Tico Pro-Spotter Service Manual Download

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TICO Manufacturing

Service Manual

44&37*$&."/6"-

TICO Manufacturing 1/30/2018

13041055&3

Summary of Contents for Pro-Spotter

Page 1: ...TICO Manufacturing Service Manual 4 4 37 6 TICO Manufacturing 1 30 2018 130 41055 3...

Page 2: ...Pro Spotter Service Manual TICO Manufacturing...

Page 3: ...ating and Air Conditioning 0 13 CONTACT TICO SUPPORT 0 15 1 GENERAL INFORMATION SAFETY 1 2 Introduction 1 2 Prepare for the Job 1 2 Safety Notices 1 2 Safety Labels 1 2 Keep Work Area Clean 1 3 Keep W...

Page 4: ...OF OPERATION 2 5 EVERY 2000 HOURS OF OPERATION 2 5 RECOMMENDED LUBRICANTS AND CAPACITIES 2 6 COOLING SYSTEM 2 6 DIESEL EXHAUST FLUID DEF 2 7 DIESEL FUEL 2 8 LUBRICATION CHART 2 9 TIRE PRESSURE 2 11 3...

Page 5: ...4 7 Installation 4 7 COOLING FAN 4 7 Removal 4 7 Inspection 4 8 Installation 4 8 DIESEL EXHAUST FLUID DEF TANK 4 9 Removal 4 9 Inspection 4 9 Installation 4 9 FUEL FILTER 4 10 Removal 4 10 Inspection...

Page 6: ...Filling 5 7 6 FRONT AXLE STEERING INTRODUCTION 6 2 CHECK FLUID LEVEL 6 2 Front Axle Fluid 6 2 DRAG LINK 6 3 Removal 6 3 Inspection 6 3 Installation 6 3 FRONT AXLE 6 4 Removal 6 4 Inspection 6 5 Instal...

Page 7: ...Drive Axle Fluid Draining 7 5 Rear Drive Axle Fluid Filling 7 5 8 AIR SYSTEM INTRODUCTION 8 2 AIR BRAKE SYSTEM TESTS 8 2 Low Air Buzzer and Light Test 8 2 Air System Maximum Pressure Test 8 2 Air Syst...

Page 8: ...emoval 9 6 Inspection 9 6 Installation 9 6 REAR QUICK RELEASE BRAKE VALVE 9 7 Removal 9 7 Inspection 9 7 Installation 9 7 10 CHASSIS LUBRICATION SYSTEM INTRODUCTION 10 2 AUTOMATIC LUBRICATION SYSTEM 1...

Page 9: ...nspection 12 3 Installation 12 3 BOOM CYLINDERS 12 4 Removal 12 4 Inspection 12 4 Installation 12 4 FIFTH WHEEL MAINTENANCE 12 5 Adjustment 12 5 Lubrication 12 6 FIFTH WHEEL TOP PLATE 12 8 Removal 12...

Page 10: ...pection 13 14 Installation 13 14 Kit Installation 13 15 WIPER MOTOR 13 16 Removal 13 16 Inspection 13 16 Installation 13 16 14 COVERS AND GUARDS INTRODUCTION 14 2 FRONT COVERS AND GUARDS 14 3 Removal...

Page 11: ...DITIONING SYSTEM 15 9 Procedure Set Up 15 9 Air Conditioner Compressor Cleaning 15 9 Condenser Flush and Purge 15 9 Evaporator Flush and Purge 15 10 Procedure Wrap Up 15 10 AIR CONDITIONER COMPRESSOR...

Page 12: ...0 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 13: ...arranty Policy 0 3 Major Components Warranty 0 4 2018 FLAT RATE GUIDELINE 0 5 3 Electrical System 0 5 4 Engine 0 5 5 Transmission 0 7 6 Front Axle and Steering 0 7 7 Rear Axle 0 8 8 Air System 0 9 9 A...

Page 14: ...bject to previous warranty terms For additional information please contact TICO factory support See Contact TICO Support on page 0 15 TERMINAL INVESTMENT CORPORATION hereinafter referred to as TICO wa...

Page 15: ...delivery or one month after the first 6 000 hours whichever comes first Within a reasonable time after such notification TICO will correct any defect in material or workmanship with either new or use...

Page 16: ...ny other party is authorized to make any warranty in addition to those made in this agreement Warranty Registration This warranty is conditioned upon receipt by TICO of a completed warranty registrati...

Page 17: ...ight Flood Spot R R 0 3 3 17 Light Marker R R 0 2 3 18 Light Strobe Beacon R R 0 6 3 19 Light Tail or Backup R R 0 3 3 20 Relay Breaker R R Each 0 3 3 21 Sender Oil Pressure for Hour Meter R R 0 6 3 2...

Page 18: ...Reduction SCR System R R 1 5 4 32 Harness Engine R R 2 5 4 33 Hose Diesel Exhaust Fluid DEF R R 1 0 4 34 Hose Lower Radiator R R 1 0 Includes Drain and Refill 4 35 Hose Lower Tube R R Each 0 5 4 36 H...

Page 19: ...ransmission R R 2 0 Includes Refill 5 03 Engine Transmission R R 20 0 Includes All Operations and Adjustments 5 04 Harness Transmission R R 3 5 5 05 Key Pad Transmission Selector R R 0 6 5 06 Transmis...

Page 20: ...Stop Axle R R 0 9 6 34 Stops Axle Steering Adjustment 0 5 6 35 Tie Rod End Cylinder R R Each 0 75 6 36 Tie Rod R R 1 3 Includes Setting Toe In 6 37 Toe In Adjustment 0 8 6 38 U Bolt Axle Mounting R R...

