Tico Pro-Spotter Service Manual
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Tico Pro-Spotter Service Manual

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TICO Manufacturing 1/30/2018
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TICO Manufacturing

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Summary of Contents for Tico Pro-Spotter

  • Page 1 TICO Manufacturing 1/30/2018 Service Manual TICO Manufacturing...
  • Page 2 Pro-Spotter Service Manual TICO Manufacturing...

  • Page 3: Table Of Contents

    CONTACT TICO SUPPORT ........
  • Page 4 TABLE OF CONTENTS PRO-SPOTTER SPECIFICATIONS ............. . 1-8 FASTENERS .
  • Page 5 PRO-SPOTTER TABLE OF CONTENTS WIRING DIAGRAMS AND SCHEMATICS ......... . 3-11 ENGINE INTRODUCTION .
  • Page 6 TABLE OF CONTENTS PRO-SPOTTER TRANSMISSION INTRODUCTION ............. . . 5-2 CHECK FLUID LEVEL .
  • Page 7 PRO-SPOTTER TABLE OF CONTENTS STEERING KNUCKLE ............6-14 Removal .
  • Page 8 TABLE OF CONTENTS PRO-SPOTTER ANTILOCK BRAKE SYSTEM (ABS) CONTROLLER ........9-2 Removal .
  • Page 9 PRO-SPOTTER TABLE OF CONTENTS HYDRAULIC PUMP ............11-6 Removal .
  • Page 10 TABLE OF CONTENTS PRO-SPOTTER CAB TILT CYLINDER ............13-11 Removal .
  • Page 11 PRO-SPOTTER TABLE OF CONTENTS R134a REFRIGERANT OIL INFORMATION ........15-4 Removal .
  • Page 12 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 13: Tico Manufacturing Service Manual

    CONTACT TICO SUPPORT ........

  • Page 14: Tico Pro-Spotter Service Information

    The purpose of the TICO PRO-SPOTTER SERVICE TERMINAL INVESTMENT CORPORATION (hereinafter INFORMATION section is to make the reader familiar referred to as “TICO”) warrants to the original owner that with TICO and its service resources. The following each new TICO Pro-Spotter Terminal Tractor will be free...

  • Page 15: Introduction

    (g) damage during shipment, or years from the date of delivery. (h) any other abuse or misuse by purchaser. b. TICO Cab – As to the driver’s structural cabin Disclaimer of Warranty. compartment, five years from the date of delivery.

  • Page 16: Major Components Warranty

    PRO-SPOTTER Limitation of Remedies. Warranty Registration. In no case shall TICO be liable for any special, incidental, This warranty is conditioned upon receipt by TICO of a or consequential damages based upon breach of completed warranty registration following delivery of warranty, breach of contract, negligence, strict tort, or any vehicle to the customer.

  • Page 17: 2018 Flat Rate Guideline

    PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION 2018 FLAT RATE GUIDELINE 3—Electrical System CODE DESCRIPTION HOUR NOTES 3.01 Alternator; R&R 3.02 Battery; R&R Add for Each Additional 3.03 Belt, Alternator; R&R 3.04 Bracket, Battery Hold-Down; R&R (Each) 3.05 Cable, Battery; R&R (Each) 0.75...
  • Page 18 TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER CODE DESCRIPTION HOUR NOTES 4.13 Cooler, Charge Air; R&R 4.14 Diesel Particulate Filter (DPF), Vertical; R&R 4.15 Diesel Particulate Filter (DPF); R&R (ISB6.7) 4.16 Dosing Pump, Diesel Exhaust Fluid (DEF); R&R 4.17 Elbow, Muffler Inlet; R&R Includes Tack Weld 4.18...

  • Page 19: 5-Transmission

    PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION CODE DESCRIPTION HOUR NOTES 4.60 Surge Tank; R&R Includes Drain and Refill 4.61 Tank, Diesel Exhaust Fluid (DEF); R&R 4.62 Tank, Fuel; Drain and Refill 4.63 Tank, Fuel; R&R Includes Drain and Refill 4.64 Tank, Lower Radiator; R&R Includes Drain and Refill 4.65...

  • Page 20: 7-Rear Axle

    TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER CODE DESCRIPTION HOUR NOTES 6.18 Pin, Front Spring; R&R (Each) 6.19 Pitman Arm; R&R 6.20 Poppet, Steering Gear; Adjustment 6.21 Power Steering System; Analyze Includes Flow & Pressure Check 6.22 Pump, Power Steering; R&R (Optional dedicated steering pump) Includes Drain and Refill 6.23...

  • Page 21: 8-Air System

    PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION 8—Air System CODE DESCRIPTION HOUR NOTES 8.01 Dryer, Air; R&R 8.02 Gauge, Air; R&R (Each) 8.03 Governor, Air; Adjustment 8.04 Governor, Air; R&R 8.05 Hose, Compressor Intake; R&R 8.06 Line, Discharge, Compressor; R&R 8.07 Pedal, Throttle; R&R 8.08...

  • Page 22: 11-Hydraulic System

    TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER 11—Hydraulic System CODE DESCRIPTION HOUR NOTES 11.01 Bearing, Cylinder; R&R (Each) Cylinder Removed 11.02 Cap and Strainer, Hydraulic Tank; R&R 11.03 Cylinder, Cab Tilt; R&R 11.04 Cylinder, Hydraulic; R&R (Each) 11.05 Hydraulic Fluid; Drain and Refill 11.06...

  • Page 23: 13-Cab

    PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION 13—Cab CODE DESCRIPTION HOUR NOTES 13.01 Belt Safety, Seat; R&R 0.75 13.02 Bracket, Cab Latch; R&R 13.03 Bracket, Lower Cab Tilt Cylinder Support; R&R 1.25 13.04 Bushing, Cab Pivot; R&R (Each) 0.75 13.05 Buzzer, Low-Pressure; R&R 13.06...

  • Page 24: 14-Covers And Guards

    TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER CODE DESCRIPTION HOUR NOTES 13.46 Radio; R&R 13.47 Rear Door Assembly; R&R 13.48 Rear Door Drive Plate; R&R 13.49 Right Mirror Post; R&R 13.50 Seat; R&R 13.51 Shock Absorber, Seat; R&R 13.52 Speedometer; R&R & Recalibrate 0.75...

  • Page 25: 15-Heating And Air Conditioning

    PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION 15—Heating and Air Conditioning CODE DESCRIPTION HOUR NOTES 15.01 Belt, A/C Compressor; R&R Operations Do Not Include Refrigerant Recovery or Evacuation 15.02 Box, HVAC; R&R Operations Do Not Include Refrigerant Recovery or Evacuation 15.03 Cable, HVAC Temperature Control; R&R...
  • Page 26 TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER CODE DESCRIPTION HOUR NOTES 15.22 Switch, Low-Pressure; R&R Operations Do Not Include Refrigerant Recovery or Evacuation 15.23 Thermostat, A/C; R&R Operations Do Not Include Refrigerant Recovery or Evacuation 15.24 Valve, Expansion; R&R Operations Do Not Include Refrigerant Recovery or Evacuation 15.25...

  • Page 27: Contact Tico Support

    To find a local dealer for support, service, or parts visit: ticotractors.com/dealer The dealer locator can also be found on the online support page. This page will provide additional resources such as the TICO operator’s manual and warranty submission. Service Manual 0-15...
  • Page 28 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 29: General Information

    Fifth Wheel Serial Tag ........... . . 1-15 Service Manual TICO Manufacturing...

