13041055&3

TICO Manufacturing 1/30/2018

4 &37*$&
."/6"-
TICO Manufacturing Service Manual
Pro-Spotter Service Manual TICO Manufacturing
 Table of Contents

0 TICO PRO-SPOTTER SERVICE INFORMATION

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Determination of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Standard Warranty 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—ABS/ATC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
11—Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
12—Boom and Fifth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
13—Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
14—Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12
15—Heating 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 Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Park Tractor Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Support Tractor Securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Use Compressed Air and 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 Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

TICO Manufacturing Repair Manual TOC-1

TABLE OF CONTENTS PRO-SPOTTER

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fastener Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tightening Sequences and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Certification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Transmission Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Fifth Wheel Serial Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

2 PREVENTATIVE MAINTENANCE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
DIESEL EXHAUST FLUID (DEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3 ELECTRICAL SYSTEM
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Solenoid Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Relay Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
FUSE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
POWER DISTRIBUTION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
VEHICLE ELECTRICAL CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

TOC-2 Service Manual TICO Manufacturing

PRO-SPOTTER TABLE OF CONTENTS

WIRING DIAGRAMS AND SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4 ENGINE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
DRAINING FUEL/WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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5 TRANSMISSION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
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 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transmission Fluid Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transmission Fluid 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
FRONT END ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
STEERING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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PRO-SPOTTER TABLE OF CONTENTS

STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
TIE ROD BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

7 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 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 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 TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
BRAKE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
RELIEVING AIR SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
WET AIR TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

9 ABS/ATC SYSTEM
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

TICO Manufacturing Service Manual TOC-5

TABLE OF CONTENTS PRO-SPOTTER

ANTILOCK BRAKE SYSTEM (ABS) CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
BOBTAIL 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
REAR MODULATOR VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Filling the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

11 HYDRAULIC SYSTEM
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
DIRECTIONAL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

TOC-6 Service Manual TICO Manufacturing

PRO-SPOTTER TABLE OF CONTENTS

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
HYDRAULIC SYSTEM SHUT OFF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

12 BOOM AND FIFTH WHEEL

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
FIFTH WHEEL TOP PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

13 CAB
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
CAB AIR BAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
CAB DOOR AIR PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CAB LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
CAB LEVELING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10

TICO Manufacturing Service Manual TOC-7

TABLE OF CONTENTS PRO-SPOTTER

CAB TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
CAB TILT HYDRAULIC FLUID MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Cab Tilt Hydraulic Fluid Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Cab Tilt Hydraulic Fluid Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
CAB TILT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Cab Tilt Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
TRAINER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
RIGHT COVERS AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13

15 HEATING AND AIR CONDITIONING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
CAUTIONS AND PROPER HANDLING OF R134a REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . 15-3
R134a REFRIGERANT HOSES AND TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

TOC-8 Service Manual TICO Manufacturing

PRO-SPOTTER TABLE OF CONTENTS

R134a REFRIGERANT OIL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
R134a REFRIGERANT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
R134a REFRIGERANT RECOVERY, RECYCLING, AND RECHARGING STATION . . . . . . . . . 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 Compressor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Condenser Flush and Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Evaporator Flush and Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Procedure Wrap-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
RECEIVER/DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19

TICO Manufacturing Service Manual TOC-9

 PRO-SPOTTER

0-0 Service Manual TICO Manufacturing

 Section 0
TICO PRO-SPOTTER SERVICE INFORMATION

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Determination of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Standard Warranty 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—ABS/ATC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
11—Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
12—Boom and Fifth Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
13—Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
14—Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12
15—Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13
CONTACT TICO SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15

TICO Manufacturing Service Manual 0-1

TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

INTRODUCTION WARRANTY
This TICO Pro-Spotter service manual provides service
and maintenance personnel with guidance on the proper NOTE
procedures for servicing, troubleshooting, maintenance Warranty information provided is effective January 1,
and repair of the TICO Pro-Spotter off-road and 2018. Tractors delivered prior to January 1, 2018 are
DOT/EPA on-road terminal tractors. For best subject to previous warranty terms.
performance and longer vehicle life, follow the For additional information, please contact TICO factory
maintenance procedures provided in this manual. support. (See “Contact TICO Support” on page 0-15.)
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
resources are found in this section: from defects in material and workmanship under normal
• TICO Pro-Spotter warranty (as of January 1, 2018) use and service for a period not to exceed 2 years or
• 2018 Flat rate guideline 6000 hours, whichever occurs first, from commencement
• TICO technical support contact information of service. For 2 years or 6000 hours both parts and labor
will be warranted.
The TICO Pro-Spotter terminal trucks have been
engineered for quick and efficient servicing, while TICO has developed a comprehensive warranty policy
minimizing down time. and warranty system. Our goal is to establish policies
that will enable consistent, prompt and equitable
For additional information, please contact TICO factory processing of warranty requests.
support. (See “CONTACT TICO SUPPORT” on
page 0-15.) The TICO warranty policy and system will enable our
distributors to “know where they stand” in most warranty
NOTES repair situations. This will enable the distributor to classify
whether or not a service repair really is warrantable. The
• The information within this publication is current as of
distributor can then deal with the customer more
the time of publication. Information within this manual
effectively. We at TICO want to make justified warranty
is subject to change at publisher’s discretion and
claim a prompt, consistent and equitable experience for
without notification.
our mutual customers. It is vital that the warranty
• TICO offers many different equipment options. Some registration be completed via registration online and PDI
options may not be covered within this manual. completed and returned to TICO immediately following
Contact your nearest TICO dealer if there are any delivery of vehicle to the customer. This triggers the
questions. warranty in our system, enabling the claim to be
• Do not make modifications to your tractor without processed. Completion of the warranty registration is
written approval from TICO Manufacturing. Your also required by the National Highway Transportation
vehicle has been designed and manufactured with Safety Administration for DOT compliant vehicles in the
safety and reliability in mind. Any modifications by event contact with user is required. Please consider each
the operator or owner could decrease the safety and claim on its own merits, remembering that this is directly
reliability of your vehicle. Any unauthorized vehicle proportionate to your future ability to provide a quality
modifications may also void the TICO Manufacturing product at a reasonable price. We recommend that all
Limited Warranty. Do not risk personal safety or people who deal with warranty service and administration
vehicle reliability by making unauthorized become familiar with the procedures contained in this
modifications to your TICO tractor. Contact TICO manual. TICO reserves the right to, at any time, change
concerning any proposed modifications to this or revise the provisions of its warranty procedures,
vehicle. effective on or after notification of authorized distributors.
All provisions of this manual are effective immediately.
PLEASE MAKE SURE THAT YOUR WARRANTY
REGISTRATION AND PDI IS COMPLETED AND
RETURNED TO TICO.

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PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

Introduction TICO will pay for the costs of correcting

defects as follows:
I. DETERMINATION OF WARRANTABLE a. For defects in material or workmanship during the
SERVICE first twenty-four months from the date of delivery or
The question as to whether a repair or replacement is the first 6,000 hours, whichever comes first, both
actually a warrantable adjustment is documented in this parts and labor are at TICO’s expense.
section to help you make that decision. All warranty All warranty work is subject to TICO’s prior
claims must be filed within the warranty period of examination and approval and will be performed by
twenty-four (24) months or 6,000 hours and within thirty TICO or at service centers designated by TICO. All
(30) days of the repair. The claim will not be honored it if transportation to and from designated service center
does not meet this criteria. will be at the purchaser’s expense and is not included
as a cost of repair covered by this warranty. These
II. DETERMINING WARRANTY remedies are the purchaser’s exclusive remedies for
RESPONSIBILITY breach of warranty.
A. Has this complaint originated during the stated
warranty period? Standard Warranty Policy
B. Is the malfunction a result of abuse or misuses?
C. Has the unit been maintained properly? What is Not Covered by This Warranty.
D. If the complaint has originated during the warranty TICO does not warrant engines, transmissions, tires,
period, there is no evidence of abuse or misuse and batteries or any other component which has a warranty
the unit has had proper maintenance, the distributor covered by its manufacturer. In addition, TICO does not
should proceed to file a warranty claim. This does warrant (a) damage caused by use of the truck for
not, however, ensure that the claim be approved. purposes other than those for which it was designed; (b)
damage caused by accident or the negligence of the
E. Is warranty registration on file?
purchaser or any third party or by disasters such as fire,
flood, wind and lightning; (c) damage caused by the
Determination of Warranty purchaser’s failure to provide normal maintenance as
customarily accepted in the industry or as set forth in the
What is Covered by This Warranty. maintenance guidelines; (d) filters, belts, brake linings,
TICO warrants, to the original purchaser only, that the lights, breakers, and lubricants which are part of normal
truck that is the subject of this sale is free from defects in maintenance service requirements; (e) damage caused
material and workmanship. The duration of this warranty by unauthorized or improper installation of attachments,
is as follows: repairs, modifications or alterations; (f) damage caused
by replacement of original parts or components with
a. Frames - As to the main structural frame, seven
unauthorized substitutes; (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
compartment, five years from the date of delivery. Disclaimer of Warranty.
c. As to all other parts and components, one year THE FOREGOING WARRANTIES ARE IN LIEU OF ALL
from date of delivery or 6,000 hours of use, OTHER WARRANTIES, EXPRESS OR IMPLIED,
whichever comes first. INCLUDING BUT NOT LIMITED TO THE IMPLIED
If the purchaser discovers within the applicable WARRANTIES OF MERCHANTABILITY AND FITNESS
period a defect in material or workmanship, it must FOR A PARTICULAR PURPOSE.
promptly notify TICO in writing. In any event such
notification shall be received by TICO, in the case a
defect in the mainframe, no later than 73 months
from date of delivery, and in the case of a defect in
any other part or component, no later than 25 months
from the date of 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 used replacement parts, at TICO’s
option.

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TICO PRO-SPOTTER SERVICE INFORMATION 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. The customer registration must
other legal theory. Such damages include, but are not be on file for any warranty claim to be considered. If no
limited to, loss of profits, loss of savings or revenue, loss Warranty registration is filed the warranty of the tractor is
of use of the truck or any associated equipment, cost of initiated at the ship date.
capital, cost of any substitute truck, equipment, facilities, *Note: Contact specific product OEM: Cummins, Dana,
or services, downtime, the claims or third parties Meritor, Allison.
including customers, and injury to property. This limitation
does not apply to claims for personal injury. Some states
do not allow limit on warranties, or on remedies for Major Components Warranty
breach in certain transactions. In such states, the limits in *For additional warranty information, please contact the
this paragraph and in paragraph (3) may not apply. major components manufacturer or visit their websites.

Warranty Claim Procedures. 1. Disclaimer of Warranty.

The purchaser must notify TICO of a warranty claim prior THE FOREGOING WARRANTIES ARE IN LIEU OF ALL
to any warranty work. TICO will provide the purchaser OTHER WARRANTIES, EXPRESS OR IMPLIED,
with further instructions on how to proceed with such INCLUDING BUT NOT LIMITED TO THE IMPLIED
warranty claim. Notice of a warranty claim and all other WARRANTIES OF MERCHANTABILITY AND FITNESS
warranty correspondence must be sent digitally to FOR A PARTICULAR PURPOSE.
[email protected] or physically to: TICO, 66
Cypress Ridge Dr, Ridgeland, SC 29936. TICO may 2. Limitation of Remedies.
designate new or additional addresses. In no case shall TICO be liable for any special, incidental
or consequential damages based upon breach of
Time Limit for Bringing Suit. warranty, breach of contract, Negligence, strict tort, or
Any action for breach of warranty as to the mainframe any other legal theory. Such damages include, but are
must be commenced within 75 months following delivery not limited to, loss of profits, loss of savings or revenue,
of the truck. Any action for breach of warranty as to any loss of use of the coach body or any associated
other part or component must be commenced within 27 equipment, cost of capital, cost of any substitute coach
months following delivery of the truck or within the first body, equipment, facilities or services, downtime, the
three months following the first 6000 hours of use, claims of third parties including customers, and injury to
whichever comes first. property. This limitation does not apply to claims for
personal injury. Some states do not allow limits on
No Other Warranties. warranties, or on remedies for breach in certain
Unless modified in writing signed by both parties, this transactions. In such states, the limits in this paragraph
agreement is understood to be the complete, and and in paragraph (3) may not apply.
exclusive agreement between the parties, superseding
all prior agreements, oral or written, and all other 3. Time Limit for Bring Suit.
communications between the parties (including without Any action for breach of warranty must be commenced
limitation any terms and conditions contained in any within three months following the expiration of the
purchase order or sales invoice issued pursuant to the warranty period.
sale of this truck) relating to the subject matter of this
agreement. No employee of TICO or any other party is 4. No Other Warranties.
authorized to make any warranty in addition to those Unless modified in a writing signed by both parties, this
made in this agreement. agreement is understood to be the complete and
exclusive agreement between the parties, superseding
all prior agreements, oral or written, and all other
communications between the parties (including without
limitation any terms and conditions contained in any
purchase order or sales invoice issued pursuant to the
sale of this truck) relating to the subject matter of this
agreement. No employee of TICO or any other party is
authorized to make any warranty in addition to those
made in this agreement.