Page 21: ...05 8 18 Valve Pressure Protection Air Tank R R 0 5 8 19 Valve Pressure Relief Supply Tank R R 0 5 8 20 Valve Quick Release R R 0 6 8 21 Valve Tractor Park Brake R R 0 8 8 22 Valve Tractor Protection R...

Page 22: ...ter R R 0 75 Includes R R of Platform 11 15 Leak Down Test Cylinder 0 6 11 16 Power Take Off PTO R R 2 0 11 17 Pressure Hydraulic System Check and Adjustment 0 5 11 18 Pump Hydraulic R R 2 1 Includes...

Page 23: ...8 0 Includes All Operations 13 18 Gauge Fuel Level R R 0 5 13 19 Gauge Hour Meter R R 0 5 13 20 Gauge Oil Pressure R R 0 5 13 21 Gauge Temperature R R 0 5 13 22 Gauge Voltmeter R R 0 5 13 23 Glad Hand...

Page 24: ...13 63 Switch Turn Signal R R 0 5 13 64 Switch Wiper Motor R R 0 5 13 65 Valve Air Horn R R 0 5 Floor or Roof Mounted 13 66 Valve Air Seat Height Control R R 0 4 13 67 Vent Side R R 0 5 13 68 Visor Sun...

Page 25: ...motek 0 09 For ACC Systems Operations Do Not Include Refrigerant Recovery or Evacuation 15 10 Evaporator R R 4 0 Operations Do Not Include Refrigerant Recovery or Evacuation 15 11 Filter HVAC R R 0 2...

Page 26: ...Recovery or Evacuation 15 24 Valve Expansion R R 1 0 Operations Do Not Include Refrigerant Recovery or Evacuation 15 25 Valve Heater Control R R 1 0 Includes Drain and Refill Operations Do Not Includ...

Page 27: ...833 UPTIME2 833 878 4632 Email inquiries to ticoservice ticotractors com Additional information is available at ticotractors com support To find a local dealer for support service or parts visit tico...

Page 28: ...1 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 29: ...Air Tools Safely 1 4 Service Tires Safely 1 4 Service Electrical Components Safely 1 4 Service Hydraulic System Safely 1 5 Service Cooling System Safely 1 5 Handle Fuel Safely 1 5 Handle Chemical Prod...

Page 30: ...l before beginning service Prepare proper work space lighting A well lit work area can make the job easier Follow procedures and safety warnings Service procedures are written to be as safe and effici...

Page 31: ...gure 1 1 Trailer Air Supply and Parking Brake Knob 3 Pull the parking brake knob 1 out to apply the parking brake 4 Allow the engine to run at idle for a minimum of 3 minutes and shut the engine off L...

Page 32: ...ctor Use proper tire mounting tools and equipment Never use screwdrivers or makeshift tools to force a tire on or off a wheel Be sure tire irons and mounting tools are free of grease and oil Grip them...

Page 33: ...ng service Always use appropriate safety equipment and clothing to protect exposed skin and eyes from high pressure oil Tighten all connections to proper specifications before applying pressure Never...

Page 34: ...r drains or into any body of water Dispose of waste fluids properly at approved local recycling centers If recycling facilities are not available contact your local community for the correct disposal...

Page 35: ...Meter 3 Cab Lift Pump 5 Fuel Tank 7 Fifth Wheel and Boom 2 Steering Gear 4 Fuel Filter 6 Diesel Exhaust Fluid DEF Tank 8 Steer Axle Quarter Fender 11 Power Distribution Center PDC 14 Exhaust 17 Auto...

Page 36: ...ard M 100 Engine mounted 20 gpm pump with priority steering WHEELS 22 5 X 8 25 Standard offset 285 mm hub pilot two hand hole TIRES Standard grade 11R x 22 5 tubeless front and rear Highway tread with...

Page 37: ...Full flow spin on element with intake strainer Power Steering Replaceable cartridge type within power steering reservoir Engine Oil Filter Fleetguard ELECTRICAL SYSTEM 12 Volt negative ground with ci...

Page 38: ...t is 1 2 inch in diameter has 13 threads per inch and is 2 inches long Figure 1 4 Standard Bolt Dimensions Metric bolts are sized according to the diameter 7 in millimeters the thread pitch distance b...

Page 39: ...gs 1 Bolt Grade 1 or 2 2 Bolt Grade 5 3 Bolt Grade 8 4 Bolt Grade 8 2 1 TPS 004 2 3 4 5 Bolt Class 4 6 7 Bolt Class 5 8 9 Bolt Class 9 8 6 Bolt Class 4 8 8 Bolt Class 8 8 10 Bolt Class 10 9 4 6 4 8 5...

Page 40: ...Figure 1 11 Tightening Sequence TORQUE CHART This torque chart is to be used as a guide when specific torque values are not listed in the instructions The torque values in the chart are approximate a...

Page 41: ...1 450 1 138 9 840 1 519 9 1 121 1 366 7 1 008 1 848 0 1 363 2 463 5 1 817 2 216 8 1 635 1 1 4 12 N m lb ft 562 7 415 749 8 553 675 2 498 1 260 9 930 1 682 6 1 241 1 514 4 1 117 2 045 9 1 509 2 727 9...

Page 42: ...ee Figures 1 14 and 1 15 The transmission nameplate 1 is located on the right rear side of the transmission The nameplate shows the transmission serial number 4 TransID TID level 3 and manufactured da...

Page 43: ...cooler housing See the Cummins engine manual for more information Figure 1 16 Engine Dataplate Location Figure 1 17 Engine Dataplate Fifth Wheel Serial Tag See Figures 1 18 and1 19 Fifth wheel serial...

