2 of 31
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(10)
(2)
(2)
(6)
(1)
(1)
(1)
(1)
(1)
A6000077-001
A6000078-001
A6000079-001
A6000080-001
A6000081-001
A6000085-001
A6000086-001
A6000087-001
3081891		
673484		
8021880		
GZ220015-003
A6030018-001
A6000099-001
A6000098-001
A6000100-001
A8700026-025
Vent, LH prim
Vent, RH prim
Duct, INT vent
Vent, LH center
Vent, RH center
Duct, vent LH
Duct, vent RH
Hose, center vent
Clamp hose 57
Clamp hose 48
Clamp hose 64
Small clamp
Controller module
Capacitor
Motor, blower
Ground wire
25A Fuse, ATO
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
LOCKOUT/TAGOUT
PROCEDURES
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 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, if
equipped.
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.
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Autocar natural gas powered vehicles require specific compliance in the service, storage and refueling procedures.
If you store or dispense Compressed Natural
Gas (CNG) or Liquid 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 Association (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 applicable 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.
Page 3 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
TO OBTAIN PARTS:
SAFETY NOTICES
Ensure that you have authorization from the
customer to perform this work, and send an
e-mail to [email protected] which
includes the following:
• VIN(s) (or last 6 digits of VIN(s)
• ‘Attention To’ name
• ‘Ship To’ address
Allow the vehicle’s engine and cooling system
to cool to ambient temperature before performing the repair procedure. A hot engine or
cooling assembly may cause burns or other
personal injury.
CLAIMS FOR REIMBURSEMENT:
Submit a claim for reimbursement in
accordance with Autocar’s Warranty
Administration Manual.
CLAIM CODING INFORMATION:
Labor
Operation
Code Number
Time
Allowance
SRT
Description
87010-0-01
12.0 HR
HVAC Upgrade
TOOLS REQUIRED:
10 mm socket
Hammer
Screwdriver
Poking rod
Needle-nose pliers
Soldering iron
Black electrical tape
Page 4 of 31
To prevent eye injury, always wear eye
protection when performing vehicle maintenance, service or inspection.
Before working on a vehicle, set the parking
brake, place the transmission in neutral and
block the wheels. Failure to do so can result
in unexpected vehicle movement and can
cause serious personal injury or death.
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
HVAC UPGRADE INSTRUCTIONS
Step 1. Remove Lower RH
Instrument Panel Trim
Panel
Step 2. Remove Lower LH
Instrument Panel Trim
Panel
1.
1.
Remove the five sheet metal screws and
set aside for reinstallation
(see Figure 2-1).
2.
Remove the trim panel and discard (see
Figure 2-1).
Remove the three sheet metal screws
and set aside for reinstallation
(see Figure 1-1).
Note: The fasteners and their quantities as
detailed in the following sections may
differ slightly depending on age of
truck.
2.
Remove the trim panel and discard (see
Figure 1-1).
(1) M4.8-1.6x25mm
(2) M4.8-1.6x20mm
(2) M4.8-1.6x20mm
(1) M4.8-1.6x25mm
(2) M4.8-1.6x20mm
Figure 1-1
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Figure 2-1
Page 5 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 3. Detach Upper Instrument
Panel From Outer Support
Brackets
1.
Remove the bolt/nut assembly on both
LH and RH sides of instrument panel and
set aside for reinstallation
(see Figure 3-1).
Step 4. Remove Two Instrument
Clusters
1.
Remove the three screw plugs and set
aside for reinstallation (see Figure 4-1).
2.
Remove the three screws and set aside
for reinstallation (see Figure 4-1).
3.
With all screws completely removed, pull
the lower portion of the cluster outwards
(see Figure 4-1).
4.
Pull the cluster downward to unhook the
upper tabs (see Figure 4-1).
Figure 3-1
(3) M3.5 -1.3 x 20 mm
Figure 4-1
Page 6 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
5.
Using quick-release mechanism on
fittings, unhook the green and red airlines
from the cluster (see Figure 4-2).
6.
Disconnect the four electrical connectors
from the cluster (see Figure 4-2).
7.
Remove the instrument cluster and set
aside for reinstallation.
Green and Red Airlines
Step 5. Remove Lower Instrument
Panel Skirt
1.