  • Page 30: Safety

    Safety Labels possible. Never take shortcuts. • Be prepared for emergencies. Accidents can happen, Become familiar with the TICO Pro-Spotter terminal even under the best conditions. Fire extinguishers tractor safety labels and locations. Safety decals are and first aid kits should be well maintained and easily critical to the safe operation of the terminal tractor.

  • Page 31: Keep Work Area Clean

    PRO-SPOTTER GENERAL INFORMATION Keep Work Area Clean Park Tractor Safely A clean, organized, well-lit work area is important to See Figure 1-1. promote safe working conditions.  WARNING • Keep floor clean of debris and clear of parts and tools.

  • Page 32: Use Lifting Equipment Safely

    GENERAL INFORMATION PRO-SPOTTER Use Lifting Equipment Safely • Always maintain air tools properly. Service Tires Safely  WARNING Always check the lifting capacity and condition of  WARNING hoists, slings, cables, or chains before use. Using underrated or worn lifting components could An inflated tire contains explosive force.

  • Page 33: Service Hydraulic System Safely

    PRO-SPOTTER GENERAL INFORMATION Service Hydraulic System Safely Handle Fuel Safely Handle fuel with care—it is highly flammable.  WARNING  WARNING The hydraulic system is under pressure, and the oil may be hot! • Never remove the fuel cap from the fuel tank or add fuel when the engine is running or •...

  • Page 34: Dispose Of Waste Materials Safely

    GENERAL INFORMATION PRO-SPOTTER Dispose of Waste Materials Safely Routine service can produce waste products such as used oil, coolant, grease, and used batteries. If not handled properly, these materials can pose a threat to the environment. Collect fluids in well-marked, approved storage containers.

  • Page 35: Nomenclature

    Hour Meter Cab Lift Pump Fuel Tank Fifth Wheel and Boom Steering Gear Fuel Filter Diesel Exhaust Fluid (DEF) Tank Figure 1-2: Pro-Spotter (Left Side) TPS-003 Steer Axle Quarter Fender Power Distribution Center (PDC) Exhaust Auto Lubrication Hydraulic Tank Air Intake...

  • Page 36: Specifications

    GENERAL INFORMATION PRO-SPOTTER SPECIFICATIONS WHEELS 22.5” X 8.25” Standard offset 285 mm hub pilot ENGINE two-hand hole Manufacturer ......Cummins®...
  • Page 37 PRO-SPOTTER GENERAL INFORMATION WARNING DEVICES: AIR SYSTEM Trailer ABS Fault Code ..... . Light WABCO 18.7 CFM turbocharged air compressor ATC Automatic Traction Control Active .

  • Page 38: Fasteners

    Figure 1-5: Metric Bolt Dimensions See Figures 1-4—1-10. Bolt heads are also used to set apart standard from TICO terminal tractors use both standard and metric metric fasteners. The width of a standard bolt head is fasteners on all equipment. Standard fasteners are often measured in inches.
  • Page 39 PRO-SPOTTER GENERAL INFORMATION TPS-004 Bolt Grade 1 or 2 Bolt Grade 5 Bolt Grade 8 Bolt Grade 8.2 Figure 1-6: Standard Bolt Grade Markings TPS-005 Bolt Class 4.6 Bolt Class 5.8 Bolt Class 9.8 Bolt Class 4.8 Bolt Class 8.8 Bolt Class 10.9...

  • Page 40: Tightening Sequences And Procedures

    400 MPa (58 015 psi) and 80% yield strength. Follow the instruction in this TICO service manual for the Class 8.8 fasteners will have an approximate tensile correct tightening sequence. If the sequence is not...
  • Page 41 PRO-SPOTTER GENERAL INFORMATION Table 1-1: Standard Fastener Torque Values SIZE UNITS GRADE 2 GRADE 5 GRADE 8 Lubricated Zinc Plated Lubricated Zinc Plated Lubricated Zinc Plated 3/8”-16 20.3 (15) 27.1 (20) 24.4 (18) 31.2 (23) 42.0 (31) 38.0 (28) 44.7 (33) 59.7 (44)

  • Page 42: Vehicle Identification

    GENERAL INFORMATION PRO-SPOTTER VEHICLE IDENTIFICATION Transmission Nameplate See Figures 1-14 and 1-15. Certification Label The transmission nameplate (1) is located on the right rear side of the transmission. The nameplate shows the See Figures 1-12 and 1-13. transmission serial number (4), TransID (TID) level (3), It is required that the Federal Motor Vehicle Safety and manufactured date (2).

  • Page 43: Engine Dataplate

    PRO-SPOTTER GENERAL INFORMATION Engine Dataplate See Figures 1-16 and 1-17. The engine dataplate (1) shows specific information about your engine. The engine serial number (2) and control parts list (CPL) (3) provide information for ordering parts and service needs. NOTES •...
  • Page 44 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 45: Preventative Maintenance

    TIRE PRESSURE ............. 2-11 Service Manual TICO Manufacturing...

  • Page 46: Introduction

    • Inspect trailer electrical cable and trailer air lines for with the required service procedures based on hour damage. usage intervals to properly maintain TICO Pro-Spotter terminal trucks. • Start engine and check transmission fluid level with parking brake applied and transmission shift selector The TICO Pro-Spotter terminal trucks have been in “neutral”.

  • Page 47: Every 500 Hours Of Operation

    • Check gladhand seals and trailer air lines. procedures to be completed after every 500 hours of • Check trailer light cord. operation on TICO Pro-Spotter terminal trucks. These procedures should only be completed by qualified • Check headlights and marker lights.
  • Page 48 PREVENTATIVE MAINTENANCE PRO-SPOTTER Under Vehicle Checks Lubrication Checks • Check steering gear. • Check and lubricate rear door bushings. • Check brake linings and drums. • Check and lubricate steering slip joint. • Check springs. • Check and lubricate steering U-joints.

  • Page 49: Every 1000 Hours Of Operation

    The following items are the preventative maintenance procedures to be completed after every 1000 hours of procedures to be completed after every 2000 hours of operation on TICO Pro-Spotter terminal trucks. These operation on TICO Pro-Spotter terminal trucks. These procedures should only be completed by qualified procedures should only be completed by qualified service or maintenance personnel.

  • Page 50: Recommended Lubricants And Capacities

    PREVENTATIVE MAINTENANCE PRO-SPOTTER RECOMMENDED LUBRICANTS AND CAPACITIES System Fluid Type Capacity Notes Engine Oil SAE 15W-40 16.7 L See Engine Operator’s Manual. (17.6 qt) Transmission Allison Approved 27.4 L Specification does not include TES 295® Automatic external lines or cooler hoses.

  • Page 51: Diesel Exhaust Fluid (Def)

    PRO-SPOTTER PREVENTATIVE MAINTENANCE DIESEL EXHAUST FLUID (DEF) Requirements System Fluid Type Capacity Notes Diesel Exhaust Fluid (DEF) System Diesel Exhaust Fluid (DEF) 18.9 L See Engine Operator’s (ISO 22241-1) Manual. (5 gal)  CAUTION • Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes.

  • Page 52: Diesel Fuel

    Failure to comply with engine manufacturer’s fuel requirements may cause severe engine damage and void the warranty on the engine. Contact your TICO dealer if you did not receive an Engine Operator’s Manual with your new TICO tractor.

  • Page 53: Lubrication Chart

    PRO-SPOTTER PREVENTATIVE MAINTENANCE LUBRICATION CHART See Figures 2-1 and 2-2. TPS-061 Figure 2-1: Chassis Lubrication Service Manual TICO Manufacturing...
  • Page 54 PREVENTATIVE MAINTENANCE PRO-SPOTTER TPS-062 Figure 2-2: Boom and Fifth Wheel Lubrication 2-10 Service Manual TICO Manufacturing...