Page 44: ...2 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 45: ...2 2 DAILY PRE OPERATION CHECKLIST 2 2 EVERY 500 HOURS OF OPERATION 2 3 EVERY 1000 HOURS OF OPERATION 2 5 EVERY 2000 HOURS OF OPERATION 2 5 RECOMMENDED LUBRICANTS AND CAPACITIES 2 6 COOLING SYSTEM 2 6...

Page 46: ...ICO factory support See CONTACT TICO SUPPORT on page 0 15 Cab Interior Checks Clean all windows if necessary Check all rear view mirrors Adjust and clean if necessary Check windshield wiper for proper...

Page 47: ...Check HVAC system defroster operation Check operation of power take off PTO control if applicable Check fifth wheel unlatch control Check operation of boom Check fire extinguisher charge if applicabl...

Page 48: ...ain water from air tanks Check and torque all wheel nuts Check wheels Check tire pressure tread depth and condition Check rear axle planetary fluid level if applicable Inspect catwalk Check frame for...

Page 49: ...interval Lubrication Checks No additional checks at this interval EVERY 2000 HOURS OF OPERATION The following items are the preventative maintenance procedures to be completed after every 2000 hours...

Page 50: ...not include external lines or cooler hoses See Transmission Operator s Manual Drive Axle Oil 85 140 synthetic is optional 39 7 L 42 qt See Axle Operator s Manual Hydraulic System Dexron III 68 1 L 18...

Page 51: ...contact immediately flush eyes with large amounts of water for a minimum of 15 minutes Do not swallow internally In the event the diesel exhaust fluid is ingested contact a physician immediately Preve...

Page 52: ...ULFUR FUEL ONLY Ultra Low Sulfur Diesel Fuel ASTM S 15 Season Cetain Number minimum Sulfur Content maximum Capacity Number 1D or 2D Blended winterized Winter 45 0 15 15 ppm 246 L 65 gal Number 2D Summ...

Page 53: ...PRO SPOTTER PREVENTATIVE MAINTENANCE TICO Manufacturing Service Manual 2 9 LUBRICATION CHART See Figures 2 1 and 2 2 Figure 2 1 Chassis Lubrication 1 TPS 061 2 3 15 7 16 8 17 9 4 10 5 6...

Page 54: ...2 10 Service Manual TICO Manufacturing PREVENTATIVE MAINTENANCE PRO SPOTTER Figure 2 2 Boom and Fifth Wheel Lubrication 18 TPS 062 18 23 20 21 21 22 24 11 12 13 14 19...

Page 55: ...esel Fuel Ultra Low Sulfur Diesel Fuel See Engine Operator s Manual 8 Universal Joint 2 used Lithoplex RT 2 9 Rear Axle Differential 85 140 synthetic is optional See Axle Operator s Manual 10 Drive Li...

Page 56: ...3 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 57: ...ecifications 3 3 Removal 3 4 Inspection 3 4 Installation 3 4 ELECTRICAL COMPONENT CHECKS 3 5 Alternator and Battery Fuse Check 3 5 Backup Alarm Check 3 5 Battery Voltage Check 3 5 Diode Check 3 6 K3 S...

Page 58: ...egulator Never ground to any of the alternator terminals Do not operate the alternator on an open circuit For additional information reference the Cummins Operation and Maintenance Manual provided wit...

Page 59: ...quired to be solder dipped Clean terminals of any oils or contaminants before being dipped Dipped terminals should be completely filled Remove excess solder to have a smooth terminal surface 5 After t...

Page 60: ...ge to the battery and other components avoid a high charging rate on a fully charged battery Verify the battery is fully charged and properly working Installation Installation is the reverse of the re...

Page 61: ...rk Tractor Safely on page 1 3 2 Disconnect the wire harness electrical connector 1 from the backup alarm 3 Connect a multimeter to pin B 3 of the wire harness electrical connector and to the frame gro...

Page 62: ...id not beep on either test Replace the diode K3 Solenoid Function Test See Figure 3 7 Figure 3 7 K3 Solenoid 1 Turn key switch to the ON position 2 Use a voltmeter to check the voltage at terminal 85...

Page 63: ...tage to terminal 86 and ground terminal 85 Does the relay click YES Relay is good Check wiring harness NO Replace relay 4 With terminal 86 still connected to the battery and terminal 85 still grounded...

Page 64: ...ck 1 Auxiliary Fuse Panel 4 Fuse Block 2 Electrical Supply Board 5 Dash 3 Fuse Block Cover 6 Cover 1 TPS 065 3 2 5 6 4 F1 Accessory 20A Fuse F13 HVAC Blower 30A Fuse F2 AM FM Radio 10A Fuse F14 Power...

Page 65: ...is equipped with an easily accessible vehicle electrical center VEC The VEC consists of two electrical modules located behind the driver front access panel This placement allows for ease of handling d...

Page 66: ...VEC1 F6 Spare 10A Fuse VEC1 F12 Spare 10A Fuse VEC1 R4 Trailer Lights Relay VEC1 F1 Flasher 20A Fuse VEC1 F7 Spare 10A Fuse VEC1 F13 Reverse 2 20A Fuse VEC1 R5 Reverse 2 Relay VEC1 F2 Taillight 20A F...

Page 67: ...ter Module 2 VEC2 VEC2 F2 TCM Battery 20A Fuse VEC2 F8 Spare 10A Fuse VEC2 R2 Wiper High Relay 5 Spare 30A Fuse VEC2 F3 Diagnostics 10A Fuse VEC2 F9 Key Switch Battery 20A Fuse VEC2 R3 Wiper Low Relay...