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PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

2018 FLAT RATE GUIDELINE

3—Electrical System

CODE DESCRIPTION HOUR NOTES

3.01 Alternator; R&R 1.0
3.02 Battery; R&R 1.1
Add for Each Additional 0.2
3.03 Belt, Alternator; R&R 0.5
3.04 Bracket, Battery Hold-Down; R&R (Each) 0.8
3.05 Cable, Battery; R&R (Each) 0.75
3.06 Chassis Power Distribution Center (PDC); R&R 3.2
3.07 Harness, Dash Bucket; R&R 4.0
3.08 Harness, Gauge Panel; R&R 2.0
3.09 Harness, Rear Light; R&R 1.2
3.10 Harness, Tail Light; R&R 1.5
3.11 Harness; Power Distribution Center (PDC) Chassis-to-Cab 2.0
3.12 Headlight; R&R 0.5 Includes Adjustment
3.13 Hold-Down, Battery; R&R (Each) 0.5
3.14 Lamp, Turn Signal; R&R 0.3
3.15 Light Bar; R&R (Each) 1.2
3.16 Light, 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
3.22 Sender, Oil Pressure; R&R 0.6
3.23 Sender, Water Temperature; R&R 1.1 Includes Drain and Refill Radiator
3.24 Sensor, Engine Speed; R&R 0.5
3.25 Solenoid, Starter; R&R 1.1
3.26 Starter, Electric; R&R 1.0
3.27 Switch, Battery Disconnect; R&R 0.8

4—Engine

CODE DESCRIPTION HOUR NOTES

4.01 Baffle, Under Radiator; R&R 0.5
4.02 Blade, Cooling Fan; R&R 1.5
4.03 Bracket, Air Cleaner Mounting; R&R 0.6
4.04 Bracket, Front Engine Mount; R&R 1.1
4.05 Bracket, Fuel Tank; R&R (Each) 1.0
4.06 Bracket, Muffler; R&R 0.6
4.07 Bracket, Rear Engine/Transmission Mount; R&R (Each) 1.1
4.08 Bracket, Standoff, Frame-to-Muffler; R&R 0.9
4.09 Catalyst, SCR; R&R (ISB6.7) 2.5
4.10 Clamp, Muffler; R&R (Each) 0.1
4.11 Clutch, Cooling Fan; R&R 2.3
4.12 Control Unit, Diesel Exhaust Fluid (DEF) Dosing; R&R 1.0

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TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

CODE DESCRIPTION HOUR NOTES

4.13 Cooler, Charge Air; R&R 2.1
4.14 Diesel Particulate Filter (DPF), Vertical; R&R 1.5
4.15 Diesel Particulate Filter (DPF); R&R (ISB6.7) 1.5
4.16 Dosing Pump, Diesel Exhaust Fluid (DEF); R&R 1.1
4.17 Elbow, Muffler Inlet; R&R 0.8 Includes Tack Weld
4.18 Elbow, Turbo; R&R 0.5
4.19 Elbow; Rubber; R&R (Each) 0.4
4.20 Element, Air Filter; R&R 0.25
4.21 Engine & Transmission; R&R 20.0 Includes All Operations and
Adjustments
4.22 Engine Cradle; R&R 0.5 With Engine Removed
4.23 Engine Heater; R&R 1.3 Includes Drain and Refill Radiator
4.24 Engine; R&R 16.0 Includes All Operations and
Adjustments
4.25 Filter, Engine Air; R&R 0.5
4.26 Filter, Fuel/Water Separator; R&R 0.25
4.27 Guard, Diesel Exhaust Fluid (DEF) Tank Top; R&R 0.4
4.28 Guard, Muffler; R&R 0.5
4.29 Guard, Selective Catalytic Reduction (SCR) Assembly; R&R 0.6
4.30 Harness, Chassis-to-Diesel Exhaust Fluid (DEF) Tank; R&R 1.1
4.31 Harness, Chassis-to-Selective Catalytic Reduction (SCR) System; 1.5
R&R
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 Hose, Upper Radiator; R&R 0.5 Includes Drain and Refill
4.37 Hose, Upper Tube, Charge Air Cooler (CAC); R&R (Each) 0.5
4.38 Indicator, Filter, Air Intake Tube; R&R 0.25
4.39 Insert Step, Bottom of Fuel Tank; R&R 0.4
4.40 Isolator, Engine; R&R (Each) 1.0
4.41 Isolator, Rubber Tank Strap; R&R (Each) 0.6
4.42 Line, Fuel Return; R&R 0.8
4.43 Line, Fuel Tank-to-Filter; R&R 0.5 Includes R&R of Platform
4.44 Mount, Lower Radiator; R&R 0.5
4.45 Mount, Side of Radiator; R&R 0.4
4.46 Mounting Band, Air Cleaner; R&R (Each) 0.7
4.47 Muffler; R&R 1.1
4.48 Muffler Extension; R&R 0.3
4.49 Oil, Engine; Drain and Refill 0.5
4.50 Pipe, Exhaust Pipe; R&R 0.5
4.51 Platform, Fuel Tank; R&R 0.3
4.52 Precleaner, Air Intake; R&R 0.3
4.53 Radiator; Drain and Refill 0.6
4.54 Radiator; R&R 6.0 Includes All Operations
4.55 Sender, Fuel Level; R&R 0.8
4.56 Sensor, Low Coolant; R&R 0.5
4.57 Separator, Fuel/Water; R&R 0.7
4.58 Sight Glass, Surge Tank; R&R 0.5 Includes Drain and Refill
4.59 Strap, Fuel Tank; R&R (Each) 0.5

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PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

CODE DESCRIPTION HOUR NOTES

4.60 Surge Tank; R&R 1.0 Includes Drain and Refill
4.61 Tank, Diesel Exhaust Fluid (DEF); R&R 1.0
4.62 Tank, Fuel; Drain and Refill 0.8
4.63 Tank, Fuel; R&R 1.6 Includes Drain and Refill
4.64 Tank, Lower Radiator; R&R 3.1 Includes Drain and Refill
4.65 Tank, Upper Radiator; R&R 2.5 Includes Drain and Refill
4.66 Tube, Air Cleaner-to-Turbo; R&R 0.6
4.67 Tube, Exhaust Flex; R&R 0.5
4.68 Tube, Lower, Charge Air Cooler (CAC); R&R 0.6
4.69 Tube, Selective Catalytic Reduction (SCR) Decomposition; R&R 1.5
4.70 Tube, Upper, Charge Air Cooler (CAC); R&R 0.6
4.71 Valve, Radiator Drain; R&R 0.8 Includes Drain and Refill
4.72 Vent Line, Fuel Tank; R&R 0.3

5—Transmission

CODE DESCRIPTION HOUR NOTES

5.01 Bracket, Rear Engine/Transmission Mount; R&R (Each) 1.1
5.02 Cooler, Transmission; 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 Transmission; R&R 8.0 Includes All Operations and
Adjustments
5.07 Transmission Fluid; Drain and Refill 1.2 Includes Replace Internal Filter
5.08 Tube, Transmission Dipstick; R&R 1.0 Includes Drain and Refill

6—Front Axle and Steering

CODE DESCRIPTION HOUR NOTES

6.01 Axle, Front; R&R 2.9 Includes All Operations
6.02 Bearing, Front Axle Wheel; Adjustment (Each) 0.5
6.03 Bearing, Front Axle Wheel; R&R (Each) 0.5
6.04 Bearing, Front Axle Wheel; Repack/Grease (Each) 0.25
6.05 Bushing, Frame, Rear Shackle; R&R (Each) 2.0
6.06 Bushing, Spring, Leaf; R&R 1.75
6.07 Column, Steering; R&R 1.4
6.08 Drag Link; R&R 1.1
6.09 End, Tie Rod; R&R (Each) 0.7
6.10 End, Tie Rod; R&R 1.4 Includes Setting Toe-In
6.11 Hose, Pressure, Pump-to-Gear; R&R 0.8
6.12 Hose, Return, Gear-to-Tank; R&R 0.8
6.13 Hose, Suction, Tank-to-Pump; R&R 0.8
6.14 Hub; R&R 2.0
6.15 Hubcap; R&R 0.4 Includes Fill With Oil
6.16 Kingpin Kit; R&R (Each) 5.3
6.17 Knuckle Assembly; R&R (Each) 3.9

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TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

CODE DESCRIPTION HOUR NOTES

6.18 Pin, Front Spring; R&R (Each) 1.0
6.19 Pitman Arm; R&R 1.1
6.20 Poppet, Steering Gear; Adjustment 0.5
6.21 Power Steering System; Analyze 0.6 Includes Flow & Pressure Check
6.22 Pump, Power Steering; R&R (Optional dedicated steering pump) 1.4 Includes Drain and Refill
6.23 Rubber Pad, Axle Stop; R&R (Each) 0.3
6.24 Seal, Hub; R&R (Each) 1.7
6.25 Seal, Steering Gear Input Shaft; R&R 1.0
6.26 Shackle, Rear Spring; R&R (Each) 1.5
6.27 Slip-Joint, Steering Column; R&R 1.75
6.28 Spacer, Axle; R&R 1.25
6.29 Spring, Leaf; R&R (Each) 1.8
6.30 Steering Arm; R&R 2.4
6.31 Steering Gear; R&R 2.5 Includes Adjustment
6.32 Steering Wheel; R&R 0.6
6.33 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 (Each) 0.5
6.39 Wheel & Tire, Front Axle; R&R 0.4

7—Rear Axle

CODE DESCRIPTION HOUR NOTES

7.01 Axle Assembly, Rear; R&R 5.3
7.02 Bearing, Rear Wheel; Adjustment (Each) 1.0
7.03 Bearing, Rear Wheel; R&R (Each) 0.2 Hub Removed
7.04 Bolt, Axle; R&R (Each) 0.5
7.05 Differential Carrier; R&R 5.2
7.06 Drive Shaft; R&R 1.0
7.07 Gasket, Differential Carrier; R&R 5.2
7.08 Hub Assembly, Rear; R&R (Each) 1.4
7.09 Seal, Axle; R&R 0.2
7.10 Seal, Pinion; R&R 1.5
7.11 Shaft, Axle; R&R (Each) 0.8
7.12 Stud, Axle Flange; R&R 0.3 Does Not Include Removal of Axle Shaft
7.13 Stud, Wheel; R&R 1.5
Add for Removal of Hub Additional 0.2
7.14 U-Joint; R&R 1.1
Add for Each Additional Joint 0.3
7.15 Wheels, Rear Duals; R&R 0.75
7.16 Yoke, Pinion; R&R 1.5

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PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

8—Air System

CODE DESCRIPTION HOUR NOTES

8.01 Dryer, Air; R&R 1.1
8.02 Gauge, Air; R&R (Each) 0.5
8.03 Governor, Air; Adjustment 0.4
8.04 Governor, Air; R&R 0.8
8.05 Hose, Compressor Intake; R&R 0.5
8.06 Line, Discharge, Compressor; R&R 1.0
8.07 Pedal, Throttle; R&R 0.5
8.08 Strap, Air Tank; R&R (Each) 0.5
8.09 Switch, Low-Pressure; R&R 0.5
8.10 Tank, Air; R&R (Each) 1.5
8.11 Valve, BP-R1 Relay; R&R 1.3
8.12 Valve, Brake Treadle; R&R 1.5
8.13 Valve, Check, Air Tank; R&R (Each) 0.6
8.14 Valve, Double Check; R&R 0.8
8.15 Valve, Drain, Air Tank; R&R 0.6
8.16 Valve, Three-Position Door; R&R 0.8
8.17 Valve, Heated, Spitter; R&R 0.05
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&R 1.0
8.23 Valve, Trailer Aux Brake; R&R 0.8
8.24 Valve, Trailer Parking Brake; R&R 0.8

9—ABS/ATC System

CODE DESCRIPTION HOUR NOTES

9.01 Control Unit, Antilock Braking System (ABS); R&R 0.7
9.02 Harness, Antilock Braking System (ABS) Cab; R&R 0.6
9.03 Harness, Antilock Braking System (ABS) Electronic Control Unit 0.8
(ECU), Front Function; R&R
9.04 Harness, Antilock Braking System (ABS) Electronic Control Unit 0.8
(ECU), Rear Function; R&R
9.05 Harness, Antilock Braking System (ABS) Front Chassis; R&R 0.6
9.06 Harness, Antilock Braking System (ABS) Rear Chassis; R&R 0.6
9.07 Sensor, Antilock Braking System (ABS) Front Wheel; R&R (Each) 1.0
9.08 Sensor, Rear Wheel; R&R (Each) 1.5
9.09 Valve, Antilock Braking System (ABS) Modulator; R&R (Each) 1.2

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TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

11—Hydraulic System

CODE DESCRIPTION HOUR NOTES

11.01 Bearing, Cylinder; R&R (Each) 0.5 Cylinder Removed
11.02 Cap and Strainer, Hydraulic Tank; R&R 0.7
11.03 Cylinder, Cab Tilt; R&R 1.3
11.04 Cylinder, Hydraulic; R&R (Each) 1.5
11.05 Hydraulic Fluid; Drain and Refill 0.8
11.06 Filter, Hydraulic; R&R 0.2
11.07 Head, Hydraulic Filter; R&R 1.2
11.08 Hose, Cab Latch Hydraulic; R&R 1.1 Includes Drain and Refill Tank
(Tank-to-Pump, Pump-to-Latch, or Latch-to-Cylinder) 0.5
11.09 Hose, Control Valve-to-Tee; R&R (Each) 1.0 Includes R&R of Platforms
11.10 Hose, Cylinder-to-Tee; R&R (Each) 0.7 Includes R&R of Platforms
11.11 Hose, Filter-to-Tank; R&R 0.75
11.12 Hose, Hydraulic Pump-to-Valve; R&R 0.75 Includes R&R of Platform
11.13 Hose, Hydraulic Tank-to-Pump; R&R 0.75 Includes Drain and Refill
11.14 Hose, Hydraulic Valve-to-Filter; 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 Drain and Refill
11.19 Sight Glass, Hydraulic Tank; R&R 0.75 Includes Drain and Refill
11.20 Tank, Hydraulic; R&R 1.8 Includes Drain and Refill
11.21 Valve, Cab Suspension Leveling; R&R 0.6
11.22 Valve, Directional Control; R&R 1.9 Includes R&R of Platforms and Pressure
Adjustment

12—Boom and Fifth Wheel

CODE DESCRIPTION HOUR NOTES

12.01 Boom Assembly; R&R 10.0
12.02 Cable, Fifth Wheel Control; Adjustment 0.6
12.03 Cable, Fifth Wheel Control; R&R 1.4 Includes Adjustment
12.04 Foot, Fifth Wheel; R&R (Each) 2.0 Includes Fifth Wheel R&R
Foot, Fifth Wheel; R&R Additional 1.0
12.05 Harness, Pigtail Jaw Lock Indicator; R&R 1.2
12.06 Lever, Fifth Wheel Control; R&R 1.0 Includes Adjustment
12.07 Pin, Boom Front Pivot; R&R 2.5
12.08 Pin, Boom Lift Cylinder Upper Pivot; R&R 0.6
12.09 Proximity Switch, Jaw Lock Indicator; R&R 0.2
12.10 Rocker Switch, Fifth Wheel Lever Control; R&R 0.25
12.11 Top Plate, Fifth Wheel; R&R 0.75
12.12 Valve, Brake Treadle; R&R 0.8