  • Page 55: Tire Pressure

    Lithoplex RT #2 Fifth Wheel Jaw Lithoplex RT #2 TIRE PRESSURE Recommendations NOTE Information provided is for the TICO Pro-Spotter standard tires. Other tire options may require different pressure specifications. See the tire manufacturer’s literature for additional information. Pressure Tire Size...
  • Page 56 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 57: Electrical System

    WIRING DIAGRAMS AND SCHEMATICS ......... . 3-11 Service Manual TICO Manufacturing...

  • Page 58: Introduction

    Mounting Cap Screw Alternator ALTERNATOR Figure 3-1: Alternator The TICO Pro-Spotter terminal tractor is equipped with a 4. Remove the drive belt (1) from the alternator pulley 160-amp Delco™ alternator. The alternator is located on (2). See the Cummins™ Operation and Maintenance the right front side of the Cummins™...

  • Page 59: Battery

    ELECTRICAL SYSTEM BATTERY Cable Specifications The specifications listed below must be followed when Standard TICO Pro-Spotter terminal trucks are equipped creating replacement battery cables. with two 12V 750 CCA 31-LHD threaded stud batteries. The batteries are contained in a battery enclosure 1.

  • Page 60: Removal

    ELECTRICAL SYSTEM PRO-SPOTTER Removal  CAUTION See Figures 3-2 and 3-3. • Prevent possible injury. Accidental contact NOTE between positive (+) battery terminal and ground can cause arcing and burns. Always If the machine is out of use for more than 30 days, disconnect the battery negative (-) cable first remove the batteries.

  • Page 61: Electrical Component Checks

    5. With the key switch still in the ON position, measure needed to aid these checks can be found by contacting the continuity between pin A (2) of the wire harness TICO support. (See “CONTACT TICO SUPPORT” on electrical connector and the frame ground. page 0-15.)

  • Page 62: Diode Check

    ELECTRICAL SYSTEM PRO-SPOTTER Diode Check K3 Solenoid Function Test See Figure 3-6. See Figure 3-7. TPS-074 Terminal 30 Terminal 86 Terminal 85 Terminal 87 Figure 3-7: K3 Solenoid 1. Turn key switch to the ON position. 2. Use a voltmeter to check the voltage at terminal 85 and terminal 86 of the K3 solenoid.

  • Page 63: Relay Check

    PRO-SPOTTER ELECTRICAL SYSTEM Relay Check See Figure 3-8. TPS-074 Standard Four Pin Relay Terminal 86 Standard Five Pin Relay Terminal 87 Terminal 30 87a Terminal 87a Terminal 85 Figure 3-8: Relay Terminals 1. Stop the engine and remove the relay from the tractor.

  • Page 64: Fuse Specifications

    PRO-SPOTTER FUSE SPECIFICATIONS See Figures 3-9 and 3-10. The TICO Pro-Spotter is equipped with an easily accessible fuse panel. This panel is located on the right side of the dash and uses blade-type fuses. The fuse decal is located to the right of the fuse block on the cover of the heat assembly.

  • Page 65: Power Distribution Center

    VEHICLE ELECTRICAL CENTER See Figures 3-11 and 3-12. See Figures 3-13, 3-14, and 3-15. The TICO Pro-Spotter is equipped with an easily The TICO Pro-Spotter is equipped with an easily accessible power distribution center (PDC). The PDC box accessible vehicle electrical center (VEC). The VEC...
  • Page 66 ELECTRICAL SYSTEM PRO-SPOTTER VEC1-R2 VEC1-R7 VEC1-F12 VEC1-F14 VEC1-F11 VEC1-F13 VEC1-F8 VEC1-R6 VEC1-F7 VEC1-F6 VEC1-R5 VEC1-F5 VEC1-F4 VEC1-R1 VEC1-F3 VEC1-F2 VEC1-F1 VEC1-F10 VEC1-F9 VEC1-R4 VEC1-R3 TPS-077 Vehicle Electrical Center Module VEC1-F4 Stop Lamp 10A Fuse VEC1-F10 Trailer Lights 10A VEC1-R2 Fan Clutch 2...

  • Page 67: Wiring Diagrams And Schematics

    These diagrams and electrical schematics are frequently updated to provide the best information possible when servicing a TICO Pro-Spotter terminal tractor. To view the most recent diagrams and schematics, contact TICO support. (See “CONTACT TICO SUPPORT”...
  • Page 68 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 69: Engine

    Installation ............. . 4-13 Service Manual TICO Manufacturing...
  • Page 70 ENGINE PRO-SPOTTER COOLING SYSTEM MAINTENANCE ..........4-14 Cooling System Draining .

  • Page 71: Introduction

    1. Park and prepare tractor for service. (See “Park systems on TICO Pro-Spotter terminal trucks. Tractor Safely” on page 1-3.) The TICO Pro-Spotter terminal trucks have been engineered for quick and efficient servicing, while minimizing down time. The external location for many of the engine related parts allow for easy access.

  • Page 72: Air Intake System

    ENGINE PRO-SPOTTER AIR INTAKE SYSTEM 7. Remove nuts (7), washers (8), and saddle clamp (9). 8. Loosen hose clamps (5 and 11) and remove hump hose (10) and air cleaner-to-hump hose tube (6). Removal See Figures 4-3, 4-4, and 4-5.

  • Page 73: Air Filter

    PRO-SPOTTER ENGINE AIR FILTER Inspection See Figure 4-8. Removal See Figures 4-6 and 4-7. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-047 Filter Gauge Blower-to-Hump Hose Tube Figure 4-8: Filter Gauge • Replace air filter when yellow indicator on the filter gauge (4) reaches red line.

  • Page 74: Charge Air Cooler

    ENGINE PRO-SPOTTER CHARGE AIR COOLER Removal See Figures 4-9, 4-10, and 4-11. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) 2. Raise cab. 3. Remove brush guard. (See “FRONT COVERS AND GUARDS” on page 14-3.)

  • Page 75: Inspection

    PRO-SPOTTER ENGINE 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 page 3-3.) TPS-052 Hose Clamp (4 used)

  • Page 76: Inspection

    ENGINE PRO-SPOTTER TPS-057 Cap Screw (4 used) Washer (4 used) Lock Washer (4 used) Cooling Fan TPS-056 Figure 4-14: Cooling Fan Upper Radiator Hose Lock Nut (8 used) Hose Clamp Washer (4 used)  CAUTION Cap Screw (12 used) Lock Washer (4 used)

  • Page 77: Diesel Exhaust Fluid (Def) Tank

    PRO-SPOTTER ENGINE DIESEL EXHAUST FLUID (DEF) TANK Removal See Figures 4-15 and 4-16. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) 2. Disconnect battery cables. (See “BATTERY” on page 3-3.) TPS-042 Diesel Exhaust Fluid (DEF) Tank...

  • Page 78: Fuel Filter

    ENGINE PRO-SPOTTER FUEL FILTER Inspection • Inspect filter head for damage or signs of leakage. Removal Replace parts found to be unserviceable. • Check hoses, fittings, and clamps for wear or See Figure 4-17. damage. Replace parts found to be unserviceable.