Page 68: ...4 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 69: ...nstallation 4 5 CHARGE AIR COOLER 4 6 Removal 4 6 Inspection 4 7 Installation 4 7 COOLING FAN 4 7 Removal 4 7 Inspection 4 8 Installation 4 8 DIESEL EXHAUST FLUID DEF TANK 4 9 Removal 4 9 Inspection 4...

Page 70: ...TICO Manufacturing ENGINE PRO SPOTTER COOLING SYSTEM MAINTENANCE 4 14 Cooling System Draining 4 14 Cooling System Flushing 4 14 Cooling System Filling 4 15 SURGE TANK 4 16 Removal 4 16 Inspection 4 16...

Page 71: ...4 1 Dipstick Location 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 2 Remove the dipstick 1 and read oil level 3 Add oil if necessary 4 Remove dipstick and read oil level...

Page 72: ...r intake filter 14 Inspection 1 Inspect air filter See AIR FILTER on page 4 5 2 Inspect the intake system for cracked silicone hoses loose clamps or punctures which can allow dirt and debris to enter...

Page 73: ...nents as necessary Inspection See Figure 4 8 Figure 4 8 Filter Gauge Replace air filter when yellow indicator on the filter gauge 4 reaches red line Check filter for wear or damage Replace parts found...

Page 74: ...for clarity 6 Remove cap screws 22 and covers 13 NOTE Condenser lines do not need to be removed 7 Remove cap screws 14 washers 15 and lock nuts 16 and set condenser 17 aside 8 Remove cap screws 20 wa...

Page 75: ...al procedure COOLING FAN Removal See Figures 4 12 4 13 and 4 14 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 2 Raise the cab 3 Disconnect battery cables See BATTERY on pa...

Page 76: ...18 washers 19 and cooling fan 20 Inspection Check for cracks loose rivets and bent or loose blades Replace cooling fan if damaged Check that the cooling fan is securely mounted and tighten any loose c...

Page 77: ...iceable Inspect DEF tank and filler cap for damage or signs of leakage Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage with th...

Page 78: ...l threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable Clean all parts of dirt and debris Installation Installation is re...

Page 79: ...ect fuel tank and filler cap for damage or signs of leakage Repair or replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage with thr...

Page 80: ...rs may need 20 to 60 strokes 6 Turn the priming hand pump 3 counterclockwise and begin pumping until resistance is felt 7 Lock the priming hand pump 8 Operate the engine and check for leaks RADIATOR R...

Page 81: ...components as necessary Inspection Check radiator for cracks broken fins or other damage Replace parts found to be unserviceable Inspect radiator piping hoses fittings and clamps for leaks holes crack...

Page 82: ...enting is provided for a fill rate of 19 L 5 gal per minute 3 Fill the system with a mixture of sodium carbonate and water or a commercially available equivalent 4 Wait for 2 to 3 minutes to allow the...

Page 83: ...em Draining on page 4 14 IMPORTANT Avoid serious engine damage and prevent air locks Properly vent air from the engine coolant passages during the fill process Avoid system damage and corrosion Never...

Page 84: ...maged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable Check wiring harness for wear or damage Replace parts found to be unserviceable Clean all part...

Page 85: ...CHECK FLUID LEVEL 5 2 Transmission Fluid 5 2 TRANSMISSION COOLER 5 4 Removal 5 4 Inspection 5 4 Installation 5 4 TRANSMISSION FILTER 5 5 Removal 5 5 Inspection 5 5 Installation 5 6 TRANSMISSION FLUID...

Page 86: ...cold check band 2 on the dipstick 1 verifies that the transmission has adequate fluid for start up and operation until it can be checked at the operating hot temperature Fluid levels for continued ope...

Page 87: ...al Hot Check 7 Remove the dipstick and observe the fluid level If the transmission fluid is within the hot check band 3 the fluid level is satisfactory 8 If necessary add or remove transmission fluid...

Page 88: ...3 Close all openings using caps and plugs 6 Remove cap screws 4 washers 5 lock nuts 6 and transmission cooler 7 Repair or replace components as necessary Inspection Check hoses lines fittings and clam...

Page 89: ...filter covers 1 and 2 4 Loosen cap screws 3 and allow transmission fluid to drain 5 Remove cap screws filter covers and gaskets 4 Properly dispose of gaskets 6 Remove and properly dispose of O rings...

Page 90: ...ransmission fluid as necessary See Transmission Fluid Filling on page 5 7 For additional information see the Allison Transmission operator s manual TRANSMISSION FLUID MAINTENANCE Transmission Fluid Dr...

Page 91: ...lug 1 and tighten to specification Figure 5 10 Dipstick 4 Clean any dirt or debris from the end of the fill tube before removing the dipstick 2 5 Remove dipstick 6 Add fluid as necessary 7 Periodicall...

Page 92: ...6 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 93: ...Preparation 6 5 Checking and Correcting Toe 6 5 Checking and Correcting Camber 6 6 Checking Wheels and Tires 6 7 FRONT WHEEL BEARINGS 6 8 Adjustment 6 8 Removal 6 10 Inspection 6 11 Installation 6 11...

Page 94: ...LEVEL Front Axle Fluid See Figure 6 1 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 Figure 6 1 Front Axle Fluid Level 2 Compare oil level line 4 to ADD and FULL lines 3 a...

Page 95: ...ve drag link 4 8 Repair or replace components as necessary Inspection Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be un...

Page 96: ...7 near the leaf spring 12 that is to be serviced See Support Tractor Securely on page 1 3 9 Remove front wheels 10 Remove drag link See DRAG LINK on page 6 3 11 Remove lock nuts 8 washers 9 spacers 10...

Page 97: ...EL BEARINGS on page 6 8 Check to ensure that the steering tie rod drag link ends and king pins are not loose Check the tires for proper inflation pressure and that the rim to floor are the same at eac...

