SP 3-873-005

SERVICE PROGRAM
November, 2017

ATTENTION:

Service Managers / Parts Managers

SUBJECT:

Replacement of a RH head lamp circuit which
can overheat and cause the diode to fail
open, causing the head lamp to lose power.

DESCRIPTION OF WORK:

This Service Program provides instructions
to remove the connector from the RH head
lamp circuit and install a diode harness with
two diodes in parallel on certain model year
2014-2017 Xpert vehicles.

SERVICE RESPONSIBILITY:

Service Programs are performed on eligible
vehicles at no charge to the owner until the
expiration date listed above.

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.

PROGRAM EXPIRES:

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.

November 30, 2018

There are 325 vehicles affected
manufactured after July 11, 2013. To
determine if a vehicle is affected by this
Service Program. To determine if a vehicle
is affected by this Service Program, log in to
the Autocar Warranty Management System
at www.autocartruck.com. Click on the blue
“Warranty Management” diamond on the right
hand side of the page. From the main menu,
select “Service Programs” and look for the
Autocar recall number above. An excel file
will be accessible with the VIN list of affected
vehicles. Alternatively, to determine if a single
vehicle is affected, select “VIN Profile” from
the main menu. In the “Chassis Number”
field, enter the last 6 of the VIN. Once the
VIN profile is displayed, scroll down to the
“Service Program Information” section.
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

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

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.

Page 1 of 10

SP 3-873-005

SERVICE PROGRAM
November, 2017

REQUIRED PARTS:

SAFETY NOTICES:

CLAIMS FOR REIMBURSEMENT:

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.

S8734001K003 Service kit
(1) A8590013-002 Diode harness
Submit a claim for reimbursement in
accordance with Autocar’s Warranty
Administration Manual.

CLAIM CODING INFORMATION:
Repair
Number
(Op Code)

36406-2-02

Time
Allowance
(SRT)

1.0 HR

Description

Install new diode
harness

TOOLS REQUIRED:

3/8” Drive ratchet
3/8” Drive 13mm socket
3/8” Drive 6” extension
Standard screwdriver
# 2 Phillips screwdriver
Wire stripping/crimping pliers
3/8” Drive torque wrench
capable of 16 Lb./ft. (22 Nm.)
Heat gun

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.

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.

Page 2 of 10

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

SP 3-873-005

SERVICE PROGRAM
November, 2017

Working on CNG/LNG Trucks

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 applicable codes (including, for
example, the California Code of Regulations
and the Texas Administrative Code).
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 trucks and
engines and the safe storage and dispensing
of CNG and LNG.

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

Working on CNG Fuel Systems

CNG fuel systems include a high pressure
(3600 psi) system for fuel storage and a low
pressure system (125 psi) for consumption by
the engine. Understanding the characteristics
of CNG and how the fuel system works will
prevent injury and damage to persons and
property.
Attempting to operate or maintain any CNG fuel
system without proper training is dangerous.
Complete training and consult instructional
bulletins from the CNG system suppliers, such
as Agility Fuel Systems’ Field Service Bulletin,
Safely Working on CNG Fuel Systems.

Welding and Hot Work Near CNG
and LNG Trucks

Welding, grinding and other “hot work” can
be safely performed on or near a CNG or
LNG vehicle, but certain precautions must
be followed. Understand and perform the
necessary precautions provided by the CNG
system suppliers, such as Agility Fuel Systems’
Field Service Bulletin, Welding and Hot Work
Precautions Near CNG and LNG Vehicles.

Page 3 of 10

SP 3-873-005

SERVICE PROGRAM
November, 2017

CNG Cylinders

CNG fuel containers must meet Federal
Motor Vehicle Safety Standard (FMVSS) 304
(Compressed Natural Gas Fuel Container
Integrity) and/or ANSI/CSA NGV2 (Basic
Requirements for Compressed Natural Gas
Vehicle Fuel Containers). Both standards
specify a detailed visual examination every
three years.
Ensure that every truck owner completes the
required inspections, in accordance with the
applicable standards and other resources, such
as the Clean Vehicle Education Foundation
and NGVAmerica’s Compressed Natural Gas
(CNG) Container Visual Inspection Advisory.
FMVSS 304 also requires that cylinders not be
used after the end of life (EOL) date provided
on the tank label. The EOL date is also
displayed in the engine compartment and at
the fueling connection of each truck. If there
is any question as to proper decommissioning
of a cylinder, contact the manufacturer, whose
name and address is also required to be on
the label.