  • Page 79: Fuel Tank

    PRO-SPOTTER ENGINE FUEL TANK Removal See Figures 4-18 and 4-19. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) 2. Disconnect battery cables. (See “BATTERY” on page 3-3.) TPS-045 Fuel Tank Strap (2 used) Nut (2 used)

  • Page 80: Draining Fuel/Water Separator

    ENGINE PRO-SPOTTER DRAINING FUEL/WATER RADIATOR SEPARATOR Removal See Figure 4-20. See Figures 4-21 and 4-22. 1. Park and prepare tractor for service. (See “Park 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) Tractor Safely” on page 1-3.) 2.

  • Page 81: Inspection

    PRO-SPOTTER ENGINE 8. Remove rods (14), rubber mounts (15), washers (16), jamnuts (17), and lock nuts (18). TPS-045 Lock Nut (2 used) Isolator (2 used) Washer (2 used) Radiator Figure 4-22: Lower Radiator 9. Remove lock nuts (19), washers (20), and isolators (21).

  • Page 82: Cooling System Maintenance

    ENGINE PRO-SPOTTER COOLING SYSTEM 3. Position a suitable container below the drain valve (4) and lower radiator hose (3). MAINTENANCE 4. Open drain valve. 5. Disconnect lower radiator hose. Cooling System Draining 6. Properly dispose of coolant. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...

  • Page 83: Cooling System Filling

    PRO-SPOTTER ENGINE 3. Add coolant as necessary. IMPORTANT 4. Wait for 2 to 3 minutes to allow the system to Avoid engine damage by cavitation of the water naturally vent air and coolant levels to stabilize. pump and localized boiling. Do not operate the 5.

  • Page 84: Surge Tank

    ENGINE PRO-SPOTTER SURGE TANK Inspection • Check hoses, fittings, and clamps for wear or Removal damage. Replace parts found to be unserviceable. • Inspect surge tank and filler cap for damage or signs 1. Park and prepare tractor for service. (See “Park of leakage.

  • Page 85: Transmission

    Transmission Fluid Filling ........... 5-7 Service Manual TICO Manufacturing...

  • Page 86: Introduction

    TRANSMISSION PRO-SPOTTER INTRODUCTION Standard TICO tractors are equipped with an Allison Transmission® fully automatic transmission. These heavy-duty transmissions are designed for stop and go operation. NOTE An Allison Transmission® operator’s manual is provided with every TICO tractor. This manual provides important information on operation of the Allison Transmissions®.
  • Page 87 PRO-SPOTTER TRANSMISSION 11. Perform a hot manual check once the transmission fluid has reached 71°—93°C (160°—200°F). For additional service and maintenance information, see the Allison Transmission® operator’s manual. Manual Check—Hot See Figures 5-3 and 5-4. The hot check band (3) on the dipstick (1) offers the best assurance of maintaining the correct fluid levels.

  • Page 88: Transmission Cooler

    TRANSMISSION PRO-SPOTTER TPS-180 Transmission Cooler Cap Screw (4 used) Transmission Line Washer (8 used) Transmission Line Lock Nut (4 used) Figure 5-6: Transmission Cooler TPS-069 4. Position a suitable container below the transmission Transmission Gear Down-Shift Button line connections on the transmission cooler (1).

  • Page 89: Transmission Filter

    PRO-SPOTTER TRANSMISSION TRANSMISSION FILTER LUBE MAIN TPS-072 Lube Filter Cover Cap Screw (12 used) O-Ring (2 used) Filter (2 used) Main Filter Cover Gasket (2 used) O-Ring (2 used) Figure 5-7: Transmission Filter Assembly Removal 6. Remove and properly dispose of O-rings (5 and 6) and filters (7).

  • Page 90: Installation

    TRANSMISSION PRO-SPOTTER TRANSMISSION FLUID Installation MAINTENANCE 1. Lubricate and install new O-rings (5 and 6) on lube and main filter covers (1 and 2). Transmission Fluid Draining 2. Lubricate O-ring inside filters (7). 3. Push filters onto filter covers. See Figure 5-8.

  • Page 91: Transmission Fluid Filling

    PRO-SPOTTER TRANSMISSION 5. While still at normal operating temperatures, remove the drain plug and allow fluid to drain completely. Specification Transmission Fluid—Capacity 27.4 L 29 qt 6. Examine the transmission fluid for signs of dirt, water, or debris. For additional information, see the Allison Transmission®...
  • Page 92 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 93: Front Axle & Steering

    Installation ............. . 6-16 Service Manual TICO Manufacturing...

  • Page 94: Introduction

    See Figure 6-1. axle, front suspension, and steering system on TICO 1. Park and prepare tractor for service. (See “Park Pro-Spotter terminal trucks.

  • Page 95: Drag Link

    PRO-SPOTTER FRONT AXLE & STEERING DRAG LINK 5. Remove cotter pin (1), nut (2), and drag link end (3). Removal See Figures 6-2 and 6-3. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) ...

  • Page 96: Front Axle

    FRONT AXLE & STEERING PRO-SPOTTER FRONT AXLE  WARNING Removal Prevent possible crushing injury or death. Use appropriate lifting device. See Figures 6-4 and 6-5. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) ...

  • Page 97: Inspection

    PRO-SPOTTER FRONT AXLE & STEERING FRONT END ALIGNMENT Inspection • Check all threaded components for damaged or Proper front end alignment is essential to tractor stripped threads. Repair light damage with thread performance and longevity. Proper alignment ensures chasers. Replace parts found to be unserviceable.

  • Page 98: Checking And Correcting Camber

    FRONT AXLE & STEERING PRO-SPOTTER Checking and Correcting Camber 5. Place a trammel bar behind the front tires with the pointers at the outside edge of the marks. See Figures 6-8 and 6-9. 6. Adjust the trammel bar to point at the centerline height of the marks and secure the pointers when the bar is in place.

  • Page 99: Checking Wheels And Tires

    PRO-SPOTTER FRONT AXLE & STEERING 6. Subtract the lowest reading from the highest reading. 14. If the calculated angle continues to exceed the Record the calculated angle. specification, take a manual camber measurement. 7. Compare the calculated angle to the specification.

  • Page 100: Front Wheel Bearings

    FRONT AXLE & STEERING PRO-SPOTTER FRONT WHEEL BEARINGS Adjustment See Figures 6-10 and 6-11. TPS-166 Cap Screw (6 used) Counter Nut Outer Wheel Bearing Inner Bearing Cup Washer (6 used) Lock Washer Outer Bearing Cup Inner Wheel Bearing Hub Cover...
  • Page 101 PRO-SPOTTER FRONT AXLE & STEERING 8. Subtract the lowest reading from the highest reading. 13. Loosen the adjustment nut completely. This number represents the axial play or total 14. Tighten the adjustment nut to specification while distance between pushing and pulling.

  • Page 102: Removal

    FRONT AXLE & STEERING PRO-SPOTTER Removal NOTE See Figure 6-12. Procedure is written for the left side wheel bearing. Right side wheel bearing procedure is similar. TPS-166 Cap Screw (6 used) Counter Nut Outer Wheel Bearing Inner Bearing Cup Washer (6 used)

  • Page 103: Inspection

    PRO-SPOTTER FRONT AXLE & STEERING LEAF SPRING Inspection • Check all threaded components for damaged or Removal stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. See Figures 6-13, 6-14, and 6-15. • Clean all parts of dirt and debris.

  • Page 104: Inspection

    FRONT AXLE & STEERING PRO-SPOTTER 5. Remove front wheel. 10. Remove bolt (10), washer (11), lock nut (12), and leaf spring. 6. Remove lock nuts (2), washers (3), spacers (4), and U-bolts (5). 11. Repair or replace components as necessary.