Page 98: ...fore returning the tractor to service See Checking the Toe on page 6 5 Checking and Correcting Camber See Figures 6 8 and 6 9 Figure 6 8 Wheel Alignment camber Camber is the angle that the front wheel...

Page 99: ...ements to specification 15 If the calculated angle continues to exceed the specification the axle or steering knuckle is bent See FRONT AXLE on page 6 4 or STEERING KNUCKLE on page 6 14 Checking Wheel...

Page 100: ...drum by the upper part and the lower part Pulling or pushing by the upper and lower part will not give the correct reading 7 Measure the axial play by pushing and pulling on each side of the hub or d...

Page 101: ...tire in both directions 13 Loosen the adjustment nut completely 14 Tighten the adjustment nut to specification while turning the tire in both directions 15 Turn the adjustment nut counterclockwise 1...

Page 102: ...over 3 and gasket 4 9 Remove counter nut 5 lock washer 6 and lock ring 7 10 Using an appropriate lifting device remove adjustment nut 8 outer wheel bearing 9 and hub 11 11 Remove sealer cup 15 and inn...

Page 103: ...e Park Tractor Safely on page 1 3 WARNING 2 Using an appropriate lifting device raise the front end of the tractor See Use Lifting Equipment Safely on page 1 4 3 Support the tractor using jack stands...

Page 104: ...damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable Clean all parts of dirt and debris Inspect parts for wear or damage Replace as needed Insta...

Page 105: ...7 8 Remove hydraulic lines 8 and 9 from steering gear box 10 Close all openings using caps and plugs WARNING 9 Using an appropriate lifting device support the steering gear box 10 Remove cap screws 1...

Page 106: ...ure 6 19 Brake Chamber left side shown 5 Install identification tags and disconnect air lines 1 Close all openings using caps and plugs 6 Remove clips 2 and pins 3 7 Remove nuts 4 washers 5 and brake...

Page 107: ...shings 19 and shims 17 for damage Replace parts found to be unserviceable Installation Installation is the reverse of the removal procedure Perform wheel alignment See FRONT END ALIGNMENT on page 6 5...

Page 108: ...d tie rod end 7 7 Remove tie rod bar 4 8 Repair or replace components as necessary Inspection Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Repl...

Page 109: ...REAR AXLE INTRODUCTION 7 2 CHECK FLUID LEVEL 7 2 Rear Drive Axle Fluid 7 2 REAR DRIVE AXLE 7 2 Removal 7 2 Inspection 7 4 Installation 7 4 REAR DRIVE AXLE FLUID MAINTENANCE 7 5 Rear Drive Axle Fluid...

Page 110: ...proper fluid See Rear Drive Axle Fluid Filling on page 7 5 6 If overfilled excess fluid will drain from fill port Allow excess fluid to drain until fluid slowly seeps 7 Install fill plug and tighten...

Page 111: ...used 15 Washer 8 used 20 Lock Nut 4 used 6 Wheel 4 used 11 Pin 2 used 16 Lock Nut 4 used 21 Upper Plate 2 used 7 Brake Chamber 2 used 12 Nut 4 used 17 Link 2 used 22 Lower Plate 2 used 8 Air Line 13 W...

Page 112: ...s 18 washers 19 lock nuts 20 and upper and lower plates 21 and 22 14 Using appropriate lifting device remove rear drive axle 15 Repair or replace components as necessary Inspection Clean all parts of...

Page 113: ...n page 7 5 Rear Drive Axle Fluid Filling See Figure 7 6 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 Figure 7 6 Rear Drive Axle Plugs 2 Install drain plug 3 if removed Ti...

Page 114: ...8 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 115: ...st 8 2 Air System Leak Down Test 8 2 Pressure Buildup Low Pressure Warning Cutoff and Governor Cutout Test 8 3 AIR DRYER 8 3 Removal 8 3 Inspection 8 4 Installation 8 4 AIR SYSTEM SCHEMATIC 8 4 AIR TA...

Page 116: ...problem Performing these tests does NOT rule out the importance and necessity of functional dynamic controllability tests and other tests required in assuring vehicle safety and performance Low Air Bu...

Page 117: ...re 8 1 Air Dryer 3 Disconnect air lines 1 3 Close all openings using caps and plugs 4 Install identification tags and disconnect electrical connector 4 5 Remove band 5 6 Remove cap screws 6 washers 7...

Page 118: ...t side air tank Right side air tank procedure is similar 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 2 Remove rear grate See GRATES AND COVERS on page 14 5 CAUTION 3 Rel...

Page 119: ...lation is the reverse of the removal procedure Loosely apply bands 14 and 19 to air tank 12 to aid in alignment Position air release valve 15 for proper operation of air release cable 5 and tighten ba...

Page 120: ...clamp 6 and set aside 1 Air Reservoir Drain Pull Cord 3 used Avoid personal injury from explosion Air system components may contain pressurized gases Exposure to excessive heat may cause components t...

Page 121: ...loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable...

Page 122: ...9 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 123: ...AIL PROPORTIONING VALVE 9 3 Inspection 9 3 Installation 9 3 FRONT MODULATOR VALVE IF EQUIPPED 9 4 Inspection 9 4 Installation 9 4 FRONT QUICK RELEASE BRAKE VALVE 9 5 Removal 9 5 Inspection 9 5 Install...

Page 124: ...1 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 2 Disconnect batteries See BATTERY on page 3 3 3 Remove front left cover See FRONT COVERS AND GUARDS on page 14 3 Figure 9...

Page 125: ...s and loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unservic...