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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 1.5
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 0.5
13.06 Cab Pivot Block; R&R 1.1
13.07 Cab, Protection Bar; R&R 8.0 Includes Intake and Exhaust Removal,
ISB
13.08 Cab, Protection Bar; R&R 5.0 Includes Intake and Exhaust Removal,
QSB
13.09 Cab; R&R 12.0 Includes All Operations
13.10 Contact, Horn; R&R 1.5
13.11 Door Cylinder, Rear Door; R&R 0.6
13.12 Door, Rear; Adjustment 0.5
13.13 Fan, Cab Auxiliary; R&R 0.5
13.14 Fender, Right Side; R&R 2.0 With Auto Lube
13.15 Fender, Right Side; R&R 1.0 Without Auto Lube
13.16 Flasher; R&R 0.3
13.17 Floor Pan; R&R 28.0 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; R&R (Each) 0.3
13.24 Glass, Side, Sliding Window; R&R 1.0
13.25 Handle Kit, Window; R&R 0.5
13.26 Handle, Cab Grab; R&R (Each) 0.2
13.27 Handle, Rear Door; R&R 0.25
13.28 Harness, A/C Switch, Dash; R&R 1.0 Operations Do Not Include Refrigerant
Recovery or Evacuation
13.29 Harness, Cab Tilt Switch; R&R 0.75
13.30 Height, Cab Suspension; Adjustment 0.2
13.31 Horn, Air; R&R 0.5
13.32 Horn, Electric; R&R 0.7
13.33 Hose, Glad Hand; R&R (Each) 0.4
13.34 Latch, Cab; R&R 0.6
13.35 Lock, Rear Door; R&R 0.4
13.36 Mirror Head, Heated; R&R 0.5
13.37 Mirror Head, Heated Remote; R&R 0.7
13.38 Mirror Head; R&R 0.5
13.39 Mirror, Convex; R&R 0.3
13.40 Motor, Wiper; R&R 1.0
13.41 Motor/Pump Assembly, Cab Tilt; R&R 1.0
13.42 Pin, Cab Pivot; R&R (Both) 0.5
13.43 Pin, Lower Cylinder; R&R 2.75
13.44 Pressure Check, Tilt System 0.5
13.45 Prop, Cab Safety; R&R 0.5

TICO Manufacturing Service Manual 0-11

TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

CODE DESCRIPTION HOUR NOTES

13.46 Radio; R&R 1.0
13.47 Rear Door Assembly; R&R 2.0
13.48 Rear Door Drive Plate; R&R 0.6
13.49 Right Mirror Post; R&R 0.5
13.50 Seat; R&R 1.1
13.51 Shock Absorber, Seat; R&R 0.5
13.52 Speedometer; R&R & Recalibrate 0.75
13.53 Speedometer; Recalibrate 0.3
13.54 Spotlight; R&R 1.2
13.55 Spring, Air Seat; R&R 0.5
13.56 Spring, Cab Air Ride, Left Side; R&R 0.7
13.57 Spring, Cab Air Ride, Right Side; R&R 0.75
13.58 Switch, Cab Tilt; R&R 0.5
13.59 Switch, Dome Light; R&R 0.4
13.60 Switch, Headlight/Floodlight; R&R (Each) 0.5
13.61 Switch, Ignition; R&R 0.75
13.62 Switch, Stop Light; R&R 0.3
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; R&R 0.3
13.69 Window, Sliding; R&R 0.75
13.70 Window, Rear of Cab; R&R 0.5
13.71 Windshield; R&R 1.0

14—Covers and Guards

CODE DESCRIPTION HOUR NOTES

14.01 Bracket, Mud Flap; R&R (Each) 0.5
14.02 Bracket, Rear Axle Quarter Fender; R&R (Each) 0.4
14.03 Bracket, Rear Full Fender; R&R (Each) 0.5
14.04 Bumper, Front; R&R 0.75
14.05 Fender, Rear Axle Full; R&R (Each) 0.5
14.06 Fender, Rear Axle Quarter; R&R (Each) 0.3
14.07 Guard, Grille; R&R 0.5
14.08 Guard, Cab Protection Bar; R&R 1.5
14.09 Guide, Boom; R&R (Each) 3.5
14.10 Guide, Boom; R&R (Each) Additional 1.0
14.11 Mud Flap; R&R (Each) 0.3
14.12 Platform, Rear Step; R&R 0.5
14.13 Platform, Transmission Cover; R&R 0.5
14.14 Radiator, Skid Plate; R&R 1.75

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PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

15—Heating and Air Conditioning

CODE DESCRIPTION HOUR NOTES

15.01 Belt, A/C Compressor; R&R 0.8 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.02 Box, HVAC; R&R 3.0 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.03 Cable, HVAC Temperature Control; R&R 0.9 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.04 Clutch, A/C Compressor; R&R 1.3 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.05 Compressor, A/C; R&R 1.4 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.06 Condenser; R&R 1.1 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.07 Core, Heater; R&R 4.0 Includes Drain and Refill
Operations Do Not Include Refrigerant
Recovery or Evacuation
15.08 Diffuser, HVAC Vent; R&R 0.75 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.09 Evacuate and Recharge System; Check for Operation & Leaks 1.8 Full Charge of 2.50 lbs.Thermotek
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 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.12 Hose, A/C; R&R (Each) 0.5 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.13 Hose, Heater; R&R 1.2 Includes Drain and Refill
Operations Do Not Include Refrigerant
Recovery or Evacuation
15.14 Motor, HVAC Blower; R&R 1.2 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.15 O-Rings, A/C Fitting; R&R (Each) 0.3 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.16 Pulley, A/C Belt; R&R 2.4 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.17 Receiver-Drier; R&R 0.5 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.18 Resistor, HVAC Fan; R&R 0.5 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.19 Switch, A/C; R&R 0.5 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.20 Switch, Blower Motor; R&R 0.5 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.21 Switch, High-Pressure; R&R 0.3 Operations Do Not Include Refrigerant
Recovery or Evacuation

TICO Manufacturing Service Manual 0-13

TICO PRO-SPOTTER SERVICE INFORMATION PRO-SPOTTER

CODE DESCRIPTION HOUR NOTES

15.22 Switch, Low-Pressure; R&R 0.3 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.23 Thermostat, A/C; R&R 0.5 Operations Do Not Include Refrigerant
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 Include Refrigerant
Recovery or Evacuation
15.26 Valve, Schrader; R&R 0.3 Operations Do Not Include Refrigerant
Recovery or Evacuation
15.27 Wheel, Blower Motor; R&R 1.4 Operations Do Not Include Refrigerant
Recovery or Evacuation

0-14 Service Manual TICO Manufacturing

PRO-SPOTTER TICO PRO-SPOTTER SERVICE INFORMATION

CONTACT TICO SUPPORT

Figure 0-1: TICO Support Decal

To contact TICO factory technical support:

• Call 1.833.UPTIME2 (833.878.4632)
• Email inquiries to:
[email protected]
• Additional information is available at:
ticotractors.com/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.

TICO Manufacturing Service Manual 0-15

 PRO-SPOTTER

1-0 Service Manual TICO Manufacturing

 Section 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 Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Park Tractor Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Support Tractor Securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Use Compressed Air and 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 Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fastener Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tightening Sequences and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Certification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Transmission Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Fifth Wheel Serial Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

TICO Manufacturing Service Manual 1-1

GENERAL INFORMATION PRO-SPOTTER

SAFETY Safety Notices

Throughout this manual, the following key safety words
Introduction will be used to alert the reader of potential hazards.
Become familiar with these words and their meaning.
Safety is the most important element of any repair Take all precautions to avoid the hazards described.
procedure for TICO Pro-Spotter terminal trucks.
Knowledge of the procedure to be performed and safe


work habits are essential to preventing death, personal
This safety alert symbol is used to
injury, or property damage. Use the following statements
alert you to potential hazards.
as a common-sense guide to proper work and tool-use
habits.

Prepare for the Job  DANGER

Preparation is essential to complete a procedure in a Indicates a potentially imminently hazardous
safe and efficient manner. situation, which if not avoided, WILL result in
• Wear proper clothing. Loose or baggy clothing could death or serious injury.
become tangled in moving parts.
• Use eye/face protection. Always use proper eye/face
protection to protect your eyes from flying debris or
chemical splatters.
 WARNING
• Wear protective footwear. Wear safety shoes Indicates a potentially hazardous situation, which
(steel-toe) to protect your feet from falling objects. if not avoided, COULD result in death or serious
injury.
• Use gloves when handling parts. Parts may have
sharp edges or may be hot to touch.
• Remove jewelry prior to servicing electrical systems.
• Prepare proper tools and equipment. Always use the  CAUTION
correct tool for the job. Improper or homemade tools Indicates a potentially hazardous situation, which
can cause injury or tractor damage. if not avoided, MAY result in minor or moderate
• Prepare needed parts and materials. Gather the injury.
needed parts and materials before beginning the
procedure.
• Allow the tractor to cool. Many components can get NOTICE
hot during operation. Be sure to allow enough time
for components to cool before beginning service. Indicates a potentially hazardous situation, which
if not avoided, MAY result in property damage. It
• Prepare proper work-space lighting. A well-lit work
may also be used to alert against unsafe
area can make the job easier.
practices.
• Follow procedures and safety warnings. Service
procedures are written to be as safe and efficient as
possible. Never take shortcuts. Safety Labels
• 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.
accessible. Inspect the tractor for any damaged, missing, or
unreadable labels. Replace labels as needed before
placing the tractor back in service.

1-2 Service Manual TICO Manufacturing

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.
• Keep floor clean of debris and clear of parts and  WARNING
tools.
Before cleaning, adjusting, or repairing this
• Clean up any spilled fuel, oil, and/or chemicals tractor, engage park brake, shift transmission to
immediately. neutral, and stop engine to prevent injuries.
• Store all air hoses and electrical cords properly when When performing maintenance other than
not in use. adjustments that require the engine to be
running, disconnect the battery negative cables
Keep Work Area Well Ventilated to prevent accidental starting and bodily injury.

 WARNING 1. Park the tractor on a solid, level surface.

2. Shift the transmission to neutral.
Never operate the engine without proper
ventilation; exhaust fumes could be fatal if
inhaled.

Certain test and adjustment procedures require the

1
engine to be running. Be sure work area is well
ventilated; never run the engine in an enclosed area.

Use Proper Eye and Face Protection

TPS-001

 WARNING 1 Parking Brake Knob

Figure 1-1: Trailer Air Supply and Parking Brake
Always use approved personal protection Knob
equipment. Avoid workplace hazards by wearing 3. Pull the parking brake knob (1) out to apply the
properly maintained, approved eye and face parking brake.
protection. Failure to use appropriate protection
equipment could result in death or serious injury. 4. Allow the engine to run at idle for a minimum of 3
minutes and shut the engine off. Lockout–tagout the
tractor.
Always wear eye protection while in a shop environment. 5. Turn off all electrical lights and accessories.
• Safety Glasses: Safety glasses offer a minimum level 6. Place wheel chocks or blocks in the front and rear of
of protection from flying debris. wheels to prevent the tractor from moving.
• Face Shields: Face shields are often used along with 7. Lower the fifth wheel if it is in the raised position.
safety glasses to offer a higher level of protection
when sparks and flying debris are present.
• Vented Goggles: Goggles offer side protection not
Support Tractor Securely
offered by safety glasses alone.
• Unvented Goggles: Unvented goggles offer  WARNING
protection from chemical splashes and vapors. • Support the tractor using properly rated jack
stands. Never work under a tractor supported
only by a jack.
• Do not use wood or concrete blocks to
support the tractor. Failure to properly
support the tractor could result in death or
serious injury.

TICO Manufacturing Service Manual 1-3

GENERAL INFORMATION PRO-SPOTTER

Use Lifting Equipment Safely • Always maintain air tools properly.

 WARNING Service Tires Safely

Always check the lifting capacity and condition of
hoists, slings, cables, or chains before use. Using  WARNING
underrated or worn lifting components could An inflated tire contains explosive force. Use care
result in death or serious injury. when handling wheels and tires.

• Always use a lifting device with a lifting capacity • Always wear safety glasses or goggles.
greater than the weight of the item being lifted. • Use proper lifting methods when working with wheels
• Secure the load to the lifting device using cables, and tires.
chains, or slings rated to handle the load being lifted. • When working on an inflated tire, never position
Fasteners being used to connect lifting devices must yourself directly over the work area.
be strong enough to handle the load. Also, be sure
the mounting point of load is strong enough to handle • When dismounting or mounting tires, use a wheel
the load. holder or tire tractor. Use proper tire mounting tools
and equipment. Never use screwdrivers or makeshift
• When connecting to the load, ensure the load is tools to force a tire on or off a wheel.
balanced.
• Be sure tire irons and mounting tools are free of
• Always use a lifting device on a hard, level surface. grease and oil. Grip them firmly.
• Lower the lifting device to the lowest point before • Inspect wheel parts for rust, damage, or distortion.
moving. Move the load slowly. Never use wheels that are out-of-round, rusted, or
• Always support the load as soon as possible; never cracked.
leave a load suspended in mid-air. • Never hammer on wheels with a steel hammer. Use
rubber-covered hammers.
Use Compressed Air and Air Tools • When inflating tires, always use an inflation cage.
Safely Always stand away from the valve stem.
• Use accurate, tested inflation gauges to set air
 WARNING pressures.

Always wear approved eye and ear protection Service Electrical Components Safely
while using compressed air. Misuse of
compressed air could result in death or serious
injury.  WARNING
• When using air nozzles, air pressure should Always disconnect the battery negative cable
not exceed 206.8 kPa (30 psi). first and battery positive cable last. Connect
• Never direct air nozzles or tools at a person. battery positive cable first and battery negative
• Never point air nozzles directly at skin. cable last. Be careful when testing live circuits to
prevent arcing. Arcing could result in death or
serious injury.
• Compressed air is a useful tool when used in a safe
manner.
• Disconnect the battery negative (–) cable before
• Always use eye and ear protection while using
removing or installing electrical components. Always
compressed air and air tools.
connect the battery negative (–) cable last.
• When using air tools, do not exceed the air pressure
• Certain test and adjustment procedures must be
rating for the tool.
performed with the battery connected. Use care to
• When using an impact wrench, always use approved prevent arcing when working on live circuits or
impact sockets. Never use standard sockets on an components. Arcing can cause component damage
impact wrench. and could ignite flammable materials.
• Disconnect the air supply before changing air tool
attachments.
• Never point air nozzles or air tools at another person.