  • Page 105: Steering Gear Box

    PRO-SPOTTER FRONT AXLE & STEERING STEERING GEAR BOX 6. Remove drag link from steering arm (4). Removal See Figures 6-17 and 6-18. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)  WARNING • Prevent possible crushing injury or death.

  • Page 106: Steering Knuckle

    FRONT AXLE & STEERING PRO-SPOTTER Inspection • Check all threaded components for damaged or stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. • Inspect hydraulic lines and fittings for leaks, holes, cracks, and loose connections. Replace parts found to be unserviceable.

  • Page 107: Inspection

    PRO-SPOTTER FRONT AXLE & STEERING TPS-179 Cap Screw (3 used) Washer (3 used) Shim (as required) Front Axle Washer (3 used) Lower Cap Grease Fitting (2 used) Nut (3 used) Upper Cap Gasket Bushing (2 used) Cotter Pin (3 used)

  • Page 108: Tie Rod Bar

    FRONT AXLE & STEERING PRO-SPOTTER TIE ROD BAR Removal See Figures 6-21 and 6-22. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)  WARNING • Prevent possible crushing injury or death. Use appropriate lifting device.

  • Page 109: Rear Axle

    Rear Drive Axle Fluid Filling ..........7-5 Service Manual TICO Manufacturing...

  • Page 110: Introduction

    7. Install fill plug and tighten to specification. service and maintenance personnel with guidance on the Specification proper procedures for servicing the rear axles and related systems on the TICO Pro-Spotter terminal trucks. Fill Plug—Torque 47.5 N·m The TICO Pro-Spotter terminal trucks have been 35 lb·ft...
  • Page 111 PRO-SPOTTER REAR AXLE TPS-121 Rear Drive Axle Clip (2 used) Washer (8 used) Lock Nut (4 used) Wheel (4 used) Pin (2 used) Lock Nut (4 used) Upper Plate (2 used) Brake Chamber (2 used) Nut (4 used) Link (2 used)

  • Page 112: Inspection

    REAR AXLE PRO-SPOTTER Inspection 7. Remove wheels (6). NOTE • Clean all parts of dirt and debris. • Check all threaded components for damaged or The rear drive axle may be removed with the brake stripped threads. Repair light damage with thread chambers (7) installed;...

  • Page 113: Rear Drive Axle Fluid Maintenance

    PRO-SPOTTER REAR AXLE REAR DRIVE AXLE FLUID Rear Drive Axle Fluid Filling MAINTENANCE See Figure 7-6. 1. Park and prepare tractor for service. (See “Park Rear Drive Axle Fluid Draining Tractor Safely” on page 1-3.) See Figure 7-5. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...
  • Page 114 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 115: Air System

    Installation ............. . . 8-7 Service Manual TICO Manufacturing...

  • Page 116: Introduction

    2. Monitor air pressure gauge. proper procedures for servicing pneumatic equipment on 3. Governor cutout should limit system air pressure to TICO Pro-Spotter terminal trucks. The air system is specification. made up of an air compressor, air dryer, and air tanks,...

  • Page 117: Pressure Buildup, Low-Pressure Warning Cutoff, And Governor Cutout Test

    PRO-SPOTTER AIR SYSTEM AIR DRYER Pressure Buildup, Low-Pressure Warning Cutoff, and Governor Cutout Removal Test See Figure 8-1. 1. Open reservoir drain valves and drain system. 1. Park and prepare tractor for service. (See “Park 2. Start engine and run at fast idle. Low-pressure Tractor Safely”...

  • Page 118: Inspection

    Air system schematics are used to aid in servicing and troubleshooting pneumatic equipment. These schematics my differ greatly depending on the optional equipment installed. To view the most accurate applicable system schematic, contact TICO support. (See “CONTACT TICO SUPPORT” on page 0-15.) AIR TANK Removal See Figures 8-2, 8-3, 8-4, and 8-5.

  • Page 119: Inspection

    PRO-SPOTTER AIR SYSTEM Inspection 6. Disconnect air lines (7 and 8). Close all openings using caps and plugs. • 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.

  • Page 120: Relieving Air System Pressure

    AIR SYSTEM PRO-SPOTTER RELIEVING AIR SYSTEM WET AIR TANK PRESSURE Removal See Figure 8-6. See Figures 8-7, 8-8, and 8-9. 1. Park and prepare tractor for service. (See “Park 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) Tractor Safely”...

  • Page 121: Inspection

    PRO-SPOTTER AIR SYSTEM 7. Disconnect air line (17). Close all openings using caps and plugs. 8. Using an appropriate lifting device, support wet air tank (16). 9. Remove cap screws (13 and 18), washers (14 and 19), lock nuts (15 and 20), lower bands (12), and wet air tank.
  • Page 122 PRO-SPOTTER Service Manual TICO Manufacturing...

  • Page 123: Abs/Atc System

    Installation ............. . . 9-7 Service Manual TICO Manufacturing...

  • Page 124: Introduction

    TICO Pro-Spotter terminal trucks. The electronic control unit provides both antilock braking and traction control functionality. The brake system is fed from the air system.

  • Page 125: Bobtail Proportioning Valve

    PRO-SPOTTER ABS/ATC SYSTEM BOBTAIL PROPORTIONING  CAUTION VALVE • Avoid personal injury from explosion. Air Removal system components may contain pressurized gases. Exposure to excessive heat may See Figure 9-2. cause components to explode. 1. Park and prepare tractor for service. (See “Park •...

  • Page 126: Front Modulator Valve (If Equipped)

    ABS/ATC SYSTEM PRO-SPOTTER FRONT MODULATOR VALVE (IF EQUIPPED) Removal See Figure 9-3. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)  CAUTION • Avoid personal injury from explosion. Air system components may contain pressurized gases.

  • Page 127: Front Quick Release Brake Valve

    PRO-SPOTTER ABS/ATC SYSTEM FRONT QUICK RELEASE BRAKE VALVE Removal See Figures 9-4 and 9-5. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)  CAUTION • Avoid personal injury from explosion. Air system components may contain pressurized gases.

  • Page 128: Rear Modulator Valve (If Equipped)

    ABS/ATC SYSTEM PRO-SPOTTER REAR MODULATOR VALVE (IF  CAUTION EQUIPPED) • Avoid personal injury from explosion. Air system components may contain pressurized Removal gases. Exposure to excessive heat may cause components to explode. See Figure 9-6. • Avoid personal injury from high-pressure 1.

  • Page 129: Rear Quick Release Brake Valve

    PRO-SPOTTER ABS/ATC SYSTEM REAR QUICK RELEASE BRAKE VALVE Removal See Figure 9-7. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)  CAUTION • Avoid personal injury from explosion. Air system components may contain pressurized gases.
  • Page 130 PRO-SPOTTER 10-0 Service Manual TICO Manufacturing...

  • Page 131: Chassis Lubrication System

    Installation ............. . 10-3 Service Manual 10-1 TICO Manufacturing...

  • Page 132: Introduction

    IMPORTANT with guidance on the proper procedures for servicing automatic lubrication systems on the TICO Pro-Spotter When exchanging a bucket of grease, ensure there are terminal trucks. no air pockets in the filler hose by making at least 3 The TICO Pro-Spotter terminal trucks have been strokes to circulate the grease.

  • Page 133: Inspection

    PRO-SPOTTER CHASSIS LUBRICATION SYSTEM TPS-035 Electrical Connector Magnetic Key Grommet (4 used) Digital Display Dust Cap Cap Screw (4 used) Backer Plate (2 used) Male Filler Coupler Lock Washer (4 used) Pump Element (24 used) Automatic Lubrication System Washer (4 used)
  • Page 134 PRO-SPOTTER 11-0 Service Manual TICO Manufacturing...