Page 126: ...pair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect air lines fittings and valves for leaks holes cracks and loose connections Replace parts found to be unser...

Page 127: ...t air lines fittings and valves for leaks holes cracks and loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage w...

Page 128: ...y Inspection Clean all parts of dirt and debris Inspect air lines fittings and valves for leaks holes cracks and loose connections Replace parts found to be unserviceable Check all threaded components...

Page 129: ...aks holes cracks and loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found...

Page 130: ...10 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 131: ...ICO Manufacturing Service Manual 10 1 Section 10 CHASSIS LUBRICATION SYSTEM INTRODUCTION 10 2 AUTOMATIC LUBRICATION SYSTEM 10 2 Filling the Reservoir 10 2 Removal 10 2 Inspection 10 3 Installation 10...

Page 132: ...e automatic lubrication system Verify coupler is free of dirt and debris IMPORTANT When exchanging a bucket of grease ensure there are no air pockets in the filler hose by making at least 3 strokes to...

Page 133: ...ipped threads Repair light damage with thread chasers Replace parts found to be unserviceable Check all lubrication lines for signs of leakage or damage Replace parts found to be unserviceable Check a...

Page 134: ...11 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 135: ...allation 11 3 HYDRAULIC FILTER ASSEMBLY 11 4 Removal 11 4 Inspection 11 4 Installation 11 4 HYDRAULIC FLUID MAINTENANCE 11 5 Hydraulic Fluid Draining 11 5 Hydraulic Fluid Filling 11 5 HYDRAULIC PUMP 1...

Page 136: ...gs or damage For additional information please contact TICO factory support See CONTACT TICO SUPPORT on page 0 15 CHECK FLUID LEVEL Hydraulic Fluid See Figure 11 1 1 Park and prepare tractor for servi...

Page 137: ...Repair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect hydraulic lines and fittings for leaks holes cracks and loose connections Replace parts found to be unse...

Page 138: ...itable container below the hydraulic filter assembly Remove and discard the hydraulic filter 2 9 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect hydraul...

Page 139: ...Hydraulic Fluid Filling See Figure 11 5 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 NOTE Fifth wheel boom should be powered down to fully lowered position whenever chec...

Page 140: ...pped threads Repair light damage with thread chasers Replace parts found to be unserviceable Installation Installation is the reverse of the removal procedure Test boom and steering operation HYDRAULI...

Page 141: ...Fluid Filling on page 11 5 Machine overloaded Remove overload from machine Improper viscosity hydraulic oil too light Drain and refill with proper oil to specified level See LUBRICATION CHART on page...

Page 142: ...GESTED SOLUTION ADDITIONAL INFORMATION Hydraulic oil foamy Suction leak between reservoir and pump Inspect and tighten all connections and lines Repair or replace any defective components Hydraulic oi...

Page 143: ...pect hydraulic lines and fittings for leaks holes cracks and loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Repair light damage...

Page 144: ...12 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 145: ...RODUCTION 12 2 BOOM 12 2 Removal 12 2 Inspection 12 3 Installation 12 3 BOOM CYLINDERS 12 4 Removal 12 4 Inspection 12 4 Installation 12 4 FIFTH WHEEL MAINTENANCE 12 5 Adjustment 12 5 Lubrication 12 6...

Page 146: ...please contact TICO factory support See CONTACT TICO SUPPORT on page 0 15 BOOM Removal See Figures 12 1 and 12 2 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 NOTE The boo...

Page 147: ...e pins found unserviceable Check boom cylinder pins 3 for excessive wear Replace pins found unserviceable Check bushings 18 for wear Press worn bushings out Check all threaded components for damaged o...

Page 148: ...floor 11 Repair or replace components as necessary Inspection Check all welds for cracks and have any cracks welded Check cylinder pins 13 for excessive wear Replace pins found unserviceable Check bus...

Page 149: ...mber XL FW10082ST en US 3 Use the lock tester to couple and uncouple the fifth wheel 3 times to help seat the yoke Figure 12 6 Compressing the Rubber Washer 4 With the locks closed around the lock tes...

Page 150: ...air line and add four drops of air tool oil to cylinder through supply fitting 12 6 Reinstall supply air line 7 Engage and disengage air cylinder control 3 times to work the air tool oil into the cyl...

Page 151: ...d grease lubricate cam profile 2 5 Using water resistant lithium based grease lubricate yoke shaft 3 along the sliding surface 6 Using water resistant lithium based grease lubricate secondary lock 4 w...

Page 152: ...t and debris Inspect air lines fittings and valves for leaks holes cracks and loose connections Replace parts found to be unserviceable Check all threaded components for damaged or stripped threads Re...

Page 153: ...ppropriate lifting device install fifth wheel top plate 1 onto mounting base 10 5 Install bracket pins 4 through the fifth wheel top plate and mounting base 6 Install cap screws 2 and nuts 3 Tighten n...

Page 154: ...13 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 155: ...E 13 9 Adjustment 13 9 Removal 13 10 Inspection 13 10 Installation 13 10 CAB TILT CYLINDER 13 11 Removal 13 11 Inspection 13 12 Installation 13 12 CAB TILT HYDRAULIC FLUID MAINTENANCE 13 12 Cab Tilt H...

Page 156: ...13 2 Service Manual TICO Manufacturing CAB PRO SPOTTER WIPER MOTOR 13 16 Removal 13 16 Inspection 13 16 Installation 13 16...

Page 157: ...el should only remove components deemed necessary for the service or maintenance procedure being performed For additional information please contact TICO factory support See CONTACT TICO SUPPORT on pa...

Page 158: ...service See Park Tractor Safely on page 1 3 Figure 13 3 Lock Bar 2 Raise cab completely and allow it to settle into detent position 1 full open 1 of the lock bar 4 CAUTION 3 Release air system pressur...