1-4 Service Manual TICO Manufacturing

PRO-SPOTTER GENERAL INFORMATION

Service Hydraulic System Safely Handle Fuel Safely

Handle fuel with care—it is highly flammable.
 WARNING
The hydraulic system is under pressure, and the
 WARNING
oil may be hot! • Never remove the fuel cap from the fuel tank
• Always allow the tractor to cool completely or add fuel when the engine is running or
before performing service. while the engine is hot.
• Always relieve pressure in the hydraulic • Do not smoke when handling fuel. Never fill
system before performing service. or drain the fuel tank indoors.
• Always use appropriate safety equipment and • Do not spill fuel. Clean up spilled fuel
clothing to protect exposed skin and eyes immediately.
from high-pressure oil. • Never handle or store fuel containers near an
• Tighten all connections to proper open flame or any device that may create
specifications before applying pressure. sparks and ignite the fuel or fuel vapors.
• Never use bare hands to check for leaks. Oil • Be sure to reinstall and tighten fuel cap
under pressure can penetrate the skin and securely.
can cause gangrene within a few hours if not • Use an approved container; the spout must fit
properly removed. Use a piece of cardboard inside the fuel filler neck. Avoid using cans
to check for leaks. and funnels to transfer fuel.
Failure to follow appropriate safety precautions
could result in death or serious injury. Store fuel according to local, state, or federal ordinances
and recommendations from your fuel supplier.
Always dispose of used hydraulic oil properly. Never overfill or allow the tank to become empty.
(See “Dispose of Waste Materials Safely” on page 1-6.) Use clean, fresh fuel.
Do not fill above the fuel filler neck.
Service Cooling System Safely
Handle Chemical Products Safely
 WARNING
Engine coolant is hot and under pressure! Allow  WARNING
the cooling system to cool completely before Exposure to chemical products could result in
performing service. serious injury. Handle chemical products with
Rotate the filler cap 1/2-turn counterclockwise care. Refer to the chemical manufacturer’s Safety
and allow pressure to vent before removing filler Data Sheet (SDS) for information regarding health
cap. hazards, safe handling, and emergency response
Failure to follow appropriate safety precautions procedures.
could result in death or serious injury.
Routine service often requires the use of various
chemical products, including lubricants and cleaning
 WARNING solutions. Many of these chemicals are flammable and
can pose health risks if not handled properly.
Contact with anti-freeze can damage your skin. • Never mix chemicals. Mixing chemicals can produce
Use gloves when working with anti-freeze. If you toxic or explosive results.
come in contact with anti-freeze, wash it off
immediately. • Follow the manufacturer’s recommendations for safe
usage and handling of the product.
• Various materials may pose a health hazard if used
Always dispose of used engine coolant properly. incorrectly. A Safety Data Sheet (SDS) contains
(See “Dispose of Waste Materials Safely” on page 1-6.) important information regarding proper handling and
health hazards, as well as emergency response
procedures. Contact the chemical manufacturer to
obtain a SDS for the chemical product.

TICO Manufacturing Service Manual 1-5

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. Some waste fluids can react with certain
types of plastics. Make sure the fluid to be stored is
compatible with the storage container. Never use food or
beverage containers to store waste fluids.

IMPORTANT
Never dispose of waste fluids by pouring on the
ground, down sewer 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 procedure for waste fluids.
• Dispose of old batteries properly. Battery electrolyte
contains sulfuric acid and other hazardous materials.
Never place an old battery in the trash. Batteries
must be disposed of in a manner consistent with EPA
and/or local regulations.

Store Volatile and Hazardous

Materials Safely
Store volatile materials (gasoline, diesel fuel, oil, etc.) in
approved containers that are clearly marked. Containers
should be stored in an approved safety cabinet away
from possible sources of ignition. Storage areas and
cabinets should be well ventilated to prevent the possible
build-up of fumes.

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PRO-SPOTTER GENERAL INFORMATION

NOMENCLATURE
See Figures 1-2 and 1-3.

7
1
4

6
2

5 TPS-002
1 Hour 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
Figure 1-2: Pro-Spotter (Left Side)

13 14

12

16
15
8 11
9

17

18
10
TPS-003
8 Steer Axle Quarter Fender 11 Power Distribution Center (PDC) 14 Exhaust 17 Auto Lubrication
9 Hydraulic Tank 12 Air Intake 15 Engine Compartment 18 Air Dryer
10 Battery Box 13 Worklight 16 Surge Tank
Figure 1-3: Pro-Spotter (Right Side)

TICO Manufacturing Service Manual 1-7

GENERAL INFORMATION PRO-SPOTTER

SPECIFICATIONS WHEELS
22.5” X 8.25” Standard offset 285 mm hub pilot
ENGINE
two-hand hole
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . .Cummins®
TIRES
Model (DOT/EPA). . . . . . . . . . . . . . . . . . . . . . 2017-B6.7
Standard grade 11R x 22.5 tubeless front and rear
Output (DOT/EPA) . . . . . . . . . . . . . 149 kW@ 2 400 rpm
Highway tread with load range G
200 hp@ 2 400 rpm
Torque (DOT/EPA) . . . . . . . . . . . . 705 N·m @ 1 500 rpm CAB
520 lb·ft @ 1 500 rpm Material . . . . . . . . . . . . . . . . . . . . . Fiberglass composite
Model (Off-Road) . . . . . . . . . . . QSB Tier IV Final Diesel Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 cm
Output (Off-Road). . . . . . . . . . . . . . . . . . . . . . . . 118 kW 68 in
158 hp Height OPTIONAL Raised Roof . . . . . . . . . . . . . 193 cm
Torque (Off-Road) . . . . . . . . . . . . . . . . . . . . . . .841 N·m 76 in
620 lb·ft Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169.55 cm
66.75 in
TRANSMISSION
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148.6 cm
Manufacturer . . . . . . . . . . . . . . . .Allison Transmission®
58.5 in
Model . . . . . . . . . . . . . . . . . . . . . . . . . .3000 RDS Gen V
CAB TILTING
FRONT AXLE
Electric/hydraulic cab lift system
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . .Meritor®
35° under power assist, with manual 90° tilt capability
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 443 kg
12 000 Ib CAB SUSPENSION
Dual air-bag system
REAR AXLE
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . .Meritor® CAB MOUNTING
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 608 kg . . . . . . . . . . . . . . . . . . . Rubber cushion front cab pivots
30 000 Ib . . . . . . . . . . . . . . . . . . . . . . . Safety type cab latching

FRONT SUSPENSION DOORS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . 6-Leaf front spring Lockable, air operated, poly-carbonate transparent rear
door. 168 x 69 cm (66 x 27 in)
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 577 kg
183 cm (72 in) high with optional raised roof
14 500 Ib
HEATER
BRAKES
DOT/EPA: 49 300 BTU, 650 CFM fresh air heater
Pneumatic (air) brake system
Off-road: 40 000 BTU fresh air heater
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS/ATV
. . . . . . . . . . . . . . . . . . . Meritor® 16.5x5” S-cam brakes DEFROSTER
. . . . . . . . . . . . . . . . . . . . . . . . Automatic slack adjusters Type . . . . . . . . . . . . . . . . . . . . . . . . . . Heater-integrated
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS/ATC DASH PANEL
. . . . . . . . . . . . . . . . . . . Meritor® 16.5x7” S-cam brakes Removable for easy maintenance with speedometer,
. . . . . . . . . . . . . . . . . . . . . . . . Automatic slack adjusters LED warning indicator display, engine oil pressure gauge,
hour meter, coolant temperature gauge, voltmeter,
Parking . . . . . . . . . . . . . . . . . . . Spring type on rear axle
ignition switch, dual air gauge, low air pressure warning
Emergency . . . . Automatic application of parking brakes light and alarm, fuel gauge, and diesel exhaust fluid
STEERING (DEF) gauge (DOT/EPA only).
Mechanical linkage with power assist Sheppard™ M-100
Engine mounted 20 gpm pump with priority steering

1-8 Service Manual TICO Manufacturing

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 . . . . . . . . . . Light Three-tank reservoir system totaling 77 576 cm³ (4 734
Charging System Indicator . . . . . . . . . . . . . . . . . . Light in³)
Lo-Air Air Pressure Low . . . . . . . . . . . . Light and Alarm DIMENSIONS
Engine Major Fault Code . . . . . . . . . . . . . . . . . . . . Light Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 cm
Warning Minor Engine Fault Code . . . . . . . . . . . . . Light 123 in
WTS Wait to Start Warning . . . . . . . . . . . . . . . . . . . Light Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 cm
Comm J1939 Datalink Backbone Failure . . . . . . . . Light 96 in
Trans Temp Exceeds Parameters. . . . . . . . . . . . . . Light Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 cm
Check Trans Fault Code . . . . . . . . . . . . . . . . . . . . . Light 201 in
Regen Icon Exhaust Regeneration Required . . . . . Light Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 cm
COOLING SYSTEM 116 in
Fin and tube radiator with integral charge air cooler VEHICLE LOAD CAPACITY
(CAC) mounted on rubber shock pads. Remote surge
GVW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 072 kg
tank. System has a 50% solution of permanent type
anti-freeze with transmission oil cooler in lower radiator. 20 000 lb
GCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 287 kg
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 L
80 000 lb
14 gal
WEIGHT (average) . . . . . . . . . . . . . . . . . . . . . . 6 123 kg
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 L
13 500 lb
65 gal
TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . 6.2 m
DEF TANK (DOT/EPS ONLY) . . . . . . . . . . . . . . . . . 19 L
20.5 ft
5 gal
DRAW BAR PULL . . . . . . . . . . . . . . . . . . . . . . 5 762 kg
EXHAUST
12 702 lb
10 cm (4 in) vertical stack mounted inboard on the cab
protection bar with an aluminum muffler shield. GRADEABILITY . . . . . . . . . . . . . . @capacity GCW 16%

FILTERS HYDRAULIC SYSTEM FOR 5TH WHEEL

Engine Air . . . . . . . . . . . . . . . . . . . . Dry type air cleaner Vented 68 L (18 gal) hydraulic tank with inboard mounted
sight glass. Engine mounted 20 gpm hydraulic pump.
Fuel (2). . . . . . . . . . . . Fleetguard® fuel/water separator,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .frame mounted FIFTH WHEEL & BOOM ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . Fleetguard® engine mounted Cab-controlled air unlatch and automatic latch.
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . Fleetguard® Dual 12.7 cm (5 in) power up and down lift cylinders
. . . . . . . . Full flow spin-on element with intake strainer FIFTH WHEEL
Power Steering . . . . . . . . . . . . . . Replaceable cartridge Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . Holland®
. . . . . . . . . . . . . . . type within power steering reservoir Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 500
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . Fleetguard® Lift Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 751 kg
70 000 lb
ELECTRICAL SYSTEM
Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 cm
12-Volt negative ground with circuit breakers
18 in
ALTERNATOR . . . . . . . . . . . . . . 160 Amp, Delco® 24SI
TRAILER EQUIPMENT
STARTER . . . . . . . . . . . . . 12 Volt, Delco® with lockout
Air . . . . . . . . . . . Two 5 m (15 ft) straight rubber air lines
BATTERY . . . . . . . . . . . . . . . Two12V 750CCA 31-LHD . . . . . . . . . . . . . . . . . . . . . . . . Color coded glad hands
Electrical . . . . . . . . 12-Volt power supply trailer light cord
. . . . . . . . . . . . . . . . . . . . 7-Wire trailer socket and cable

TICO Manufacturing Service Manual 1-9

GENERAL INFORMATION PRO-SPOTTER

FASTENERS Metric bolts are sized according to the diameter (7) in

millimeters, the thread pitch (distance between threads in
Fasteners consist of screws, bolts, studs, and nuts. millimeters) (8), and the length (6) in millimeters. For
These parts are used to hold components together. To example, an M12 - 1.75 x 50 metric bolt is 12 mm in
prevent loosening, fasteners use locking devices such as diameter, has a thread pitch of 1.75 mm and is 50 mm
locking tabs, thread adhesive, or lock nuts and washers. long.
When removing fasteners, inspect all parts for wear or
damage and replace as needed. Lock nuts with nylon
inserts must be replaced after removal. For installation, 8
clean and apply a penetrating oil to fasteners to prevent
rust and breakage.
Special tools may be needed to remove broken and 7
extremely rusted fasteners. These special tools are
commonly available at local tool stores.
When removing washers, inspect for wear or damage 5
and replace as needed. Always install lock washers and 6
flat washers exactly as they were removed. Never use a TPS-010
lock washer on a material softer than the washer metal. 5 Bolt Property Class 8 Thread Pitch (distance
Marking between threads in
6 Length millimeters)
Fastener Sizes 7 Diameter

See Figures 1-4—1-10. Figure 1-5: Metric Bolt Dimensions

TICO terminal tractors use both standard and metric Bolt heads are also used to set apart standard from
fasteners on all equipment. Standard fasteners are often metric fasteners. The width of a standard bolt head is
referred to as USS or SAE. A standard fastener cannot measured in inches. Standard bolt heads also have radial
be substituted with a metric fastener. A metric fastener lines that signify the bolt grade. The bolt grade is the
cannot be substituted with a standard fastener. A strength of the bolt. The more grade lines a bolt head
standard wrench should only be used on standard nuts has, the stronger the bolt.
and bolts. A metric wrench should only be used on metric The width of a metric bolt head is measured in
nuts and bolts. It is important to know the difference millimeters. Metric bolt heads also show the property
between these two hardware characteristics. class number of the bolt. The property class is the
strength of the bolt. A stronger bolt will have a larger
NOTE property class number.
SAE refers to a non-metric fine thread fastener. USS The same applies to standard and metric nuts. Standard
refers to a non-metric coarse thread fastener. nuts are marked with dots to show the grade strength.
Standard bolts are sized according to the diameter (3) in The more dots a nut has, the stronger the nut. Metric nuts
inches, the thread pitch (number of threads per inch) (4), show the property class number. A stronger nut will have
and the length (2) in inches. For example, a standard 1/2 a larger property class number.
- 13 x 2 bolt is 1/2 inch in diameter, has 13 threads per Metric studs are also labeled with the same property
inch and is 2 inches long. class number used for metric bolts. However, smaller
studs use a geometric code to signify property class.
4
NOTE
If a fastener has no grade or property class marking,
3 verify if it is standard or metric by measuring the thread
pitch.
When replacing standard or metric fasteners, be sure the
1 new part is of the same or larger grade or property class.
2 Always install fasteners in the same location they were
TPS-009 removed.
1 Bolt Grade Marking 4 Thread Pitch (number of
2 Length threads per inch)
3 Diameter
Figure 1-4: Standard Bolt Dimensions

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PRO-SPOTTER GENERAL INFORMATION

1 2 3 4
TPS-004
1 Bolt Grade 1 or 2 2 Bolt Grade 5 3 Bolt Grade 8 4 Bolt Grade 8.2
Figure 1-6: Standard Bolt Grade Markings

.9
6

10
4.