  • Page 135: Hydraulic System

    Installation ............. . 11-9 Service Manual 11-1 TICO Manufacturing...

  • Page 136: Introduction

    See Figure 11-1. replacing the various hydraulic components on the TICO 1. Park and prepare tractor for service. (See “Park Pro-Spotter terminal trucks. Tractor Safely” on page 1-3.)

  • Page 137: Directional Control Valve

    PRO-SPOTTER HYDRAULIC SYSTEM DIRECTIONAL CONTROL VALVE 5. Install identification tags and disconnect hydraulic lines (1—6). Close all openings using caps and plugs. Removal 6. Install identification tags and disconnect solenoid See Figure 11-2. (11) electrical connectors. 1. Park and prepare tractor for service. (See “Park 7.

  • Page 138: Hydraulic Filter Assembly

    HYDRAULIC SYSTEM PRO-SPOTTER HYDRAULIC FILTER ASSEMBLY 4. Position a suitable container below the hydraulic filter assembly (1). 5. Install identification tags and disconnect hydraulic Removal lines (3 and 4). Close all openings using caps and See Figure 11-3. plugs. 1. Park and prepare tractor for service. (See “Park 6.

  • Page 139: Hydraulic Fluid Maintenance

    PRO-SPOTTER HYDRAULIC SYSTEM HYDRAULIC FLUID Hydraulic Fluid Filling MAINTENANCE See Figure 11-5. 1. Park and prepare tractor for service. (See “Park Hydraulic Fluid Draining Tractor Safely” on page 1-3.) NOTE See Figure 11-4. 1. Park and prepare tractor for service. (See “Park Fifth wheel boom should be powered down to fully Tractor Safely”...

  • Page 140: Hydraulic Pump

    HYDRAULIC SYSTEM PRO-SPOTTER HYDRAULIC PUMP Installation Installation is the reverse of the removal procedure. Removal • Test boom and steering operation. See Figure 11-6. HYDRAULIC SYSTEM SHUT OFF 1. Park and prepare tractor for service. (See “Park VALVES Tractor Safely” on page 1-3.) 2.

  • Page 141: Hydraulic System Troubleshooting

    PRO-SPOTTER HYDRAULIC SYSTEM HYDRAULIC SYSTEM TROUBLESHOOTING ADDITIONAL SYMPTOM POSSIBLE CAUSE SUGGESTED SOLUTION INFORMATION Hydraulic pump Hydraulic oil level is low Fill reservoir with proper oil See “CHECK FLUID LEVEL” excessively noisy to specified level. on page 11-2 or see “Hydraulic Fluid Filling”...

  • Page 142: Hydraulic Tank

    HYDRAULIC SYSTEM PRO-SPOTTER ADDITIONAL SYMPTOM POSSIBLE CAUSE SUGGESTED SOLUTION INFORMATION Hydraulic oil Suction leak between Inspect and tighten all foamy reservoir and pump connections and lines. Repair or replace any defective components. Hydraulic oil level is low Fill hydraulic tank with See “CHECK FLUID LEVEL”...

  • Page 143: Inspection

    PRO-SPOTTER HYDRAULIC SYSTEM 9. Install identification tags and disconnect hydraulic lines (20 and 21). Close all openings using caps and plugs.  CAUTION Prevent possible crushing injury from heavy component. Use appropriate lifting device. 10. Using an appropriate lifting device, support hydraulic tank (11).
  • Page 144 PRO-SPOTTER 12-0 Service Manual TICO Manufacturing...

  • Page 145: Boom And Fifth Wheel

    Installation ............. . 12-9 Service Manual 12-1 TICO Manufacturing...

  • Page 146: Introduction

    See Figures 12-1 and 12-2. fifth wheel systems on the TICO Pro-Spotter terminal 1. Park and prepare tractor for service. (See “Park trucks.

  • Page 147: Inspection

    PRO-SPOTTER BOOM AND FIFTH WHEEL Inspection  CAUTION • Check all welds for cracks and have any cracks Prevent possible crushing injury from heavy welded. component. Use appropriate lifting device. • Check boom pin (20) for excessive wear. Replace pins found unserviceable.

  • Page 148: Boom Cylinders

    BOOM AND FIFTH WHEEL PRO-SPOTTER BOOM CYLINDERS Removal See Figures 12-3 and 12-4. 1. Raise boom approximately 15.2 cm (6 in). 2. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) 3. Remove boom grate and boom heat shield covers.

  • Page 149: Fifth Wheel Maintenance

    PRO-SPOTTER BOOM AND FIFTH WHEEL FIFTH WHEEL MAINTENANCE 3. Use the lock tester to couple and uncouple the fifth wheel 3 times to help “seat” the yoke. Adjustment See Figures 12-5, 12-6, and 12-7. Fifth wheel adjustments should be performed at a...

  • Page 150: Lubrication

    BOOM AND FIFTH WHEEL PRO-SPOTTER Lubrication Contact Surface See Figure 12-9. Air Cylinder See Figure 12-8. TPS-025 Lubrication Surface (as TPS-028 necessary) Figure 12-9: Fifth Wheel Lubrication Surface Air Cylinder Tube Supply Fitting Piston Shaft 1. Park and prepare tractor for service. (See “Park Figure 12-8: Air Cylinder Tractor Safely”...

  • Page 151: Fifth Wheel Top Plate

    PRO-SPOTTER BOOM AND FIFTH WHEEL Locking Mechanism See Figure 12-10. TPS-027 Yoke Tip (2 used) Secondary Lock Cam Pivot Point Fifth Wheel Top Plate Cam Profile Release Handle Air Cylinder Tube Lubrication Surface (as necessary) Yoke Shaft Lock Jaw (2 used)

  • Page 152: Fifth Wheel Top Plate

    BOOM AND FIFTH WHEEL PRO-SPOTTER FIFTH WHEEL TOP PLATE  CAUTION Removal Prevent possible crushing injury from heavy component. Use appropriate lifting device. See Figures 12-11 and 12-12. 1. Park and prepare tractor for service. (See “Park 6. Using an appropriate lifting device, remove the top Tractor Safely”...

  • Page 153: Installation

    PRO-SPOTTER BOOM AND FIFTH WHEEL Specification Top Plate Vertical Movement— 12.7 mm Distance (maximum) 0.5 in c. Pocket inserts are severely chipped, cracked, or gouged. Installation See Figures 12-14 and 12-15. TPS-029 Fifth Wheel Top Plate Bracket Pin (2 used)
  • Page 154 PRO-SPOTTER 13-0 Service Manual TICO Manufacturing...

  • Page 155: Cab

    Kit Installation ............13-15 Service Manual 13-1 TICO Manufacturing...
  • Page 156 PRO-SPOTTER WIPER MOTOR ............. . 13-16 Removal .

  • Page 157: Introduction

    NOTE TICO Pro-Spotter terminal trucks. The TICO Pro-Spotter terminal trucks have been Procedure is written for the right side cab latch. Left side engineered for quick and efficient servicing while cab latch procedure is similar.

  • Page 158: Removal

    PRO-SPOTTER Removal See Figures 13-3, 13-4, 13-5, and 13-6. NOTE Removal of the left side cab air shock is shown. Right side cab air shock procedure is similar. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)

  • Page 159: Inspection

    PRO-SPOTTER TPS-152 Housing Cab Air Bag Striker Lock Nut (2 used) Cab Air Bag Figure 13-5: Cab Air Bag Striker 9. Remove lock nuts (15) and cab air bag striker (16) from cab air bag (17). TPS-151 Air Line Linkage...