Remove the cup holders on either side
of the lower instrument panel skirt and
discard (see Figure 5-1).
2.
Remove the screws securing the lower
instrument panel skirt and set aside for
reinstallation (see Figure 5-2).
3.
Remove the lower instrument panel skirt
and discard.
(2) M4.8-1.6 x 22 mm
Electrical Connectors
Figure 4-2
Figure 5-1
(3) M4.8-1.6 x 26.5 mm
(3) Washer OD 18 mm
ID 6.2 mm
Figure 5-2
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 7 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 6. Remove Instrument Panel
Middle Bracket Screw
Step 7. Remove Rear Instrument
Panel Screws
1.
1.
Remove the screw and washer and set
aside for reinstallation (see Figure 6-1).
Remove the screws and washers and set
aside for reinstallation (see Figure 7-1).
(1 of 5) M6 x 1.0 x 25 mm
(1) M4.8-1.6 x 22 mm
Figure 7-1
Figure 6-1
Page 8 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 8. Remove Center Console
Panel
1.
Remove the eight screw caps and set
aside for reinstallation (see Figure 8-1).
2.
Remove the eight M4 screws and set
aside for reinstallation (see Figure 8-1).
4.
Push switches through the slots so that
the center console panel can be removed
(see Figure 8-3).
(8) M4 x 17.5 mm
Figure 8-3
5.
Disconnect the transmission shift selector
connectors, the mirror switch connectors,
the ignition barrel connector, push to
start button connector, and the HVAC
controller connector and set aside for
reinstallation (see Figure 8-4).
Figure 8-1
3.
Pull switches out of their slots and break
them apart by pushing one down and the
other up (see Figure 8-2).
Figure 8-2
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Figure 8-4
Page 9 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
6.
Remove the gauge panel caps and set
aside for reinstallation (see Figure 8-5).
Optional Gauge Locations/Caps
Figure 8-6
9.
Remove the instrument top panel and set
aside for reinstallation.
10. Remove the ignition barrel and set aside
for reinstallation (see Figure 8-7).
Figure 8-5
7.
Disconnect the lighters.
Figure 8-7
8.
Locate the terminals/connectors behind
the lighters through the access holes in
the center portion of the upper dashboard
panel (see Figure 8-6).
Page 10 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
11. Using a 10 mm socket, remove
the transmission shift selector by
removing the two nuts and set aside for
reinstallation (see Figure 8-8).
Step 9
Remove Park Brake Valves
In order to remove the main instrument panel,
the two park brake valves must be removed
(see Figure 9-1).
1.
Pull back the rubber grommets and find
the yellow handle locating pins (located
at the base of the park brake valve yellow
handle) (see Figure 9-1).
2.
Carefully hammer out the locating pins
with a small punch.
3.
Remove the yellow handles.
4.
Remove the nut clamping the valves
to the dashboard and push the valves
through into the dashboard, and set
aside for reinstallation.
Figure 9-1
Figure 8-8
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 11 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 10. Remove Old Panel Ducting
from Instrument Panel
(Outer Vents)
1.
Disconnect the ducting at the vent end
on both LH and RH sides
(see Figure 10-1).
3.
Remove the intermediate duct attached
to the main defrost duct. Seal the screw
holes by reinstalling the screws used to
attach the intermediate ducting. Perform
this on both LH and RH sides
(see Figure 10-3).
Figure 10-3
Figure 10-1
2.
Disconnect the ducting at the HVAC unit
end on both LH and RH sides
(see Figure 10-2).
Figure 10-2
Page 12 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 11. Replace Blower Motor
1.
Remove the screw from the HVAC
housing and set aside for reinstallation
(see Figure 11-1).
Figure 11-1
2.
3.
Remove retaining clips securing the head
of the HVAC unit along its perimeter and
set aside for reinstallation
(see Figure 11-2).
Remove the HVAC unit head
(see Figure 11-3).
Figure 11-3
4.
Remove the blower motor fan speed
control module (see Figure 11-4).
Figure 11-4
Figure 11-2
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 13 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
5.
Remove the three screws which secure
the HVAC motor in the housing
(see Figure 11-5).
Figure 11-7
7.
Figure 11-5
6.
Install the new motor (A6000098-001) by
performing step 11-1 through step 11-6 in
reverse order.