4.

5.

8.

9.
5 6 7 8 9 10
TPS-005
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
Figure 1-7: Metric Bolt Property Class Markings

15

11 12
TPS-006
11 Hex Nut Grade 5 (3 dots) 12 Hex Nut Grade 8 (6 dots)
Figure 1-8: Standard Hex Nut Grade Markings

16 17 18
TPS-008
15 Metric Stud 17 Stud Property Class 9.8
16 Stud Property Class 10.9 18 Stud Property Class 8.8
Figure 1-10: Metric Stud Property Class Markings
9 10
13 14
TPS-007
13 Hex Nut Property Class 9 14 Hex Nut Property Class 10
Figure 1-9: Metric Hex Nut Property Class Markings

TICO Manufacturing Service Manual 1-11

GENERAL INFORMATION PRO-SPOTTER

Tightening Sequences and TORQUE CHART

Procedures This torque chart is to be used as a guide when specific
torque values are not listed in the instructions. The torque
Torque values in the chart are approximate and are for reference
It is important that fasteners get tightened using the only when tightening fasteners. It is recommended that
correct torque value. Too much torque can cause the nuts and bolts be of the same standard grade. If a nut
fastener to break or become weak. Not enough torque and bolt are of different grades, use the torque value of
will cause the fastener to be loose. Be sure to follow the the lower grade fastener.
torque instructions in this TICO service manual or the The torque values in the Standard Fastener Torque
provided manufacture’s manual. If a specific torque value Values table, See Table 1-1 on page 1-13, are based on
is not listed, use the torque chart found in this section. a bolt pre-load stress of 75% of the proof strength. Grade
The size and grade or property class must be known to 2 fasteners with a bolt size from 3/8” to 3/4” have a proof
determine how much force to use. More torque can be strength of 55 000 psi. Bolt sizes from 7/8” to 1-3/8” have
used on fasteners with higher grade and property class a proof strength of 33 000 psi. Grade 5 fasteners with a
ratings. bolt size from 3/8” to 1” have a proof strength of 85 000
psi. Bolt sizes from 1-1/8” to 1-3/8” have a proof strength
Tightening Sequences of 74 000 psi. Grade 8 fasteners have a proof strength of
It is important to understand how a tightening sequence 120 000 psi.
works to prevent bending or deforming of components. The torque values in the Metric Fastener Torque Values
When fasteners are arranged in a pattern, they must be table, See Table 1-2 on page 1-13, have a proof strength
tightened or loosened in a specific order. Oil pans and equal to or greater than the tensile strength of the bolt. A
cylinder heads are a couple examples that use fasteners Class 4.6 fastener will have an approximate tensile
in a pattern. strength of 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 strength of 800 MPa (116 030 psi) and 80% yield
stated, start by installing all nuts and bolts only finger strength. Class 10.9 fasteners will have an approximate
tight. Then apply one full turn to each fastener, working in tensile strength of 1 000 MPa (145 038 psi) and 90%
a star pattern. Repeat the star pattern, only applying one yield strength.
half turn for this sequence. Lastly, tighten each fastener
by applying one quarter turn until the proper torque is IMPORTANT
reached. The reverse of this process is used to remove Applying too much or too little torque can cause
fasteners. damage to components. Caution should always be
used when applying any torque value. Use these
torque values at your own risk.
1
12 5

8 9

4 3

10 7

6 11
2 TPS-017
Figure 1-11: Tightening Sequence

1-12 Service Manual TICO Manufacturing

PRO-SPOTTER GENERAL INFORMATION

Table 1-1: Standard Fastener Torque Values

SIZE UNITS GRADE 2 GRADE 5 GRADE 8
Lubricated Dry Zinc Plated Lubricated Dry Zinc Plated Lubricated Dry Zinc Plated
3/8”-16 N·m (lb·ft) 20.3 (15) 27.1 (20) 24.4 (18) 31.2 (23) 42.0 (31) 38.0 (28) 44.7 (33) 59.7 (44) 52.9 (39)
3/8”-24 N·m (lb·ft) 23.0 (17) 31.2 (23) 27.1 (20) 35.3 (26) 47.5 (35) 42.0 (31) 50.2 (37) 66.4 (49) 59.7 (44)
7/16”-14 N·m (lb·ft) 32.5 (24) 43.4 (32) 39.3 (29) 50.2 (37) 66.4 (49) 59.7 (44) 70.5 (52) 94.9 (70) 85.4 (63)
7/16”-20 N·m (lb·ft) 36.6 (27) 48.8 (36) 43.4 (32) 55.6 (41) 74.6 (55) 67.8 (50) 78.6 (58) 105.8 (78) 94.9 (70)
1/2”-13 N·m (lb·ft) 50.2 (37) 66.4 (49) 59.7 (44) 77.3 (57) 101.7 (75) 92.2 (68) 108.5 (80) 143.7 (106) 130.2 (96)
1/2”-20 N·m (lb·ft) 55.6 (41) 74.6 (55) 66.4 (49) 86.8 (64) 115.2 (85) 103.0 (76) 122.0 (90) 162.7 (120) 146.4 (108)
5/8”-11 N·m (lb·ft) 99.0 (73) 131.5 (97) 118.0 (87) 153.2 (113) 203.4 (150) 183.0 (135) 215.6 (159) 287.4 (212) 259.0 (191)
5/8”-18 N·m (lb·ft) 111.2 (82) 149.1 (110) 134.2 (99) 172.2 (127) 230.5 (170) 207.4 (153) 244.0 (180) 325.4 (240) 292.9 (216)
3/4”-10 N·m (lb·ft) 174.9 (129) 233.2 (172) 210.2 (155) 271.2 (200) 362.0 (267) 325.4 (240) 382.3 (282) 509.8 (376) 459.6 (339)
3/4”-16 N·m (lb·ft) 195.2 (144) 260.3 (192) 234.6 (173) 302.3 (223) 402.7 (297) 362.0 (267) 427.1 (315) 569.4 (420) 512.5 (378)
7/8”-9 N·m (lb·ft) 169.5 (125) 226.4 (167) 203.4 (150) 436.6 (322) 581.6 (429) 523.3 (386) 616.9 (455) 821.6 (606) 738.9 (545)
7/8”-14 N·m (lb·ft) 187.1 (138) 249.5 (184) 223.7 (165) 481.3 (355) 642.7 (474) 577.6 (426) 680.6 (502) 907.0 (669) 816.2 (602)
N·m 253.5 339.0 305.1 654.9 873.1 785.0 923.3 1 232.4 1 109.1
1”-8
(lb·ft) (187) (250) (225) (483) (644) (579) (681) (909) (818)
N·m 277.9 371.5 333.5 715.9 954.5 859.6 1 011.4 1 349.0 1 213.5
1”-12
(lb·ft) (205) (274) (246) (528) (704) (634) (746) (995) (895)
N·m 360.6 480.0 432.5 808.1 1 076.5 969.4 1 309.7 1 746.3 1 571.4
1-1/8”-7
(lb·ft) (266) (354) (319) (596) (794) (715) (966) (1 288) (1 159)
N·m 404.0 538.3 484.0 905.7 1 206.7 1 086.0 1 468.4 1 957.8 1 762.6
1-1/8”-12
(lb·ft) (298) (397) (357) (668) (890) (801) (1 083) (1 444) (1 300)
N·m 508.4 677.9 610.1 1 138.9 1 519.9 1 366.7 1 848.0 2 463.5 2 216.8
1-1/4”-7
(lb·ft) (375) (500) (450) (840) (1 121) (1 008) (1 363) (1 817) (1 635)
N·m 562.7 749.8 675.2 1 260.9 1 682.6 1 514.4 2 045.9 2 727.9 2 455.4
1-1/4”-12
(lb·ft) (415) (553) (498) (930) (1 241) (1 117) (1 509) (2 012) (1 811)
N·m 665.7 888.1 799.9 1 494.1 1 991.7 1 792.4 2 421.5 3 229.6 2 906.9
1-3/8”-6
(lb·ft) (491) (655) (590) (1 102) (1 469) (1 322) (1 786) (2 382) (2 144)
N·m 757.9 1 011.4 909.8 1 700.2 2 266.9 2 040.5 2 757.7 3 677 3 308.2
1-3/8”-12
(lb·ft) (559) (746) (671) (1 254) (1 672) (1 505) (2 034) (2 712) (2 440)

Table 1-2: Metric Fastener Torque Values

SIZE UNITS CLASS 4.6 CLASS 8.8 CLASS 10.9
Lubricated Dry Zinc Plated Lubricated Dry Zinc Plated Lubricated Dry Zinc Plated
M6-1 N·m (lb·ft) 2.7 (2) 4.1 (3) 4.1 (3) 8.1 (6) 10.8 (8) 9.5 (7) 10.8 (8) 14.9 (11) 12.2 (9)
M7-1 N·m (lb·ft) 5.4 (4) 6.8 (5) 5.4 (4) 13.6 (10) 17.6 (13) 14.9 (11) 19.0 (14) 25.8 (19) 21.7 (16)
M8-1.25 N·m (lb·ft) 8.1 (6) 9.5 (7) 8.1 (6) 19.0 (14) 25.8 (19) 21.7 (16) 27.1 (20) 36.6 (27) 31.2 (23)
M10-1.5 N·m (lb·ft) 14.9 (11) 19.0 (14) 16.3 (12) 38.0 (28) 50.2 (37) 43.4 (32) 54.2 (40) 71.9 (53) 61.0 (45)
M12-1.75 N·m (lb·ft) 25.8 (19) 33.9 (25) 28.5 (21) 66.4 (49) 88.1 (65) 74.6 (55) 94.9 (70) 126.1 (93) 107.1 (79)
M14-2 N·m (lb·ft) 40.7 (30) 54.2 (40) 46.1 (34) 105.8 (78) 141.0 (104) 119.3 (88) 150.5 (111) 200.7 (148) 170.8 (126)
M16-2 N·m (lb·ft) 63.7 (47) 84.1 (62) 71.9 (53) 164.1 (121) 218.3 (161) 185.7 (137) 234.6 (173) 311.8 (230) 265.7 (196)
M18-2.5 N·m (lb·ft) 88.1 (65) 116.6 (86) 99.0 (73) 226.4 (167) 301.0 (222) 256.2 (189) 324.0 (239) 431.2 (318) 366.1 (270)
M20-2.5 N·m (lb·ft) 123.4 (91) 165.4 (122) 141.0 (104) 320.0 (236) 425.7 (314) 362.0 (267) 456.9 (337) 608.8 (449) 517.9 (382)
M22-2.5 N·m (lb·ft) 169.5 (125) 225.1 (166) 191.2 (141) 435.2 (321) 580.3 (428) 493.5 (364) 623.7 (460) 831.1 (613) 706.4 (521)
N·m 214.2 286.1 242.7 551.8 736.2 625 789.1 1 053.5 894.8
M24-3
(lb·ft) (158) (211) (179) (407) (543) (461) (582) (777) (660)
N·m 314.5 418.9 355.2 809.4 1 079.2 916.5 1 157.9 1 544.3 1 312.4
M27-3
(lb·ft) (232) (309) (262) (597) (796) (676) (854) (1 139) (968)
N·m 425.7 568.1 482.7 1 096.9 1 462.9 1 243.3 1 570.0 2 093.4 1 778.8
M30-3.5
(lb·ft) (314) (419) (356) (809) (1 079) (917) (1 158) (1 544) (1 312)
N·m 578.9 772.8 656.2 1 492.8 1 990.3 1 692.1 2 136.8 2 848.6 2 421.5
M33-3.5
(lb·ft) (427) (570) (484) (1 101) (1 468) (1 248) (1 576) (2 101) (1 786)
N·m 744.3 992.5 843.3 1 918.5 2 557.1 2 173.4 2 744.2 3 659.4 3 110.2
M36-4
(lb·ft) (549) (732) (622) (1 415) (1 886) (1 603) (2 024) (2 699) (2 294)

TICO Manufacturing Service Manual 1-13

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
See Figures 1-12 and 1-13. rear side of the transmission. The nameplate shows the
transmission serial number (4), TransID (TID) level (3),
It is required that the Federal Motor Vehicle Safety and manufactured date (2). The serial number must be
Standards Certification be affixed to the vehicle. The provided when ordering replacement parts or requesting
certification label (1) is located inside the cab on the service information.
upper left side. The label shows the vehicle type (2),
vehicle identification number (VIN) (3), and date of See the Allison Transmission® manual for more
manufacture (4). It also shows the gross vehicle weight information.
rating (GVWR) (5), front and rear gross axle weight
ratings (GAWR) (6), tire size (7), wheel size (8), and cold
tire pressure (9) specifications.

1
1

TPS-015
1 Transmission Nameplate
Figure 1-14: Transmission Nameplate Location

1
2

TPS-011
1 Certification Label MADE BY UAW 933 IN INDIANAPOLIS, IN USA
Figure 1-12: Certification Label Location

2
3
4
5
3 4
6 TPS-016
9
1 Transmission Nameplate 3 TransID (TID) Level
2 Manufactured Date 4 Serial Number

8 Figure 1-15: Transmission Nameplate

7 TPS-012

1 Certification Label 6 Gross Axle Weight Rating

2 Vehicle Type (GAWR)
3 Vehicle Identification 7 Tire Size
Number (VIN) 8 Wheel Size
4 Date of Manufacture 9 Cold Tire Pressure
5 Gross Vehicle Weight
Rating (GVWR)
Figure 1-13: Certification Label

1-14 Service Manual TICO Manufacturing

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.
1
NOTES
• The engine dataplate must not be changed unless
approved by Cummins® Engine Company, Inc.
• If the engine dataplate (1) is not legible, the serial
number can also be found engraved on the engine
block near the oil cooler housing. TPS-013
See the Cummins® engine manual for more information. 1 Engine Dataplate
Figure 1-16: Engine Dataplate Location

1 2 3

TPS-014
1 Engine Dataplate 2 Engine Serial Number 3 Control Parts List (CPL)
Figure 1-17: Engine Dataplate

Fifth Wheel Serial Tag The part number and serial number are listed on the tag.