  • Page 160: Cab Door Air Pressure Adjustment

    PRO-SPOTTER CAB DOOR AIR PRESSURE ADJUSTMENT See Figures 13-7 and 13-8. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-181 Air Pressure Gauge Air Regulator Valve Adjustment Knob Figure 13-8: Air Regulator Valve 3. Read air pressure gauge (5) and determine if adjustment is necessary.

  • Page 161: Cab Latch

    PRO-SPOTTER CAB LATCH Adjustment See Figures 13-9 and 13-10. NOTE Procedure is written for the left side cab latch. Right side cab latch procedure is similar. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)

  • Page 162: Removal

    PRO-SPOTTER Removal See Figures 13-11 and 13-12. NOTE Procedure is written for the left side cab latch. Right side cab latch procedure is similar. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-149 Hydraulic Line...

  • Page 163: Cab Leveling Valve

    PRO-SPOTTER CAB LEVELING VALVE Adjustment See Figures 13-13 and 13-14. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-148 Cab Leveling Valve Lock Nut (2 used) Figure 13-14: Adjusting Cab Leveling Valve 4. Loosen lock nuts (12).

  • Page 164: Removal

    PRO-SPOTTER Removal See Figures 13-15 and 13-16. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-147 Cab Leveling Valve Air Line Linkage Air Line Washer (2 used) Air Line Lock Nut (2 used) Figure 13-16: Cab Leveling Valve 4.

  • Page 165: Cab Tilt Cylinder

    PRO-SPOTTER CAB TILT CYLINDER Removal See Figures 13-17 and 13-18. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-084 TPS-083 Cab Tilt Cylinder Cab Tilt Pump-to-Cab Tilt Cylinder Hydraulic Line Detent Position 1 (full open)

  • Page 166: Inspection

    PRO-SPOTTER Inspection 7. Remove cab tilt pump if necessary. (See “CAB TILT PUMP” on page 13-13.) • Clean all parts of dirt and debris. 8. Drain cab tilt hydraulic fluid from cab tilt pump • Inspect hydraulic hoses, fittings, and clamps for reservoir.

  • Page 167: Cab Tilt Pump

    PRO-SPOTTER CAB TILT PUMP CHECK FLUID LEVEL Removal Cab Tilt Hydraulic Fluid See Figure 13-21. See Figure 13-22. 1. Park and prepare tractor for service. (See “Park 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) Tractor Safely”...

  • Page 168: Trainer Seat

    PRO-SPOTTER TRAINER SEAT Removal See Figures 13-23 and 13-24. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) 2. Fold trainer seat (9) up into storage position. TPS-170 Trainer Seat Washer (10 used) Cap Screw (5 used)

  • Page 169: Kit Installation

    PRO-SPOTTER Kit Installation See Figures 13-25, 13-26, 13-27, and 13-28. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.) TPS-173 Cap Screw Mounting Location (6 used) Figure 13-27: Cap Screw Mounting Locations 4. Remove floor mat to reveal floor cap screw mounting locations (19).

  • Page 170: Wiper Motor

    PRO-SPOTTER WIPER MOTOR Inspection • Clean all parts of dirt and debris. Removal • Inspect washer hoses, fittings, and clamps for leaks, holes, cracks, and loose connections. Replace parts See Figures 13-29 and 13-30. found to be unserviceable. 1. Park and prepare tractor for service. (See “Park •...

  • Page 171: Covers And Guards

    Installation ............. 14-13 Service Manual 14-1 TICO Manufacturing...

  • Page 172: Introduction

    The purpose of the COVERS AND GUARDS section is to provide service and maintenance personnel with guidance on the proper procedures for removing and replacing the various protective covers on the TICO Pro-Spotter terminal trucks. The TICO Pro-Spotter terminal trucks have been engineered for quick and efficient servicing while minimizing downtime.

  • Page 173: Front Covers And Guards

    PRO-SPOTTER COVERS AND GUARDS FRONT COVERS AND GUARDS Removal See Figures 14-1, 14-2, 14-3, and 14-4. TPS-108 Screw (14 used) Front Right Cover Washer (24 used) Radiator Guard Front Left Cover Bumper Nut (12 used) Screw (14 used) Cap Screw (12 used)

  • Page 174: Inspection

    COVERS AND GUARDS PRO-SPOTTER TPS-053 Cap Screw (5 used) Lock Nut (5 used) Washer (10 used) Brush Guard Figure 14-2: Brush Guard TPS-139 6. Remove cap screws (9), washers (10), lock nuts (11), Engine Block Heater Connector Release Button and brush guard (12).

  • Page 175: Grates And Covers

    PRO-SPOTTER COVERS AND GUARDS GRATES AND COVERS NOTE While the D.O.T. and Off-Road tractor covers are Removal different, the procedures are similar. See Figures 14-5, 14-6, 14-7, 14-8, 14-9, and 14-10. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...
  • Page 176 COVERS AND GUARDS PRO-SPOTTER 4. Raise the cab. TPS-144 Entry Tread Plate Washer (8 used) Cap Screw (4 used) Lock Nut (4 used) Figure 14-7: Entry Tread Plate 5. Remove cap screws (11), washers (14), lock nuts (15), and entry tread plate (2).

  • Page 177: Inspection

    PRO-SPOTTER COVERS AND GUARDS Inspection 1. Check all threaded components for damaged or stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. Installation Installation is the reverse of the removal procedure. TPS-109 Top Fuel Tank Grate...

  • Page 178: Left Covers And Guards

    COVERS AND GUARDS PRO-SPOTTER LEFT COVERS AND GUARDS NOTE While the D.O.T. and Off-Road tractor covers are Removal different, the procedures are similar. See Figures 14-11, 14-12, 14-13, 14-14, 14-15, and 1. Park and prepare tractor for service. (See “Park 14-16.
  • Page 179 PRO-SPOTTER COVERS AND GUARDS TPS-124 Cab Lift Pump Cover Washer (2 used) Cap Screw (2 used) Figure 14-13: Cab Lift Pump TPS-110 3. Remove cap screws (22), washers (23), and cab lift pump cover (2). Diesel Exhaust Fluid (DEF) Washer (4 used)

  • Page 180: Inspection

    COVERS AND GUARDS PRO-SPOTTER 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 found to be unserviceable. Installation Installation is the reverse of the removal procedure.

  • Page 181: Removal

    PRO-SPOTTER COVERS AND GUARDS RIGHT COVERS AND GUARDS NOTE While the D.O.T. and Off-Road tractor covers are Removal different, the procedures are similar. See Figures 14-17, 14-18, 14-19, and 14-20. 1. Park and prepare tractor for service. (See “Park Tractor Safely” on page 1-3.)
  • Page 182 COVERS AND GUARDS PRO-SPOTTER TPS-167 Lower Aftertreatment Washer (8 used) Washer (6 used) Washer (5 used) Cover Intermediate Lock Nut (4 used) Lock Nut (3 used) Lock Nut (5 used) Aftertreatment Cover Upper Aftertreatment Plate Rear Heat Shield Mud Guard...

  • Page 183: Inspection

    PRO-SPOTTER COVERS AND GUARDS Inspection 1. Check all threaded components for damaged or stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. Installation Installation is the reverse of the removal procedure. TPS-127 Mud Flap (2 used)
  • Page 184 PRO-SPOTTER 15-0 Service Manual TICO Manufacturing...

