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ASSEMBLY INSTRUCTION

AC-AI-365-0804-P62R02

JUNE 2008AI 3-129-001

Questions? Visit the Autocar website atwww.autocartruck.com and click the Web-Link Direct icon to request emergency service assistance.

ATTENTION: SERVICE MANAGERS / PARTS MANAGERS

SUBJECT: INSTALLATION OF A MANUAL REGENERATION SWITCH FOR THE DIESEL PARTICULATE FILTER (DPF)

DATE: 23 JUNE 2008

Service Bulletin InformationService bulletins are product modifications and/or product improvements that Autocar has determined will enhance the reliability of the vehicle.

This bulletin provides information regarding the installation of a switch to manually initiate a regeneration cycle for vehicles equipped with DPFs, as part of the 2007 EPA-mandated emissions system. It has been brought to Autocar’s attention that in some cases, the driving conditions encountered on a refuse collection route may not generate enough exhaust heat to initiate a passive regeneration cycle of the DPF. This service bulletin provides instruction in installing a switch which the vehicle’s operator may use to manually initiate a parked regeneration cycle.

RepairIf the duty cycle of the vehicle is not sufficient to initiate a passive regeneration cycle of the DPF, install the manual regeneration switch as described in the REPAIR PROCEDURE, beginning on page 2.

PartsSet forth below are the parts to install one manual regeneration switch:

Part number and description QuantityS1290024-002 (DPF wire harness) ........................1GZ120002-012 (Switch) .........................................1GZ120005-035 (Actuator) ......................................1

ToolsThe following tools are required to perform this service bulletin:

• 4mm Allen wrench • Diagonal cutters • (2) Switch blank removal tool (GZ120003-004) • Laptop computer with Cummins Insite (version 7.1) and appropriate cables

Continuous Product ImprovementAutocar strives to continually evaluate and improve our trucks’ performance in the field. It is our goal that every truck performs to the high standards by which Autocar trucks are built. Autocar is committed to continuous product improvement but has no legal obligation to update existing chassis or bear the cost of any updates after a vehicle has been placed in service, outside of its limited warranty.

LOCKOUT/TAGOUT PROCEDURES

Before entering the vehicle or vehicle body, read and follow OSHA regulations concerning entry and working in “CONFINED SPACE” OSHA 1910.146 and “LOCKOUT/TAGOUT” OSHA 1910.147.

Follow OSHA regulations while performing any work on the vehicle.

The vehicle must be disabled by the following steps before performing any work on the vehicle:

1. Place the transmission in PARK.2. Set the parking brake.3. Shut the engine OFF.4. Turn the battery disconnect switch OFF.5. Lock cab doors, keep the key in your pocket,

and block the wheels before entering the body or performing any work on the vehicle.

6. Place magnetic “DANGER” signs on both cab doors before entering the body or performing any work on the vehicle.

2 of 4

ASSEMBLY INSTRUCTION

JUNE 2008AI 3-129-001

AC-AI-365-0804-P62R02

Questions? Visit the Autocar website atwww.autocartruck.com and click the Web Link-Direct

icon to request emergency service assistance.

WARNINGTo prevent eye injury, always wear eye

protection when performing vehicle maintenance, service, or inspection.

SAFETY NOTICES

DANGERBefore working on a vehicle, turn the engine to off,

set the parking brake, place the transmission in park, and block the wheels. Failure to do so can result in unexpected vehicle movement, resulting

in serious personal injury or death.

REPAIR PROCEDURE

STEP 1: Route the DPF switch harness through the cab pass-through, located in the left-side floor board. The DPF switch harness must be routed so the bare wire end and small wire connector are outside of the cab; the large wire connector will remain inside the cab.

STEP 2: Raise the cab

• Remove or secure all loose articles and close all doors before raising the cab. The area above and ahead of the cab must be clear from obstructions. Place front wheels in a straight ahead position.

• Remove the pump handle from its storage on the inside wall of the driver or passenger side door.

WARNINGDue to the danger of sustaining personal injury and/or damage to the vehicle, never attempt to raise the cab outdoors under extremely windy conditions. The strong wind conditions could

force the cab beyond the normal limits of its travel.

• Place the selector lever on the hydraulic pump in the RAISE position. Insert the pump handle into the pump and operate the handle in an up and down motion. The hydraulic cab latches will open, then the hydraulic cylinders will lift the cab until the midpoint (top) is reached.