See Figures 1-18 and1-19.

Fifth wheel serial tag (1) is located on the handle side of
the fifth wheel top plate above the fifth wheel bracket pin,
or is located on the pickup ramps.
X

1 TPS-024
1 Fifth Wheel Serial Tag
Figure 1-19: Fifth Wheel Serial Tag
See the SAF-Holland® owner’s manual for more
1 information.

TPS-054
1 Fifth Wheel Serial Tag
Figure 1-18: Fifth Wheel Serial Tag Location

TICO Manufacturing Service Manual 1-15

 PRO-SPOTTER

2-0 Service Manual TICO Manufacturing

 Section 2

PREVENTATIVE MAINTENANCE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
DIESEL EXHAUST FLUID (DEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

TICO Manufacturing Service Manual 2-1

PREVENTATIVE MAINTENANCE PRO-SPOTTER

INTRODUCTION Exterior (Cab Down) Checks

• Check all fluid levels: engine oil, hydraulic oil,
The purpose of the PREVENTATIVE MAINTENANCE
coolant, and diesel exhaust fluid (DEF).
section is to provide service and maintenance personnel
with the required service procedures based on hour • Inspect trailer electrical cable and trailer air lines for
usage intervals to properly maintain TICO Pro-Spotter damage.
terminal trucks. • Start engine and check transmission fluid level with
The TICO Pro-Spotter terminal trucks have been parking brake applied and transmission shift selector
engineered for quick and efficient servicing while in “neutral”.
minimizing down time. The hydraulic system is • Check all lights for proper operation: headlights, turn
responsible for fifth wheel boom and power steering signals, brake lights, hazard lights, and marker lights.
operation. • Check and fill fuel tank.
Service and maintenance personnel should inspect the
entire hydraulic system frequently for leaks, loose fittings, Exterior (Cab Up) Checks
or damage. • Check cab hold down latch and the air suspension
For additional information, please contact TICO factory unit for proper latching.
support. See “CONTACT TICO SUPPORT” on
page 0-15. Under Vehicle Checks
• None at this interval.
DAILY PRE-OPERATION Chassis Checks
CHECKLIST • Check tires for damage and proper inflation.
The Daily Pre-Operation Checklist should be completed • Drain any moisture from air tanks.
by any operator or service and maintenance personnel • Check cab and frame for any structural damage or
prior to operating the machine. cracks.
Identified areas of concern should be addressed by • Ensure that all steps, walkways, and handholds are
qualified personnel only. References to procedures installed and in good working order.
documented within this manual or additional sources of
information have been provided where applicable. Lubrication Checks
For additional information, please contact TICO factory • Check fifth wheel grease.
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 operation.
• Check steering system for any binding. Make sure
steering effort is smooth and tight.
• Check transmission shift lever for any binding.
• Check horn(s) for proper operation.
• Check boom control lever for proper operation.
• Check accelerator for proper operation; should
operate smoothly and without any binding.

2-2 Service Manual TICO Manufacturing

PRO-SPOTTER PREVENTATIVE MAINTENANCE

EVERY 500 HOURS OF Exterior (Cab Down) Checks

OPERATION • Check cab access steps and handles.
• Check rear door bushings.
The following items are the preventative maintenance
• Check gladhand seals and trailer air lines.
procedures to be completed after every 500 hours of
operation on TICO Pro-Spotter terminal trucks. These • Check trailer light cord.
procedures should only be completed by qualified • Check headlights and marker lights.
service or maintenance personnel. • Check turn signals.
References to procedures documented within this • Check strobe light (if applicable).
manual or additional sources of information have been
• Check spotlights.
provided where applicable.
• Check wiper blades.
For additional information, please contact TICO factory
support. See “CONTACT TICO SUPPORT” on • Check windshield washer fluid level.
page 0-15.
Exterior (Cab Up) Checks
Cab Interior Checks • Check operation of cab tilt pump.
• Check operation of neutral start. • Check cab safety prop.
• Check operation of all gauges. • Check cab suspension and latch.
• Check low air buzzer and light. • Check intake ducting for leaks.
• Check windshield wiper operation. • Check radiator for leaks.
• Check windshield washer operation (if applicable). • Check radiator mounts.
• Check accelerator for free operation. • Check coolant level and concentration.
• Check horn(s) operation. • Check and adjust coolant additive (if applicable).
• Check air system for maximum 827 kPa (120 psi). • Check coolant hoses and clamps.
• Check air system for leak down. • Check fan clutch for operation (if applicable).
• Check operation of backup alarm. • Check engine cooling fan for cracks.
• Check operation of shift lock out. • Check engine belt(s) and tensioner.
• Check heating, ventilation, and air conditioning • Check engine and transmission for leaks.
(HVAC) system blower motor operation. • Drain fuel water separator.
• Check HVAC system temperature control. • Change fuel filter and fuel water separator.
• Check HVAC system auxiliary fan(s) (if applicable). • Check air restriction gauge (if applicable).
• Check HVAC system A/C operation (if applicable). • Check air filter. Change as necessary.
• Check HVAC system defroster operation. • Check air dryer desiccant. Change as necessary.
• Check operation of power take-off (PTO) control (if • Check exhaust system.
applicable).
• Check transmission fluid level.
• Check fifth wheel unlatch control.
• Clean transmission breather.
• Check operation of boom.
• Check fire extinguisher charge (if applicable).
• Check seat belt operation.
• Check rear door operation.
• Check dome light operation.
• Check all glass and mirrors.
• Check operation of windows.

TICO Manufacturing Service Manual 2-3

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.
• Check power steering pump. • Check and lubricate king pins and tie rod ends.
• Check hydraulic pump. • Check and lubricate drag link.
• Check starter mounting and connections. • Check and lubricate slack adjusters.
• Check engine and transmission for leaks. • Check and lubricate spring pins and bushings.
• Check engine and transmission mounts. • Check and lubricate driveline U-joints.
• Change engine oil and filter. • Check and lubricate lower boom cylinder bearing.
• Change transmission external filter. • Add grease to auto lube reservoir (if applicable).
• Check wheel seals for leaks. • Clean, check, adjust, and lubricate fifth wheel jaws.
• Check rear axle breather. • Check and lubricate fifth wheel top plate.
• Check differential for leaks. • Check and lubricate fifth wheel pivot pins.
• Check differential oil level. • Check and lubricate boom pivot bearings.
• Check lift cylinders for leaks. • Check and lubricate upper boom cylinder bearing.
• Torque rear axle mounting bolts.

Chassis Checks
• Check front axle oil level (if applicable).
• Repack front wheel bearings (if applicable).
• Check battery cables and hold downs.
• Check batteries for cracking or acid leaks.
• Clean battery cable connections.
• Check battery box cover hold downs.
• Drain 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 cracks.
• Check mud flaps and fenders (if applicable).
• Change hydraulic system filter.
• Check hydraulic fluid level.
• Change hydraulic fluid.
• Clean hydraulic tank vent.

2-4 Service Manual TICO Manufacturing

PRO-SPOTTER PREVENTATIVE MAINTENANCE

EVERY 1000 HOURS OF EVERY 2000 HOURS OF

OPERATION OPERATION
The following items are the preventative maintenance 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. service or maintenance personnel.
References to procedures documented within this References to procedures documented within this
manual or additional sources of information have been manual or additional sources of information have been
provided where applicable. provided where applicable.
For additional information, please contact TICO factory For additional information, please contact TICO factory
support. See “CONTACT TICO SUPPORT” on support. See “CONTACT TICO SUPPORT” on
page 0-15. page 0-15.

NOTE NOTE
All items listed are in addition to those of the every 500 All items listed are in addition to those of the every 500
hours check section. For more information, see “EVERY and 1000 hours check sections. For more information,
500 HOURS OF OPERATION” on page 2-3. see “EVERY 500 HOURS OF OPERATION” on page 2-3
and “EVERY 1000 HOURS OF OPERATION” on
Cab Interior Checks page 2-5.
• No additional checks at this interval.
Cab Interior Checks
Exterior (Cab Down) Checks • No additional checks at this interval.
• Clean heater and air conditioner filter (if applicable).
Exterior (Cab Down) Checks
Exterior (Cab Up) Checks • No additional checks at this interval.
• No additional checks at this interval.
Exterior (Cab Up) Checks
Under Vehicle Checks • Change engine coolant (except for optional extended
• No additional checks at this interval. life coolant).

Chassis Checks Under Vehicle Checks

• No additional checks at this interval. • Torque front axle mounting bolts.
• Torque king pin draw key nut(s).
Lubrication Checks • Change transmission fluid.
• No additional checks at this interval. • Change differential oil.

Chassis Checks
• No additional checks at this interval.

Lubrication Checks
• No additional checks at this interval.

TICO Manufacturing Service Manual 2-5

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 (29 qt) external lines or cooler hoses.
Transmission Fluid See Transmission Operator’s
Manual.
Drive Axle Oil 85-140 (synthetic is 39.7 L See Axle Operator’s Manual.
optional) (42 qt)
Hydraulic System Dexron® III 68.1 L Includes power steering.
(18 gal)
Chassis Fittings Lithoplex RT #2 as needed
Auto Lube Pump Reservoir Lithoplex RT #2 4 kg
(8.8 lb)
Cab Tilt Pump Dexron® III 1.9 L
(0.5 gal)

COOLING SYSTEM
Recommendations

System Fluid Type Capacity Notes

Cooling System 50/50 solution 53 L See Engine Operator’s Manual.
(ethylene glycol (56 qt)
Radiator permanent 37.9 L
antifreeze and (40 qt)
softened water)

2-6 Service Manual TICO Manufacturing

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) (5 gal) Manual.

 CAUTION
• Diesel exhaust fluid (DEF) contains urea. Do
not get the substance in your eyes. In case of
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.

NOTICE
• Prevent possible machine aftertreatment
system damage. Do not attempt to create
diesel exhaust fluid (DEF) by mixing
agricultural-grade urea with water.
Agricultural-grade urea does not meet the
required specifications.
• Prevent possible machine aftertreatment
system damage. Do not add any
chemicals/additives to the diesel exhaust
fluid in an effort to prevent freezing.

TICO Manufacturing Service Manual 2-7

PREVENTATIVE MAINTENANCE PRO-SPOTTER

DIESEL FUEL
Requirements

Ultra-Low Sulfur Diesel Fuel Cetain Number Sulfur Content

(ASTM S-15) Season (minimum) (maximum) Capacity
Number 1D or 2D Blended Winter 45 0.15% 246 L
(winterized) 15 ppm (65 gal)
Number 2D Summer 42

NOTICE
Prevent possible engine damage. TICO Manufacturing
requires that the operator of any TICO tractor comply
with the engine manufacturer’s fuel requirements. 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.

All TICO tractors come with an Engine Operator’s Manual

provided by the engine manufacturer. This manual is for
the specific engine in your vehicle. Refer to this Engine
Operator’s Manual for additional fuel requirements. On
road certified engines (Cummins ISB’s) require use of
“ULTRA LOW SULFUR FUEL” ONLY.

2-8 Service Manual TICO Manufacturing

PRO-SPOTTER PREVENTATIVE MAINTENANCE

LUBRICATION CHART
See Figures 2-1 and 2-2.

2
3
4

5
16
7

15

17

10

TPS-061
Figure 2-1: Chassis Lubrication

TICO Manufacturing Service Manual 2-9

PREVENTATIVE MAINTENANCE PRO-SPOTTER

23 24
18

19 21
20

18 22

14 21
13 12 11
TPS-062
Figure 2-2: Boom and Fifth Wheel Lubrication

2-10 Service Manual TICO Manufacturing

PRO-SPOTTER PREVENTATIVE MAINTENANCE

CALL OUT COMPONENT LUBRICANT USED

1 Coolant/Antifreeze 50/50 Ethyl-Glycol/Water
2 Engine Oil SAE 15W-40 (See Engine Operator’s Manual)
3 Slack Adjuster Brake Cam Pivot Lithoplex RT #2
4 Front Axle King Pin (2 used) Lithoplex RT #2
5 Tie Rod End (2 used) Lithoplex RT #2
6 Transmission Fluid Allison Approved TES 295® Automatic Transmission Fluid
(See Transmission Operator’s Manual)
7 Diesel 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 Line Slip Yoke Lithoplex RT #2
11 Spring Shackle Pin (4 used) Lithoplex RT #2
12 Wheel Bearing (4 used) 85-140 (synthetic is optional) (See Axle Operator’s Manual)
13 Drag Link Pivot (2 used) Lithoplex RT #2
14 Spring Guide Pin (2 used) Lithoplex RT #2
15 Hydraulic Oil Dexron® III
16 Power Steering Dexron® III
17 Cab Lift Pump Dexron® III
18 Steering Shaft U-Joint (2 used) Lithoplex RT #2
19 Steering Slip Joint Lithoplex RT #2
20 Boom Pivot Lithoplex RT #2
21 Cylinder Bearing (4 used) Lithoplex RT #2
22 Fifth Wheel Pivot Lithoplex RT #2
23 Fifth Wheel Top Plate Lithoplex RT #2
24 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 Location (maximum)
11R X 22.5-16PR Front 724 kPa
(105 psi)
Rear 655 kPa
(95 psi)

TICO Manufacturing Service Manual 2-11

 PRO-SPOTTER

3-0 Service Manual TICO Manufacturing

 Section 3
ELECTRICAL SYSTEM

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Solenoid Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Relay Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
FUSE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
POWER DISTRIBUTION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
VEHICLE ELECTRICAL CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
WIRING DIAGRAMS AND SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

TICO Manufacturing Service Manual 3-1

ELECTRICAL SYSTEM PRO-SPOTTER

INTRODUCTION
The purpose of the ELECTRICAL SYSTEM section is to
7
provide service and maintenance personnel with
guidance on the proper procedures for servicing
electrical equipment on TICO Pro-Spotter terminal 5
trucks. The electrical system is made up of a 12-volt 6
negative ground system, power distribution center (PDC), 1
160-amp Delco™ alternator, and a Delco™ starter. It 4
also consists of switches, wiring, instruments, etc., which 2
are required for the electrical system to perform its
functions.
The TICO Pro-Spotter terminal trucks have been 10
engineered for quick and efficient servicing while 3
minimizing downtime. 9 8 TPS-060
For additional information, please contact TICO factory 1 Drive Belt 6 Nut
support. (See “CONTACT TICO SUPPORT” on 2 Pulley 7 Bracket
page 0-15.) 3 Electrical Connector 8 Cap Screw
4 Electrical Connector 9 Nut
5 Mounting Cap Screw 10 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™ engine. When Manual.
servicing the alternator, follow these guidelines: 5. Install identification tags and disconnect electrical
• Always disconnect the negative (-) battery cable connectors (3 and 4).
when the engine is stopped and the alternator is not 6. Remove mounting cap screw (5) and nut (6).
in use before servicing the part.
7. Remove cap screw (8), nut (9), and alternator (10).
• Never disconnect or connect alternator wires while
the batteries are connected or the alternator is in
operation. Inspection
• Do not attempt to polarize the alternator or regulator. • Inspect alternator for damage. Repair or replace as
• Never ground to any of the alternator terminals. needed.
• Do not operate the alternator on an open circuit. • Inspect bolts, brackets, and wiring for damage.
Replace as needed.
For additional information, reference the Cummins™
Operation and Maintenance Manual provided with your • Inspect pulley and belt for wear or cracks. Replace as
TICO tractor. needed.

