SP 2-219-002

SERVICE PROGRAM
August, 2016

ATTENTION:

Service Managers / Parts Managers

SUBJECT:

Charge air cooler (CAC) pipe replacement.

DESCRIPTION OF WORK:

This service program provides information
regarding the replacement of the CAC pipe
on certain 2016 model year Xpert vehicles
equipped with ISB engines.

PROGRAM EXPIRES:
August 31, 2017

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.

VEHICLES AFFECTED:

While being committed to continuous product
improvement, Autocar is not liable for
updating existing chassis after they have been
placed in service.

SERVICE RESPONSIBILITY:

Questions regarding this Service Program
should be directed to Autocar Technical
Support at 888-218-3611.

This Service Program covers 33 vehicles.
Refer to the VIN list beginning on page 5.
Service Programs are performed on eligible
vehicles at no charge to the owner until the
expiration date listed above.

TO OBTAIN PARTS:

DO NOT submit a Solutions ticket.
Ensure that you have authorization from the
customer to perform this work and send an
e-mail to: [email protected]
Include:
1. VIN(s) (or) (last 6 digits of the VIN(s))
2. Attention To Name
3. Ship To Address.

Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Page 1 of 6

SP 2-219-002

SERVICE PROGRAM
August, 2016

REQUIRED PARTS:

S2192000K002 Service kit
(1) A2190235-001 CAC pipe

CLAIMS FOR REIMBURSEMENT:
Submit a claim for reimbursement in
accordance with Autocar’s Warranty
Administration Manual.

CLAIM CODING INFORMATION:
Repair
Number
(Op Code)

Time
Allowance
(SRT)

26503-2-02

1.00 HR

SAFETY NOTICES:

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.

Description

Charge Air Cooler (CAC)
Pipe Replacement

To prevent eye injury, always wear eye
protection when performing vehicle
maintenance, service or inspection.

TOOLS REQUIRED:

3/8” drive 1/2” deep socket
3/8” drive 5/16” deep socket
3/8” drive ratchet
3/8” drive torque wrench capable of 72 inch
pounds / 6 foot pounds

Page 2 of 6

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 2-219-002

SERVICE PROGRAM
August, 2016

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 6

SP 2-219-002

SERVICE PROGRAM
August, 2016

CAC PIPE REPLACEMENT:
1.

2.

After turning the key to the “OFF”
position, remove the key and allow
sufficient time for the vehicle to cool
down completely.
Raise the cab in accordance with
the following safety precautions and
procedures.

Due to the danger of sustaining
personal injury and/or damage to the
vehicle, never attempt to raise the
cab outdoors under extremely windy
conditions. Strong wind conditions
could force the cab beyond the normal
limits of its travel. Never rely on the
hydraulic pressure to hold the cab in
an open position. Always use the safety
pin in the cab tilt lock tube to prevent
serious personal injury or death.

Remove or secure all loose articles
and close all doors before raising the
cab. The area above and ahead of the
cab must be clear from obstructions.
Place front wheels in a straight ahead
position.
Remove the pump handle from its
storage on the inside of the cab near the
driver or passenger seat.
Place the selector lever on the hydraulic
pump in the RAISE position. Insert the
pump handle into the pump and operate
the handle in an up and down motion.
The hydraulic cab latches will open,
then the hydraulic cylinders will lift the
cab until the midpoint (top) is reached.
Once the cab has reached its midpoint
the cab will move forward to the fully
open position. The safety pin in the cab
tilt lock device must be installed when
the holes line up in the sliding bar.
Remove the pump handle when not in
use. It may stick out and could cause
injury to passersby.

Page 4 of 6

Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

SP 2-219-002

SERVICE PROGRAM
August, 2016

3.

Remove and discard the CAC pipe by
first loosening the T-Bolt clamps and then
removing the constant torque clamp, and
set aside for reinstallation (See Figure 1).

CAC Pipe
T-Bolt Clamps

T-Bolt Clamps

A2190235-001 CAC pipe

Figure 2
Constant Torque Clamp
Figure 1
4.

5.

Lower the cab.

6.

Replacement of the CAC pipe is
complete.

Install the new CAC pipe (A2190235001) and tighten the T-Bolt clamps to 72
in.-lb of torque. Reinstall the constant
torque clamp and tighten to 76 in.-lb of
torque (See Figure 2).

Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Page 5 of 6

SP 2-219-002

SERVICE PROGRAM
August, 2016

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Page 6 of 6

Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486