Remove the motor and discard
(see Figure 11-6 and Figure 11-7).
Note: Before the motor can be removed,
detach the terminals from the motor
power connector so that the wires can
be fed through the housing.
Figure 11-6
Page 14 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 12. Install HVAC Capacitor
The new HVAC controller (A6030018-001)
requires that a capacitor (A6000099-001) be
added to the HVAC harness.
1.
Locate connector number 73 (it is located
in the area below the LH cup holder in
the lower instrument panel skirt which at
this point has not been reinstalled – the
wires on the female side of the connector
are blue, gray, red and purple)
(see Figure 12-1).
2.
Splice in the capacitor to the purple and
red wires with a soldering iron. Positive
(+) to the red wire and Negative (-) or
(black electrical tape) to the purple wire.
Cable tie capacitor to the HVAC harness
(see Figure 12-2).
Figure 12-2
Figure 12-1
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 15 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 13. Install Additional Ground
Wire
Step 14. Replace HVAC Circuit’s
Fuse
The new blower motor draws a higher current
than the discarded unit. Additional grounding
is required. This is achieved by adding a
ground wire that terminates directly at the cab
ground stud in the cab’s bulkhead.
1.
Locate the LH fuse box behind the LH
seat.
2.
Remove the 20 Amp fuse from slot F39
(refer to label under fuse bank cover)
(see Figure 14-1).
3.
Install the new 25 Amp fuse (A8700026025) to location F39 (see Figure 14-1).
1.
Splice the new ground wire (A6000100001) to fan speed control module’s lower
RH purple wire using a soldering iron
(smaller purple wire on RH side of the
HVAC housing) (see Figure 13-1).
2.
The ring terminal on the ground wire
must terminate at the RH dashboard
mount bracket at the upper mount bolt
(see Figure 13-1).
Figure 14-1
4.
Reinstall the instrument panel.
Figure 13-1
Page 16 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 15. Center Console Panel
Preparation
1.
Install the new ignition barrel (A8220015001) in center console panel
(see Figure 15-1).
Figure 15-1
2.
Figure 15-2
Using a 10 mm socket, install the
transmission shift selector (A5700071001) using the two nuts in the center
console panel (see Figure 15-2).
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 17 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 16. Install Instrument Panel
and Screws Along
Windshield
Step 17. Vent Swap
U LT R A L O W
SULFUR DIESEL
F U E L O N LY
1.
Install the new instrument panel
(A5700040-001.
2.
Reinstall the screws and washers
(see Figure 16-1).
Note: Ensure all the screws have been
partially fastened before tightening any
of them; use a small screw driver or
poking tool to line up the holes in the
panel and in the sheet metal.
U LT R A L O W
SULFUR DIESEL
F U E L O N LY
Figure 17-1
Note: Figure 17-2 and Figure 17-3 shows
the correct vent port configuration.
Some trucks were fitted with
different configurations, and must be
reconfigured to match the images
below.
(1 of 5) M6 x 1.0 x 25 mm
Figure 16-1
Figure 17-2
Page 18 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 18. Reattach Upper Instrument
Panel to Outer Support
Brackets
1.
Figure 17-3
1.
For each vent, remove the 4 screws
securing the locating bracket in place
(see Figure 17-4).
2.
Remove the locating bracket.
3.
Push vent out through front of
dashboard.
4.
Reverse steps 17-1 to 17-3 to reinstall
vent.
Reinstall the bolt/nut assembly on both
LH and RH sides of the instrument panel
(see Figure 18-1).
Note: The support brackets are slotted
– push instrument panel upward
while performing step 18-1 to
ensure instrument panel is at top of
adjustment range.
Figure 18-1
Figure 17-4
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 19 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 19. Reinstall the Park Brake
Valves
1.
Push the valves through the holes in the
dashboard.
2.
Clamp the valve to the dashboard using
the clamping nut.
3.
Push the handles onto the valves.
4.
Carefully hammer in the handle locating
pins.
5.
Pull the rubber grommet over the valve
handle’s shaft.
Step 20. Reconnect the Lighters
1.
Locate the lighter harness terminals
under the dashboard.
2.
Connect the new adapter harness with
the new style lighters (A5941003-001).
3.
Connect the lighter harness connector to
the back of the lighter.