Page 159: ...ace components as necessary Inspection Clean all parts of dirt and debris Inspect air lines fittings and connections for leaks holes cracks and loose connections Replace parts found to be unserviceabl...

Page 160: ...cing beyond this range can cause damage to the air closure or operating mechanism 5 Turn adjustment knob clockwise to increase cab door air pressure 6 Turn adjustment knob counterclockwise to decrease...

Page 161: ...to detent position 1 full open 1 of the lock bar 4 Figure 13 10 Cab Latch left side shown 3 Apply alignment marks to bracket and adjuster to aid when adjusting 4 Loosen lock nuts 9 5 Adjust cab latch...

Page 162: ...5 Remove cap screws 7 washers 8 lock nuts 9 and cab latch 10 6 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect hydraulic lines fittings and connections...

Page 163: ...ks to bracket and adjuster to aid when adjusting Figure 13 14 Adjusting Cab Leveling Valve 4 Loosen lock nuts 12 5 Adjust cab leveling valve 5 by repositioning lower portion of cab leveling valve as n...

Page 164: ...leveling valve 5 7 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect air lines fittings and connections for leaks holes cracks and loose connections Repl...

Page 165: ...ove roll pin 6 6 Using appropriate lifting device support cab tilt cylinder 7 Remove cylinder pin 7 and spacers 8 8 Remove roll pin 10 9 Remove cylinder pin 12 spacers 11 and cab tilt cylinder 10 Repa...

Page 166: ...er below the cab tilt pump to cab tilt cylinder hydraulic line 1 at the rear of the cab tilt pump 1 5 Install identification tags and disconnect cab tilt pump to cab tilt cylinder hydraulic line 6 All...

Page 167: ...threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable Inspect electrical connectors and wiring for damage corrosion or lo...

Page 168: ...and trainer seat 6 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Check all threaded components for damaged or stripped threads Repair light damage with threa...

Page 169: ...ons 19 5 Replace floor mat Drill corresponding holes through the floor mat to access cap screw mounting locations Figure 13 28 Trainer Seat Belt 6 Install cap screws 10 washers 11 lock nuts 12 and tra...

Page 170: ...7 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Inspect washer hoses fittings and clamps for leaks holes cracks and loose connections Replace parts found to b...

Page 171: ...VERS AND GUARDS 14 3 Removal 14 3 Inspection 14 4 Installation 14 4 GRATES AND COVERS 14 5 Removal 14 5 Inspection 14 7 Installation 14 7 LEFT COVERS AND GUARDS 14 8 Removal 14 8 Inspection 14 10 Inst...

Page 172: ...rucks The TICO Pro Spotter terminal trucks have been engineered for quick and efficient servicing while minimizing downtime Removing the covers and guards allows the service and maintenance personnel...

Page 173: ...nd front left cover 2 3 Remove screws 3 and front right cover 4 CAUTION 4 Using an appropriate lifting device support front bumper 5 5 Remove cap screws 6 washers 7 nuts 8 and front bumper 1 Screw 14...

Page 174: ...release button 18 and disconnect engine block heater connector if equipped 11 Remove radiator guard 12 Repair or replace components as necessary Inspection 1 Check all threaded components for damaged...

Page 175: ...oad tractor covers are different the procedures are similar 1 Park and prepare tractor for service See Park Tractor Safely on page 1 3 2 Lower the boom and fifth wheel Figure 14 5 Grates and Covers of...

Page 176: ...cap screws 19 washers 20 lock washers 21 nylon washer 22 transmission heat shields 23 and 24 and transmission grate 6 1 Handrail 9 Washer 8 used 8 Cap Screw 4 used 10 Lock Nut 4 used 1 TPS 140 8 9 10...

Page 177: ...Repair or replace components as necessary Inspection 1 Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable In...

Page 178: ...Figure 14 11 Left Covers and Guards off road tractor shown Figure 14 12 Left Front Fender NOTE Figure 14 12 shows the cab lift pump removed for clarity 2 Remove cap screws 8 washers 9 nuts 10 and fro...

Page 179: ...d bottom fuel tank grate 4 Figure 14 15 Diesel Exhaust Fluid DEF Tank Cover 6 Remove cap screws 14 washers 15 lock nuts 16 and diesel exhaust fluid DEF tank cover 5 2 Cab Lift Pump Cover 23 Washer 2 u...

Page 180: ...18 8 Remove rear fender 6 mud flaps 7 and rear fender brackets 21 as an assembly 9 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Check all threaded component...

Page 181: ...tor for service See Park Tractor Safely on page 1 3 Figure 14 17 Right Covers and Guards off road tractor shown Figure 14 18 Front Mud Flap 2 Remove cap screws 7 washers 8 lock nuts 9 and front mud fl...

Page 182: ...lock nuts 33 and front heat shield 34 3 Lower Aftertreatment Cover 14 Washer 8 used 21 Washer 6 used 28 Washer 5 used 4 Intermediate Aftertreatment Cover 15 Lock Nut 4 used 22 Lock Nut 3 used 29 Lock...

Page 183: ...screws 35 and nuts 36 11 Remove rear fender 2 mud flaps 1 and rear fender brackets 37 as an assembly 12 Repair or replace components as necessary Inspection 1 Check all threaded components for damaged...

Page 184: ...15 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 185: ...TATION 15 6 Installation 15 6 Recover R134a Refrigerant 15 7 Evacuate R134a System 15 7 Recharge R134a System 15 8 FLUSH AND PURGE AIR CONDITIONING SYSTEM 15 9 Procedure Set Up 15 9 Air Conditioner Co...