• Once the cab has reached its midpoint, the cab will free fall forward to the fully open position. The safety pin in the cab tilt lock device must be installed when the holes line up in the sliding bar.

STEP 3: Using a 4mm Allen wrench, remove the engine electronic control unit (ECU) wire connector from the engine ECU.

STEP 4: Open the ECU wire harness connector and remove the orange plug from cavity 20 (ISC/ISL) or cavity 2 (ISM) (Figure 1). Insert wire 574 (as labeled in the DPF switch harness) into location 20 of the ECU connector (Figure 2).

DANGERNever rely on the hydraulic pressure to hold the

cab in an open position. Always use the safety pin in the cab tilt lock tube to prevent serious personal

injury or death.

CAUTIONRemove the pump handle when not in use. It may

stick out and could cause injury to passersby.

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ASSEMBLY INSTRUCTION

AC-AI-365-0804-P62R02

JUNE 2008AI 3-129-001

Questions? Visit the Autocar website atwww.autocartruck.com and click the Web-Link Direct icon to request emergency service assistance.

STEP 5: Using a 4mm Allen wrench, reinstall the ECU wire connector on the engine ECU.

STEP 6: Locate the remote throttle 2-pin connector, which is approximately 8 to 10 inches from the ECU connector on the main engine harness (Figure 3). Remove and discard the cap on the remote throttle pin connector. Connect the 2-pin plug on the DPF switch harness kit to the remote throttle 2-pin connector.

NOTE: The 2-pin plug on the DPF switch harness is shown already connected to the remote throttle 2-pin connector on the main engine harness.

STEP 7: Lower the cab

• Remove the safety pin in the sliding cab tilt lock bar. Place the selector lever on the hydraulic pump to the LOWER position.

• Insert the pump handle into the pump and operate the handle in an up and down motion. The hydraulic cylinders then lower the cab until the midpoint (top) is reached.

• Once the cab has reached its midpoint, stop pumping and the cab will free fall rearward to the fully lowered position. When the cab is lowered, the hydraulic cab latches will automatically close, securing the cab to the frame.

STEP 8: Secure the DPF switch harness along the main vehicle wiring harness to the pass-through in floor in the left side of the cab, taking up the slack in the DPF switch harness. Secure the DPF switch harness to the vehicle’s main wiring harness with zip ties and trim the excess length.

Figure 1

Figure 2

Figure 3

CAUTIONRemove the pump handle when not in use. It may

stick out and could cause injury to passersby.

4 of 4

ASSEMBLY INSTRUCTION

JUNE 2008AI 3-129-001

AC-AI-365-0804-P62R02

Questions? Visit the Autocar website atwww.autocartruck.com and click the Web Link-Direct

icon to request emergency service assistance.

STEP 9: Route the DPF switch harness along the main harness under the dashboard, and to a vacant switch location in the center switch console. Using the blank removal tool (GZ120003-004), remove a switch blank from the dashboard and install the DPF switch (Figure 4). Fasten the DPF switch harness underneath the dashboard with zip ties and trim the excess length.

STEP 10: Power-up the laptop computer, and start the Cummins Insite software.

STEP 11: Using the appropriate cables, connect the laptop computer to the 9-pin diagnostic port, located under the dashboard.

STEP 12: Using the Cummins Insite software, configure the engine ECU to recognize the DPF manual regeneration switch:

• Access the Features and parameters. • Select the Aftertreatment option. • Select the Diesel particulate filter regen start

switch option. • Select the Enable option. • Save the configuration change, as prompted

by the Insite software.

• Access the Data monitor. • Select the Switches option. • The value will be OFF. • Depress and hold the DPF regeneration

switch (hold for 2 seconds) - the value will be displayed as ON.

• Release the DPF regeneration start switch - the value will be displayed as OFF.

• By observation of the value change from ON to OFF, the correct operation of the switch has been verified. If the value does not change to ON when the switch is depressed and held (hold for 2 seconds), recheck all wire harness connections and repeat Step 12.

STEP 13: Disconnect the laptop computer from the engine ECU.

This completes the installation and programming for the manually-initiated DPF regeneration switch. Please direct all questions regarding this service bulletin to: info@autocartruck.com or call the service hotline at 877-973-3486 (extension 6062).Figure 4

NOTICEBefore depressing the DPF manual regeneration

switch, check to ensure that there are no obstructions in the path of the exhaust gas. During a DPF regeneration cycle, increased

exhaust gas temperature may cause a fire hazard if the vehicle is parked so that the exhaust

discharge is directed against trees, brush, or other flammable objects.