Figure 20-1
Figure 19-1
Page 20 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 21. Install the New Panel
Ducting (Outer Vents)
1.
3.
Slide the hose clamps loosely at the duct
connection locations (see Figure 21-3).
On the RH side, apply foam insulation
(obtain locally) to the vent and then install
the new outer vent duct (A6000078-001)
(see Figure 21-1).
Figure 21-3
4.
Figure 21-1
2.
Install hose clamps (673484) over duct
interface, but do not tighten
(see Figure 21-4 and Figure 21-5).
Apply foam insulation (obtain locally) to
the HVAC unit outlet, then install the RH
Internal vent duct (A6000076-001)
(see Figure 21-2).
Figure 21-4
Figure 21-2
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 21 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Note: In order for the new ducting not to
interfere with the instrument clusters,
the ducting much be pushed as
far downward as possible prior to
tightening any of the clamps (the
ducts coming out of the HVAC unit
have an up/down adjustment range of
approximately 1 inch).
Step 22. Remove Panel Ducting
(Internal Vents)
1.
Remove the screws from the top and
side of the central outlet on the HVAC
unit and set aside for reinstallation
(see Figure 22-1).
Figure 22-1
Figure 21-5
5.
Tighten hose clamps (see Figure 21-5).
2.
After loosening the clamps at the center
vents, remove the center duct and
discard (see Figure 22-2).
Figure 22-2
Page 22 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 23. Install New Panel Ducting
(Internal Vents)
1.
Apply foam insulation (obtain locally) to
the duct and center vents (A6000079001) (see Figure 23-1).
4.
Install the flexible duct onto the LH vent
(A6000077-001) (ensure that hose
clamps (1) and (2) are loosely fitted)
(see Figure 51).
5.
Complete the connection at the middle
connection by rotating the formed duct
into the flexible duct.
1
3
Figure 23-1
2.
2
Pre-install the center ducts (A6000080001 and A6000081-001) for greater ease
of installation (see Figure 23-2).
Figure 23-3
6.
Tighten hose clamps (see Figure 23-4).
Figure 23-2
3.
Using self-tapping screws (3), attach the
center adapter (A6000079-001) on LH
and RH edges (LH edge shown in figure
23-3 - arrow 3), and on the top portion on
the LH and RH (see Figure 23-3).
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Figure 23-4
7.
Repeat the steps 23-4 through 23-6 for
the RH side.
Page 23 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 24. Install Lower RH
Instrument Panel Trim
Panel
1.
2.
Step 25. Install Lower LH Instrument
Panel Trim Panel
1.
Align the new lower RH instrument panel
trim panel (A5700043-001) with mounting
spring nuts on the upper instrument
panel (see Figure 24-1).
Align the new lower LH instrument panel
trim panel (A5700042-001) with mounting
spring nuts on the upper instrument
panel (see Figure 25-1).
2.
Reinstall the three sheet metal screws,
ensuring they are driven through the
spring nuts (see Figure 24-1).
Reinstall the three upper sheet metal
screws, ensuring they are driven through
the spring nuts (see Figure 25-1).
3.
Install the lower two sheet metal screws
(see Figure 25-1)
Note: Pre-drill holes in the floor to
accommodate the two sheet metal
screws to mount the lower kick panel.
(2) M4.8-1.6x20mm
(1) M4.8-1.6x25mm
(1) M4.8-1.6x25mm
Figure 24-1
(2) M4.8-1.6x20mm
(2) M4.8-1.6x20mm
Figure 25-1
Page 24 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 26. Install Upper Instrument
Panel Middle Support
Bracket Screws
1.
Install the screw and washer
(see Figure 26-1).
2.
Certain trucks requiring HVAC kit were
not fitted with the middle support bracket
(A5700070-001). This bracket has been
included in upgrade kit (S5704001K001).
Pre-drill a hole in the upper dash panel
in the location where the screw is to be
installed. Drive the base screws through
the sheet metal floor of the cab. Pre-drill
holes in the floor for this purpose.
Step 27. Install Lower Instrument
Panel Skirt
1.
Install the five screws securing the lower
instrument panel skirt (A5700044-001)
(see Figure 27-1).
2.
Install the cup holders (A5700046-001
and A5700045-001) and the center
storage bin/cover (A5700044-001), if
equipped (see Figure 27-2).