Page 186: ...ice Manual TICO Manufacturing HEATING AND AIR CONDITIONING PRO SPOTTER HEATER CORE 15 17 Removal 15 17 Inspection 15 18 Installation 15 18 RECEIVER DRYER 15 19 Removal 15 19 Inspection 15 19 Installat...

Page 187: ...mental to the ozone in the atmosphere However it is illegal to discharge any refrigerant into the atmosphere It must be recovered using an appropriate refrigerant recovery recycling and recharging sta...

Page 188: ...fely See R134a REFRIGERANT HOSES AND TUBING on page 15 4 2 Park and prepare tractor for service See Park Tractor Safely on page 1 3 CAUTION 3 Remove and repair or replace air conditioner compressor Se...

Page 189: ...ditioning system See Evacuate R134a System on page 15 7 5 Recharge R134a air conditioning system See Recharge R134a System on page 15 8 R134a REFRIGERANT LEAK TEST Inspection CAUTION 1 Handle refriger...

Page 190: ...recovery recycling and recharging station 1 4 Remove caps from low and high pressure test ports 2 and 3 5 Connect blue low pressure hose 4 from refrigerant recovery recycling and recharging station t...

Page 191: ...ycling and recharging stations Do not mix refrigerant hoses fittings components or refrigerant oils 3 Connect refrigerant recovery recycling and charging station See R134a REFRIGERANT RECOVERY RECYCLI...

Page 192: ...RANT RECOVERY RECYCLING AND RECHARGING STATION on page 15 6 4 Evacuate system See Evacuate R134a System on page 15 7 IMPORTANT Before beginning to charge air conditioning system the following conditio...

Page 193: ...or side to side 3 Remove both plugs from manifold ports and drain flushing solvent from air conditioner compressor 4 Connect battery power and ground to engage air compressor clutch solenoid Rotate pu...

Page 194: ...a piece of cardboard continue purging until cardboard is dry 5 Dispose of cooling system flushing solvent properly Procedure Wrap Up 1 Install a new receiver dryer See RECEIVER DRYER on page 15 19 2 A...

Page 195: ...ioning system lines and tubing See R134a REFRIGERANT HOSES AND TUBING on page 15 4 3 Check components lines and fittings for signs of leakage See R134a REFRIGERANT LEAK TEST on page 15 5 Installation...

Page 196: ...er 5 Install identification tags and disconnect electrical connectors 9 12 6 Install identification tags and disconnect hoses 13 17 7 Remove cap screws 18 and upper cover 19 Figure 15 7 Blower Motor C...

Page 197: ...r 14 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Repla...

Page 198: ...air or replace components as necessary Inspection Clean all parts of dirt and debris Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts...

Page 199: ...7 and 8 as an assembly Figure 15 13 Blower Motor Cover 6 Install identification tags and disconnect electrical connectors 9 12 7 Install identification tags and disconnect hoses 13 17 8 Remove cap sc...

Page 200: ...t and debris Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found to be unserviceable Check condition of air conditioning system li...

Page 201: ...7 and 8 as an assembly Figure 15 20 Blower Motor Cover 6 Install identification tags and disconnect electrical connectors 9 12 7 Install identification tags and disconnect hoses 13 17 8 Remove cap sc...

Page 202: ...s and plugs 17 Remove heater core 36 18 Repair or replace components as necessary Inspection Clean all parts of dirt and debris Check all threaded components for damaged or stripped threads Repair lig...

Page 203: ...ard receiver dryer 2 9 Repair or replace components as necessary Inspection 1 Check all threaded components for damaged or stripped threads Repair light damage with thread chasers Replace parts found...

Page 204: ...IDX 0 Service Manual TICO Manufacturing PRO SPOTTER...

Page 205: ...ers and Guards 0 12 15 Heating and Air Conditioning 0 13 A ABS ATC System Flat Rate Guideline 0 9 Adjustment Fifth Wheel Maintenance 12 5 Front Wheel Bearings 6 8 Air Brake System Tests Air System Lea...

Page 206: ...n Fluid 5 2 Check fluid level Front wheel bearings 6 10 Checking and Correcting Camber Front End Alignment 6 6 Checking and Correcting Toe Front End Alignment 6 5 Checking Wheels and Tires Front End A...

Page 207: ...12 8 Installation 12 8 Removal 12 8 Filling the Reservoir Automatic Lubrication System 10 2 Flush and Purge Air Conditioning System Air Conditioner Compressor Cleaning 15 9 Condenser Flush and Purge 1...

Page 208: ...ressor 15 11 Air Dryer 8 4 Air Filter 4 5 Air Intake System 4 4 Air Tank 8 5 Alternator 3 2 Antilock Brake System ABS Controller 9 2 Automatic Lubrication System 10 3 Blower Motor 15 13 Bobtail Propor...

Page 209: ...g Station 15 6 Radiator 4 13 Rear Drive Axle 7 4 Rear Modulator Valve if equipped 9 6 Rear Quick Release Brake Valve 9 7 Receiver Dryer 15 19 Steering Gear Box 6 14 Steering Knuckle 6 15 Surge Tank 4...

Page 210: ...Recommended Lubricants and Capacities 2 6 Recover R134a Refrigerant R134a Refrigerant Recovery Recycling and Recharging Station 15 7 Relieving Air System Pressure 8 6 Removal 11 3 Air Conditioner Com...

Page 211: ...ion 1 3 Safety Labels Safety 1 2 Safety Notices Safety 1 2 Steering Gear Box Inspection 6 13 Installation 6 13 Removal 6 13 Steering Knuckle Inspection 6 14 Installation 6 14 Removal 6 14 Surge Tank I...

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