  • Page 185: Heating And Air Conditioning

    Installation ............. 15-16 Service Manual 15-1 TICO Manufacturing...
  • Page 186 HEATING AND AIR CONDITIONING PRO-SPOTTER HEATER CORE ............. . 15-17 Removal .

  • Page 187: Introduction

    The purpose of the HEATING AND AIR CONDITIONING REFRIGERANT section is to provide service and maintenance personnel with guidance on the proper procedures for servicing heating and air conditioning systems on the TICO  CAUTION Pro-Spotter terminal trucks. The TICO Pro-Spotter terminal trucks have been Prevent refrigerant from contacting eyes or skin.

  • Page 188: R134A Refrigerant Hoses And Tubing

    HEATING AND AIR CONDITIONING PRO-SPOTTER R134a REFRIGERANT HOSES R134a REFRIGERANT OIL AND TUBING INFORMATION Inspection Removal IMPORTANT  CAUTION Air conditioning system hoses contain special Prevent refrigerant from contacting eyes or skin. barriers in the walls which prevent migration of Refrigerant will freeze eyes or skin on contact.

  • Page 189: Inspection

    PRO-SPOTTER HEATING AND AIR CONDITIONING R134a REFRIGERANT LEAK Inspection TEST 1. Check all threaded components for damaged or stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. Inspection 2. Check condition of air conditioning system lines and tubing.

  • Page 190: R134A Refrigerant Recovery, Recycling, And Recharging Station

    HEATING AND AIR CONDITIONING PRO-SPOTTER R134a REFRIGERANT  CAUTION RECOVERY, RECYCLING, AND Avoid possible injury from air conditioning RECHARGING STATION system refrigerant. Do not remove high-pressure relief valve. Air conditioning system will Installation discharge rapidly. See Figure 15-1. IMPORTANT Prevent possible air conditioning system damage.

  • Page 191: Recover R134A Refrigerant

    PRO-SPOTTER HEATING AND AIR CONDITIONING Recover R134a Refrigerant Evacuate R134a System   CAUTION CAUTION Prevent refrigerant from contacting eyes or skin. Prevent refrigerant from contacting eyes or skin. Refrigerant will freeze eyes or skin on contact. Refrigerant will freeze eyes or skin on contact.

  • Page 192: Recharge R134A System

    HEATING AND AIR CONDITIONING PRO-SPOTTER Recharge R134a System Specifications  Vacuum—Pressure at Sea Level 98 kPa CAUTION 980 mbar Prevent refrigerant from contacting eyes or skin. 29 in Hg Refrigerant will freeze eyes or skin on contact. Pressure Above Sea Level Subtract 3.4...

  • Page 193: Flush And Purge Air Conditioning System

    PRO-SPOTTER HEATING AND AIR CONDITIONING Specification NOTE A new receiver/dryer must be installed anytime the air Air Conditioning System 1.12—1.37 kg conditioning system is discharged. Refrigerant Charge Weight 2.48—3.03 lb 5. Remove and discard receiver/dryer. (See “RECEIVER/DRYER” on page 15-19.) 7.

  • Page 194: Evaporator Flush And Purge

    HEATING AND AIR CONDITIONING PRO-SPOTTER AIR CONDITIONER 5. Test for cooling system flushing solvent. Hold hose close to a piece of cardboard; continue purging until COMPRESSOR cardboard is dry. 6. Dispose of cooling system flushing solvent properly. Removal Evaporator Flush and Purge See Figures 15-2 and 15-3.

  • Page 195: Inspection

    PRO-SPOTTER HEATING AND AIR CONDITIONING Inspection 1. Check all threaded components for damaged or stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. 2. Check condition of air conditioning system lines and tubing. (See “R134a REFRIGERANT HOSES AND TUBING”...

  • Page 196: Blower Motor

    HEATING AND AIR CONDITIONING PRO-SPOTTER BLOWER MOTOR 4. Remove cap screws (4 and 5). Remove interior covers (7 and 8) as an assembly. Removal See Figures 15-4, 15-5, 15-6, 15-7, 15-8, and 15-10. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...

  • Page 197: Inspection

    PRO-SPOTTER HEATING AND AIR CONDITIONING 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 found to be unserviceable. Installation Installation is the reverse of the removal procedure.

  • Page 198: Condenser

    HEATING AND AIR CONDITIONING PRO-SPOTTER CONDENSER Inspection • Clean all parts of dirt and debris. Removal • Check all threaded components for damaged or stripped threads. Repair light damage with thread See Figure 15-10. chasers. Replace parts found to be unserviceable.

  • Page 199: Evaporator

    PRO-SPOTTER HEATING AND AIR CONDITIONING EVAPORATOR 5. Remove cap screws (4 and 5). Remove interior covers (7 and 8) as an assembly. Removal See Figures 15-11, 15-12, 15-13, 15-14, 15-15, 15-16, and 15-17. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...

  • Page 200: Inspection

    HEATING AND AIR CONDITIONING PRO-SPOTTER TPS-134 TPS-133 Evaporator Refrigerant Line Blower Motor Cover Electrical Connector Cap Screw (2 used) Refrigerant Line Electrical Connector Blower Motor Plate Figure 15-15: Blower Motor Figure 15-17: Evaporator 11. Install identification tags and disconnect electrical 15.

  • Page 201: Heater Core

    PRO-SPOTTER HEATING AND AIR CONDITIONING HEATER CORE 5. Remove cap screws (4 and 5). Remove interior covers (7 and 8) as an assembly. Removal See Figures 15-18, 15-19, 15-20, 15-21, 15-22, 15-23, and 15-24. 1. Park and prepare tractor for service. (See “Park Tractor Safely”...

  • Page 202: Inspection

    HEATING AND AIR CONDITIONING PRO-SPOTTER TPS-134 TPS-133 Cap Screw (2 used) Coolant Line Blower Motor Cover Electrical Connector Plate Heater Core Electrical Connector Blower Motor Coolant Line Figure 15-22: Blower Motor Figure 15-24: Heater Core 11. Install identification tags and disconnect electrical 15.

  • Page 203: Receiver/Dryer

    PRO-SPOTTER HEATING AND AIR CONDITIONING RECEIVER/DRYER Inspection 1. Check all threaded components for damaged or Removal stripped threads. Repair light damage with thread chasers. Replace parts found to be unserviceable. See Figure 15-25. 2. Check condition of air conditioning system lines and NOTE tubing.
  • Page 204 PRO-SPOTTER IDX-0 Service Manual TICO Manufacturing...
  • Page 205 PRO-SPOTTER INDEX Numerics Air Brake System Tests Air System Leak Down Test ... . . Air System Maximum Pressure Test ..3—Electrical System Low Air Buzzer and Light Test ...
  • Page 206 Installation ......9-3 Contact TICO Support ....0-15 Removal .
  • Page 207 PRO-SPOTTER INDEX Flush and Purge Air Conditioning System Air Conditioner Compressor Cleaning ..15-9 Condenser Flush and Purge ... . 15-9 Electrical Components Evaporator Flush and Purge ... .
  • Page 208 INDEX PRO-SPOTTER General Information Inspection Nomentclature ......1-7 Air Conditioner Compressor ... 15-11 Air Dryer .
  • Page 209 PRO-SPOTTER INDEX Installation Lifting Equipment Air Conditioner Compressor ... . 15-11 Safety ......
  • Page 210 INDEX PRO-SPOTTER R134a Refrigerant Recovery, Recycling, and Removal ......11-3 Recharging Station Air Conditioner Compressor .
  • Page 211 PRO-SPOTTER INDEX Tire Pressure ......2-11 Tires Safety Service Safety ......

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