Removal Installation
See Figure 3-1. Installation is the reverse of the removal procedure.
1. Park and prepare tractor for service. (See “Park IMPORTANT
Tractor Safely” on page 1-3.) Avoid damage to the alternator diodes. Never reverse
2. Raise cab. the polarity of the batteries.
• Verify the alternator wires are correctly connected
IMPORTANT before installing the batteries.
Avoid damage to the alternator diodes. Never
disconnect the battery while the alternator is in
operation.
Specifications
3. Disconnect batteries. (See “BATTERY” on page 3-3.) Mounting Cap Screw—Toque Value 40 N·m
30 lb·ft
Cap Screw—Toque Value 24 N·m
212 lb·in

3-2 Service Manual TICO Manufacturing

PRO-SPOTTER ELECTRICAL SYSTEM

BATTERY Cable Specifications

Standard TICO Pro-Spotter terminal trucks are equipped The specifications listed below must be followed when
with two 12V 750 CCA 31-LHD threaded stud batteries. creating replacement battery cables.
The batteries are contained in a battery enclosure 1. The battery cable should have the following SAE
mounted on the right side frame exterior of the tractor. specification:
• Wire Type: SGX
 CAUTION • SAE Specification: J1127
• Prevent possible injury. Accidental contact • SAE Description: Low voltage battery cables
between positive (+) battery terminal and • Covers wires larger than 6 gauge
ground can cause arcing and burns. Always
2. Dimensions are shown in inches.
disconnect the battery negative (-) cable first
and battery positive (+) cable last. Connect • All dimensions shall be within 0.25” per foot.
battery positive (+) cable first and battery • Overall dimensions are from center of ring to
negative (-) cable last. center of ring.
• Prevent possible injury. Battery gas is • Dimensions for cables with one ring are from
explosive. Keep flash and fire away from center of ring to bare end of the cable.
batteries. 3. Terminals are required to be machine crimped.
• Prevent possible serious injury or burn. • Refer to the terminal manufacturer’s
Sulfuric acid within the battery electrolyte is a documentation for proper wire strip length.
hazardous material and direct contact should
• No loose strands are allowed.
be avoided.
• Crimp must meet manufacturer’s minimum
crimp specifications.
NOTE • Terminal must be tin-plated brass.
Black and (-) are used to identify the negative battery 4. After termination, terminals are required to be solder
terminal. Red and (+) are used to identify the positive dipped.
battery terminal. • 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 terminals have cooled, cover with an adhesive
filled heat-shrink tubing.
6. Install required cable protection.
• A 300-degree loom must be sized to completely
cover the cable.
• Red battery cables require a red loom.
• Black battery cables require a black loom.
• If a braid is required, the braid must be Nylon 6
or an equivalent.
7. The completed assembly must have a part number
label attached to one end of the cable.
• Label will include a part number, revision level,
and date of manufacture.
8. For instances where there are two battery cables
together as a set, use the following rules:
• Apply the requirements in steps 1—7 to each
individual cable.
• Use bonding tape to assemble cables together.
• Only one part number label is required per set.

TICO Manufacturing Service Manual 3-3

ELECTRICAL SYSTEM PRO-SPOTTER

Removal
See Figures 3-2 and 3-3.
 CAUTION
• Prevent possible injury. Accidental contact
NOTE between positive (+) battery terminal and
If the machine is out of use for more than 30 days, ground can cause arcing and burns. Always
remove the batteries. Store the batteries in a dry, cool, disconnect the battery negative (-) cable first
well-ventilated area and out of the reach of children and and battery positive (+) cable last. Connect
pets. battery positive (+) cable first and battery
1. Park and prepare tractor for service. (See “Park negative (-) cable last.
Tractor Safely” on page 1-3.) • Prevent possible injury. Battery gas is
explosive. Keep flash and fire away from
batteries.
• Prevent possible serious injury or burn.
Sulfuric acid within the battery electrolyte is a
2
hazardous material and direct contact should
3 be avoided.

1
4. Remove nuts (4), black battery jumper cable (5), and
busbar (6) from negative (-) battery terminals.
5. Remove nuts (4), red battery jumper cable (7), and
busbar (6) from positive (+) battery terminals.
6. Remove nuts (8), washers (9), and J-bolts (10)
7. Remove batteries (12) and battery covers (11).
TPS-020
1 Handle (2 used) 2 Battery Box 3 Rubber Mat
Inspection
Figure 3-2: Rubber Mat • Inspect cables and brackets for damage. Replace as
needed.
2. Unlatch the handles (1) to open the battery box (2).
• Clean battery and cables of dirt and corrosion using
3. Remove rubber mat (3).
an approved battery-cleaning solution.
• Check the water level and add water as needed.

IMPORTANT
7
4 4 To prevent damage to the battery and other
components, avoid a high charging rate on a fully
12 charged battery.
• Verify the battery is fully charged and properly
5
6 working.
4
4
9 Installation
Installation is the reverse of the removal procedure.
8 • Connect battery positive (+) cable first and battery
11
negative (-) cable last.
10 • Apply an anti-corrosion solution to battery terminals.
TPS-021 • Properly tighten all cables to the battery terminals to
4 Nut (4 used) 9 Washer (4 used) prevent weak electrical connections.
5 Jumper Cable 10 J-Bolt (4 used)
6 Busbar (2 used) 11 Battery Cover (2 used)
7 Jumper Cable 12 Battery (2 used)
8 Nut (4 used)
Figure 3-3: Battery Removal

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PRO-SPOTTER ELECTRICAL SYSTEM

ELECTRICAL COMPONENT 4. Turn key switch to the ON position.

CHECKS Is battery voltage measured?

YES Replace backup alarm.
The following checks are performed on electrical
components throughout the tractor. Wiring diagrams NO Check fuses and wiring.
needed to aid these checks can be found by contacting 5. With the key switch still in the ON position, measure
TICO support. (See “CONTACT TICO SUPPORT” on the continuity between pin A (2) of the wire harness
page 0-15.) electrical connector and the frame ground.
Prior to troubleshooting any electrical component, Is continuity measured?
perform the following checks: YES Replace backup alarm.
• Ensure the battery has full charge and cables are NO Backup alarm is good. Check wiring.
securely mounted to battery terminals.
• Inspect relays and circuit breakers.
Battery Voltage Check
• Check for broken, loose, or corroded wires and
connectors. See Figure 3-5.
• Study the appropriate wiring diagram.

Alternator and Battery Fuse Check

1. Remove fuse.
4
2. Measure the continuity of the terminals of the fuse.
Is continuity measured?
YES Fuse is good. Check wiring.
NO Replace the fuse.
5
Backup Alarm Check
See Figure 3-4.
6

TPS-021
1
4 Positive (+) Battery 6 Battery (2 used)
Terminal
5 Negative (-) Battery
Terminal
Figure 3-5: Battery Voltage Check
1. Turn key switch to the OFF position.
2 3 2. Connect a multimeter to the negative (-) battery
terminal (5) that is grounded to the frame and the
TPS-079 positive (+) battery terminal (4) that is connected to
1 Electrical Connector 3 Pin B the tractor.
2 Pin A 3. Measure the battery (6) voltage.
Figure 3-4: Back Up Alarm Connector (wire harness
side) Is the voltage between 12V and 14V?
YES Batteries are good.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) NO Batteries are not fully charged. Charge the
batteries.
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 ground.

TICO Manufacturing Service Manual 3-5

ELECTRICAL SYSTEM PRO-SPOTTER

Diode Check K3 Solenoid Function Test

See Figure 3-6. See Figure 3-7.

85 86
7

30

87

TPS-074
9 30 Terminal 30 86 Terminal 86
11 85 Terminal 85 87 Terminal 87
Figure 3-7: K3 Solenoid
10
1. Turn key switch to the ON position.
2. Use a voltmeter to check the voltage at terminal 85
TPS-075 and terminal 86 of the K3 solenoid.
7 Multimeter 10 Negative Multimeter Probe Does the voltage measure 12 volts?
8 Diode Test Function 11 Diode
9 Positive Multimeter Probe YES Solenoid is functional.
Figure 3-6: Diode Test NO Replace the K3 solenoid.
1. Remove the diode. 3. Use a voltmeter to check the voltage at terminal 30 to
the ground busbar.
2. Test the diode (11) using the diode test function (8)
on the multimeter (7). Does the voltage measure 12 volts?
Does the multimeter beep? YES Solenoid is functional.
YES Reverse the multimeter probes (9 and 10) NO Replace the K3 solenoid.
and test the diode again. 4. Use a voltmeter to check the voltage at terminal 87 to
NO Reverse the multimeter probes and test the the ground busbar.
diode again. Does the voltage measure 12 volts?
Does the multimeter beep? YES Solenoid is functional.
YES The multimeter beeped on the second test NO Replace the K3 solenoid.
but not on the first test. The diode is good.
YES The multimeter beeped on both tests.
Replace the diode.
NO The multimeter did not beep on the second
test but did beep on the first test.
The diode is good.
NO The multimeter did not beep on either test.
Replace the diode.

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PRO-SPOTTER ELECTRICAL SYSTEM

Relay Check
See Figure 3-8.

87 87

87 87 87a
86 85 86 85

86 85 86 85
87a

30
30 30 30

12 13 TPS-074
12 Standard Four Pin Relay 86 Terminal 86
13 Standard Five Pin Relay 87 Terminal 87
30 Terminal 30 87a Terminal 87a
85 Terminal 85
Figure 3-8: Relay Terminals
1. Stop the engine and remove the relay from the
tractor.
2. Measure the continuity between terminal 30 and
terminal 87a.
Is continuity measured?
YES Relay is good. Check wiring harness.
NO Replace relay.
3. Connect battery voltage 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, measure the continuity
between terminal 30 and terminal 87.
Is continuity measured?
YES Relay is good. Check wiring harness.
NO Replace relay.

TICO Manufacturing Service Manual 3-7

ELECTRICAL SYSTEM PRO-SPOTTER

FUSE SPECIFICATIONS
\

See Figures 3-9 and 3-10.

F1
The TICO Pro-Spotter is equipped with an easily F2
accessible fuse panel. This panel is located on the right
side of the dash and uses blade-type fuses. The fuse F3
decal is located to the right of the fuse block on the cover F4
of the heat assembly. This decal is to be used as a
reference to identify the fuses. F5
F6
For additional information, please contact TICO factory
support. (See “CONTACT TICO SUPPORT” on F7
page 0-15.) F8

IMPORTANT F9 F10
Install fuse with correct amperage rating to
prevent electrical system damage from overload. F11 F12

F13 F14

1 F15 F16

F17 F18
2
F19 F20

F21 F22

F24
F23

TPS-064
F1 Accessory 20A Fuse F13 HVAC Blower 30A Fuse
F2 AM/FM Radio 10A Fuse F14 Power Window 25A Fuse
4 3 F3 Computer 10A Fuse F15 Accessory 20A Fuse
F4 Spare 20A Fuse F16 Work Lights-Outboard 20A Fuse
F5 Lube System 10A Fuse F17 Work Lights-Inboard 20A Fuse
F6 Daytime Running Lights F18 Transmission Control Module
(DRL) Battery 10A Fuse (TCM) 5A Fuse
F7 Computer 10A Fuse F19 Engine Control Unit (ECU) 5A
Fuse
F8 AM/FM Radio 10A Fuse F20 Antilock Brake System (ABS)
5 6 Ignition 5A Fuse
F9 Camera/Outlet 10A Fuse F21 Strobe 10A Fuse
TPS-065
F10 Lube System 10A Fuse F22 Boom 10A Fuse
1 Auxiliary Fuse Panel 4 Fuse Block F11 Door/HVAC Actuators F23 Gauges 10A Fuse
2 Electrical Supply Board 5 Dash 10A Fuse
3 Fuse Block Cover 6 Cover F12 Dome/Fan 20A Fuse F24 Mirrors 20A Fuse
Figure 3-9: Fuse Block Location Figure 3-10: Fuse Block

3-8 Service Manual TICO Manufacturing

PRO-SPOTTER ELECTRICAL SYSTEM

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
is located on the exterior right side of the tractor next to consists of two electrical modules located behind the
the battery enclosure box. This placement allows for driver front access panel. This placement allows for ease
ease of handling during servicing, while minimizing of handling during servicing, while minimizing downtime.
downtime. These modules are also referred to as the cab power
For additional information, please contact TICO factory distribution center (CPDC).
support. (See “CONTACT TICO SUPPORT” on For additional information, please contact TICO factory
page 0-15.) support. (See “CONTACT TICO SUPPORT” on
page 0-15.)