Page 4 of 10

CNG Fuel Container Pressure
Relief Devices (PRDs)

PRDs must be properly maintained and
positioned for safe operation of a CNG fuel
system. Missing vent caps can allow moisture
into PRDs and vent lines, which can freeze
and damage these safety components. Debris
which clogs the PRDs and/or vent lines can
prevent proper function.
PRDs must be positioned to vent upward, not
outward, from a vehicle.
Ensure that every truck owner completes
periodic inspections of the PRDs and vent lines
and systems, in accordance with guidance
provided by the system component suppliers.

Alert First Responders to CNG
and LNG

In the event of a fire or other emergency, alert
first responders to the presence and location
of CNG fuel systems, tanks and dispensers.
Ensure that emergency personnel are aware
of proper precautions, such as those provided
in Agility’s First Responder Guide: CNG and
LNG Vehicle Fuel Systems.

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

SP 3-873-005

SERVICE PROGRAM
November, 2017

INSTALLATION OF NEW DIODE
HARNESS:
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

1.

Disconnect all battery terminals, negative
first and then positive.

2.

Open the left side door and tilt the seat
forward (see Figure 1).

Figure 1

Page 5 of 10

SP 3-873-005

SERVICE PROGRAM
November, 2017

3.

Locate the fuse box directly behind the
left side seat (see Figure 2).

5.

Figure 2
4.

Open the fuse box for access to the fuse
panel (see Figure 3).

Figure 4
6.

Figure 3

Locate the ring terminals and the circuit
breaker (see Figure 5).

Figure 5
7.

Page 6 of 10

Disconnect the wiring harness
connectors from the fuse panel
(see Figure 4).

Make note of the wire numbers and their
locations and the orientation of the circuit
breaker for reinstallation.

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

SP 3-873-005

SERVICE PROGRAM
November, 2017

8.

Remove the four screws and four
washers retaining the ring terminals and
set the screws, washers and the circuit
breaker aside for reinstallation
(see Figure 6).

9.

Remove the four fuse panel mounting
bolts and four washers and set aside for
reinstallation (see Figure 7).

Figure 6
Figure 7

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

Page 7 of 10

SP 3-873-005

SERVICE PROGRAM
November, 2017

10. Remove the fuse panel from the fuse box
and place the fuse panel on a work table
face down (see Figure 8).

13. Remove the fuse panel access cover and
set aside for reinstallation.
14. There are two diodes contained in the
fuse panel. Locate the diode and wiring
marked with circuit numbers 41B and
41B-1. Cut wire 41B and wire 41B-1 and
discard the diode and connector
(see Figure 10 and Figure 11).

Figure 8
11. Remove or peel back the center decal
to access one of eighteen fuse panel
access cover screws
(see Figure 9).

Figure 9
12. Remove all eighteen fuse panel
access cover screws and set aside for
reinstallation.

Figure 10

Page 8 of 10

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

SP 3-873-005

SERVICE PROGRAM
November, 2017

16. Match the wire numbers 41B of the new
diode harness (A8590013-002) to the
wire 41B of the fuse panel and the wire
41B-1 of the new diode harness to wire
41B-1 of the fuse panel and crimp the
wires in place
(see Figure 12 and Figure 13).

Figure 11
15. Strip 1/4” (6.35 mm) of insulation from
wires 41B and 41B-1.

Figure 12
Autocar Industries, LLC
551 South Washington Street
Hagerstown, IN 47346
877-973-3486

Page 9 of 10

SP 3-873-005

SERVICE PROGRAM
November, 2017

17. Heat seal the connections installed in
Step 15.

18. Reinstall the fuse panel access cover
onto the fuse panel and secure with
eighteen screws that were set aside in
steps 11 and 12.
19. Reinstall the fuse panel into the fuse box
and secure with the four mounting bolts
and four washers that were set aside in
step 9, and tighten to 16 Lb./ft. (22 Nm.)
of torque.
20. Reinstall the ring terminals and circuit
breaker into their original orientation and
secure with four screws and four washers
that were set aside in step 8.
21. Plug in the wiring harness connectors
that were disconnected in step 5.
22. Close the fuse box.
23. Connect the battery terminals that were
disconnected in step 1, positive first and
then negative.
24. Perform a functional test of the head
lamps and verify proper operation.
Note: If you have any questions regarding
this Service Program, please call
Autocar technical support at 888-2183611.
25. Repairs are complete.

Figure 13

Page 10 of 10

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