(2) M4.8-1.6 x 22 mm
Figure 27-1
(3) M4.8-1.6 x 26.5 mm
(3) Washer OD 18 mm
ID 6.2 mm
Figure 27-2
Figure 26-1
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 25 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 28. Install the Instrument
Cluster
1.
2.
Connect the four electrical connectors
(see Figure 28-1).
3.
Hook the upper tabs under the upper
perimeter of the cluster cut-out in the
instrument panel (see Figure 28-2).
4.
Push the lower portion of the cluster
forward, ensuring the cluster bezel
locates securely in the cluster cut-out in
the instrument panel (see Figure 28-2).
5.
Install the three screws, ensuring that
they are aligned with the spring nuts
(see Figure 28-2).
6.
Install the three screw plugs
(see Figure 28-2).
Connect the airlines, green to the RH
port, red to the LH port (see Figure 28-1).
Green and Red Airlines
Electrical Connectors
Figure 28-1
(3) M3.5 -1.3 x 20 mm
Figure 28-2
Page 26 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 29. Install New HVAC
Controller
1.
2.
Remove the clamp bracket
(see Figure 29-2).
Remove the four screws affixing the
clamp bracket to the rear of the HVAC
controller (see Figure 29-1).
Figure 29-2
2.
Slide the old controller out
(see Figure 29-3).
Figure 29-3
3.
Install the new controller (A6030018-001)
by reversing steps 29-3 to 29-1.
Figure 29-1
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
Page 27 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 30. Reconnect the Center
Console Panel Controls
Step 31. Interior Temp Sensor
Location Verification
1.
Connect the transmission shift selector
connectors (see Figure 30-1).
1.
2.
Connect the mirror switch (A6220043001) connectors (see Figure 30-1).
3.
Connect the ignition barrel connector
and the HVAC controller (A6030018-001)
connector (see Figure 30-1).
Ensure the interior temperature sensor is
located correctly on the upper shroud of
the LH steering column.
Mirror Switch (A6220043-001)
Transmission Shift Selector
Ignition Barrel
HVAC Controller (A6030018-001)
Figure 30-1
Page 28 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 32. Test the HVAC System
7.
While the set temp is at any setting
other than “HI” or “LO”, press the defrost
button, and ensure the following occur:
• Only windshield vents should be open.
• Fan speed should set to highest setting.
• Air source should be set to fresh air.
1.
Start the engine and let it warm up.
2.
Turn on the HVAC system by pressing
the increase fan speed button.
3.
Test the fan at all speeds.
4.
While fan is at max speed, cycle
through the 4 vent modes and ensure
air is coming out of all the correct
vents: panel, floor, windshield, floor and
windshield (allow at least 5 seconds for
vent selection valve to adjust between
modes).
5.
Drop the set temp to 64°F and turn on
air-conditioning compressor (press frost
symbol button). Ensure air becomes cool.
6.
Increase set temp to HI while compressor
is still running. Ensure that heater core is
able to overcome the cooling effect of the
evaporator core.
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486
• Pressing the defrost button again
should resume previous settings.
8.
Set fan speed to the third speed level
and check instrument cluster for stop
or check engine lights. If either of these
lamps is illuminated, check that capacitor
has been installed correctly.
Note: If at any point the stop or check
engine lights illuminate, check that the
capacitor has been installed correctly.
Page 29 of 31
SP 8-600-001
SERVICE PROGRAM
July, 2014
Step 33. Reconnect Switches
1.
2.
3.
Route the switches through the slots in
the center console panel in their original
locations (see Figure 33-1).
Reassemble the switch banks in the
same configuration that they were before
breaking apart in step 8-3
(see Figure 33-1).
Push the switches through the slots in
the center console until they snap into
place (see Figure 33-2).
Step 34. Install Center Console
Panel
1.
Install the eight M4 screws (do not
tighten until all the screws have been
located and the panel aligned correctly)
(see Figure 34-1).
2.
Install the eight screw caps ((A5700058001) (see Figure 34-1).
3.
Install gage panel caps
(see Figure 34-1).
4.
Push switches into their locating slots
(see Figure 34-1).
(8) M4 x 17.5 mm
Figure 33-1
Figure 34-1
5.
HVAC upgrade is complete.
Figure 33-2
Page 30 of 31
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486