1
1

2
TPS-003
1 Power Distribution Center (PDC)
Figure 3-11: Power Distribution Center (PDC)
Location
TPS-068
1 Vehicle Electrical Center 2 Vehicle Electrical Center
Module 1 (VEC1) Module 2 (VEC2)
6 7 8 Figure 3-13: Vehicle Electrical Center Modules

4
10
11

3 2 TPS-063
1 Power Distribution Center (PDC) 7 Lift Motor 125A Fuse 1
2 50A Circuit Breaker 8 Spare 125A Fuse
3 Fuse Box 9 Ignition 120A Circuit
4 Solenoid Breaker
5 Cab Battery 250A Fuse 10 Electrical Connector
6 Intake Heater 250A Fuse 11 Ignition Solenoid
Figure 3-12: Power Distribution Center (PDC)
Chassis Mounted

TICO Manufacturing Service Manual 3-9

ELECTRICAL SYSTEM PRO-SPOTTER

VEC1-R2 VEC1-R7
1
VEC1-F12 VEC1-F14

VEC1-F11 VEC1-F13 3

VEC1-F8
VEC1-F7 VEC1-R6
VEC1-F6
VEC1-F5 VEC1-R5
VEC1-F4
VEC1-F3 VEC1-R1

VEC1-F2
VEC1-F1

VEC1-F10 VEC1-F9
4

VEC1-R3 VEC1-R4
TPS-077
1 Vehicle Electrical Center Module VEC1-F4 Stop Lamp 10A Fuse VEC1-F10 Trailer Lights 10A VEC1-R2 Fan Clutch 2
1 (VEC1) Fuse Relay
3 Spare 20A Fuse (2 used) VEC1-F5 Spare 10A Fuse VEC1-F11 Reverse 20A Fuse VEC1-R3 Horn Relay
4 Spare 10A Fuse (2 used) 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 Fuse VEC1-F8 Fan Clutch 10A Fuse VEC1-F14 Spare 10A Fuse VEC1-R6 Fan Clutch 1
Relay
VEC1-F3 Headlight 20A Fuse VEC1-F9 Horn 10A Fuse VEC1-R1 Reverse Relay VEC1-R7 High Beam
Relay
Figure 3-14: Vehicle Electrical Center Module 1 (VEC1)

3-10 Service Manual TICO Manufacturing

PRO-SPOTTER ELECTRICAL SYSTEM

VEC2-R3 VEC2-R7
2
VEC2-R2

VEC2-F10 VEC2-F12
5
VEC2-F8
VEC2-F7 VEC2-R6
VEC2-F6 6
VEC2-F5
VEC2-F4 7
VEC2-F3 VEC2-R5
VEC2-F2
VEC2-F1 8

VEC2-F9 VEC2-F11

VEC2-R1 VEC2-R4

TPS-078
2 Vehicle Electrical Center VEC2-F2 TCM Battery 20A Fuse VEC2-F8 Spare 10A Fuse VEC2-R2 Wiper High Relay
Module 2 (VEC2)
5 Spare 30A Fuse VEC2-F3 Diagnostics 10A Fuse VEC2-F9 Key Switch Battery 20A VEC2-R3 Wiper Low Relay
Fuse
6 Spare 20A Fuse VEC2-F4 Hour Meter 10A Fuse VEC2-F10 Park Switch 10A Fuse VEC2-R4 Starter Lockout
Relay
7 Spare 10A Fuse VEC2-F5 Wiper 30A Fuse VEC2-F11 Engine Battery 30A Fuse VEC2-R5 Neutral Start Relay
8 Spare 5A Fuse VEC2-F6 Oil Pressure 5A Fuse VEC2-F12 Spare 10A Fuse VEC2-R6 Spare Relay
VEC2-F1 Start 30A Fuse VEC2-F7 Spare 10A Fuse VEC2-R1 Start Relay VEC2-R7 Spare Relay
Figure 3-15: Vehicle Electrical Center Module 2 (VEC2)

WIRING DIAGRAMS AND

SCHEMATICS
Wiring diagrams and electrical schematics are used to
aid in checking wire circuits and electrical
troubleshooting. 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” on page 0-15.)

TICO Manufacturing Service Manual 3-11

 PRO-SPOTTER

4-0 Service Manual TICO Manufacturing

 Section 4
ENGINE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
DRAINING FUEL/WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

TICO Manufacturing Service Manual 4-1

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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-2 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

INTRODUCTION 4. Remove dipstick and read oil level again.

The purpose of the ENGINE section is to provide service

and maintenance personnel with guidance on the proper
Coolant Level
procedures for servicing the Cummins™ engine and its See Figure 4-2.
related components, including the air intake and cooling 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.
For additional information, please contact TICO factory 3
support. (See “CONTACT TICO SUPPORT” on
page 0-15.) 1

CHECK FLUID LEVEL 2

Engine Oil Level

See Figure 4-1.
TPS-019
IMPORTANT 1 Sight Glass 2 Surge Tank 3 Surge Tank Cap

Avoid damage to the engine. Never operate the Figure 4-2: Coolant Level Check
engine with the oil level below the “L” (Low) mark or 2. Ensure the coolant level is up to the sight glass (1) on
above the “H” (High) mark. the surge tank (2).

NOTES
• Wait at least 15 minutes after shutting off the engine
 CAUTION
to allow time for the oil to drain into the oil pan before To avoid personal injury from escaping heated
checking the engine oil. coolant under pressure, allow engine to reach a
temperature of 49°C (120°F) or below. Relieve
• The vehicle must be level when checking the oil level
pressure from the coolant system by slowly
to make sure the measurement is correct.
removing the surge tank cap.

3. Remove surge tank cap (3) if necessary.

4. Using a syringe type tester, ensure coolant is
protected to at least -32°C (-25°F).

IMPORTANT
• Avoid damage to engine castings. Do not add
1 cold coolant to a hot engine. Allow engine to cool
to 49°C (120°F) before adding coolant.
• Avoid coolant system plugging and engine
overheat caused by inadequate coolant flow.
2 Never use a sealing additive to stop leaks in the
coolant system.
TPS-038
5. Add coolant if necessary.
1 Dipstick 2 Fuel Filter
6. Ensure the coolant level is up to the sight glass on
Figure 4-1: Dipstick Location
the surge tank.
1. Park and prepare tractor for service. (See “Park 7. Install surge tank cap.
Tractor Safely” on page 1-3.)
2. Remove the dipstick (1) and read oil level.
3. Add oil if necessary.

TICO Manufacturing Service Manual 4-3

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.
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.)
14

3
2
6
1

4 13
12
6

5 TPS-048
1 Filter Gauge 4 Hump Hose
2 Blower-to-Hump Hose Tube 5 Hose Clamp (3 used) TPS-050
3 Electrical Connector 6 Air Cleaner-to-Hump Hose 12 Cap Screw (4 used) 14 Air Intake Filter
Tube 13 Washer (4 used)
Figure 4-3: Air Intake System Removal Figure 4-5: Air Intake System Removal
4. Install identification tags and disconnect electrical 9. Remove cap screws (12), washers (13), and air
connector (3). intake filter (14).
5. Remove filter gauge (1) if necessary.
6. Loosen hose clamps (5) and remove hump hose (4) Inspection
and blower-to-hump hose tube (2).
1. Inspect air filter. (See “AIR FILTER” on page 4-5.)
2. Inspect the intake system for cracked silicone hoses,
9 loose clamps, or punctures, which can allow dirt and
7 debris to enter the engine.
3. Inspect the air inlet piping including all joints, clamps,
11
6 hoses, and connections to ensure they are tight.
8 4. Verify no holes or tears are present in the system.
5. Inspect air intake pipe supports to ensure no broken
or loose supports exist.
6. Repair or replace parts as necessary.
5

10 Installation
TPS-049 Installation is reverse of the removal procedure.
5 Hose Clamp (3 used) 9 Saddle Clamp
6 Air Cleaner-to-Hump Hose Tube 10 Hump Hose
7 Nut (2 used) 11 Hose Clamp
8 Washer (2 used)
Figure 4-4: Air Intake System Removal

4-4 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

AIR FILTER Inspection

See Figure 4-8.
Removal
See Figures 4-6 and 4-7. 5 4
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)

1
TPS-047
4 Filter Gauge 5 Blower-to-Hump Hose Tube
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
to be unserviceable.
1
• Clean all parts of dirt and debris.

TPS-039 Installation
1 Latch (4 used)
Installation is reverse of the removal procedure.
Figure 4-6: Air Filter
2. Unfasten latches (1) and remove cover. NOTE
Filter gauge should be reset when a new filter is installed.
• Install new filter if necessary and reset filter gauge.

2
3
TPS-040
2 Air Filter 3 Dust Cap
Figure 4-7: Air Filter Removal
3. Remove air filter (2).
4. Remove dust cap (3) and dispose of debris.
5. Repair or replace components as necessary.

TICO Manufacturing Service Manual 4-5

ENGINE PRO-SPOTTER

CHARGE AIR COOLER 19 20

18 21
Removal 25
See Figures 4-9, 4-10, and 4-11. 17
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
2. Raise cab. 22
15
3. Remove brush guard. (See “FRONT COVERS AND
16
GUARDS” on page 14-3.) 14
2 1
4 2
1 7
6 3
5

22
8

TPS-052
1 Hose Clamp (4 used) 5 Washer (2 used)
2 Hump Hose (2 used) 6 Lock Nut (2 used)
3 U-Bolt 7 Bracket
4 Charge Air Cooler Tube 8 Charge Air Cooler Tube 22 13
(left side) (right side) TPS-051
Figure 4-9: Charge Air Cooler (CAC) Removal 13 Cover (2 used) 19 Washer (4 used)
14 Cap Screw (4 used) 20 Cap Screw (2 used)
4. Remove U-bolt (3), bracket (7), washers (5), and lock 15 Washer (4 used) 21 Shield
nuts (6). 16 Lock Nut (4 used) 22 Cap Screw (6 used)
5. Disconnect tubes (4 and 8). Close all openings using 17 Condenser 25 Charge Air Cooler (CAC)
caps and plugs. 18 Lock Nut (2 used)
Figure 4-10: Charge Air Cooler (CAC)
(shown removed 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), washers (19), lock nuts
(18), and shield (21).

4-6 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

COOLING FAN

25
Removal
See Figures 4-12, 4-13, and 4-14.
1. Park and prepare tractor for service. (See “Park
23 Tractor Safely” on page 1-3.)
2. Raise the cab.
3. Disconnect battery cables. (See “BATTERY” on
page 3-3.)

2 1
2
4 1
24 7
6
3
5

TPS-052
1 Hose Clamp (4 used) 5 Washer (2 used)
2 Hump Hose (2 used) 6 Lock Nut (2 used)
TPS-055
3 U-Bolt 7 Bracket
23 Cap Screw (2 used) 25 Charge Air Cooler (CAC) 4 Charge Air Cooler (CAC) 8 Charge Air Cooler (CAC)
24 Transmission Cooler Tube (left side) Tube (right side)
Figure 4-11: Charge Air Cooler Cap Screws Figure 4-12: Charge Air Cooler (CAC) Tube Removal
9. Remove cap screws (23) and charge air cooler 4. Remove U-bolt (3), bracket (7), washers (5), and lock
(CAC) (25). nuts (6).
5. Disconnect tubes (4 and 8). Close all openings using
Inspection caps and plugs.

• Check CAC for cracks, holes, or other damage.

Replace parts found to be unserviceable.
• Inspect CAC piping, hoses, fittings, and clamps for
leaks, holes, cracks, and loose connections. Replace
parts found to be unserviceable.
• Clean all parts of dirt and debris.

Installation
Installation is reverse of the removal procedure.

TICO Manufacturing Service Manual 4-7

ENGINE PRO-SPOTTER

10

17
15 16
14 18
11 19 20
12

11
TPS-057
12 17 Cap Screw (4 used) 19 Washer (4 used)
13 18 Lock Washer (4 used) 20 Cooling Fan
TPS-056
Figure 4-14: Cooling Fan
9 Upper Radiator Hose 13 Lock Nut (8 used)
10 Hose Clamp 14 Washer (4 used)
11
12
Cap Screw (12 used)
Washer (20 used)
15
16
Lock Washer (4 used)
Upper Fan Shroud
 CAUTION
Figure 4-13: Cooling Fan Removal Prevent possible injury due to fan blade failure.
Never pull or pry on the fan. This may damage fan
NOTE blades and cause fan failure.

A suitable container is needed for draining coolant from

the upper radiator hose. The surge tank will also drain at 8. Remove cap screws (17), lock washers (18),
the radiator inlet port. washers (19), and cooling fan (20).
6. Loosen hose clamp (10). Disconnect upper radiator
hose (9) and allow coolant to drain. Close all Inspection
openings using caps and plugs. • Check for cracks, loose rivets, and bent or loose
7. Remove cap screws (11), washers (12 and 14), lock blades. Replace cooling fan if damaged.
washer (15), lock nuts (13), and upper fan shroud • Check that the cooling fan is securely mounted and
(16). tighten any loose cap screws.
• Clean all parts of dirt and debris.

Installation
Installation is reverse of the removal procedure.

4-8 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

DIESEL EXHAUST FLUID (DEF)

TANK
6
Removal 8
See Figures 4-15 and 4-16. 9
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.)
11
10
7
TPS-042
6 Diesel Exhaust Fluid (DEF) Tank 9 Coolant Return Hose
5 7 Diesel Exhaust Fluid (DEF) 10 Coolant Inlet Hose
Suction Line
8 Diesel Exhaust Fluid (DEF) 11 Electrical Connector
Return Line
6
Figure 4-16: DEF Tank Removal
4
5. Install identification tags and disconnect electrical
connector (11).
6. Install identification tags and disconnect hoses (9
and 10). Close all openings using caps and plugs.
7. Install identification tags and disconnect DEF lines (7
and 8). Close all openings using caps and plugs.
3 3
8. Remove DEF tank (6).
2 2
9. Properly drain or dispose of DEF.
2 2
1 1
Inspection
• Check hoses, lines, fittings, and clamps for wear or
damage. Replace parts found to be unserviceable.
TPS-041
1 Lock Nut (4 used) 5 Diesel Exhaust Fluid (DEF)
• Inspect DEF tank and filler cap for damage or signs
2 Washer (8 used) Tank Cover of leakage. Replace parts found to be unserviceable.
3 Bolt (4 used) 6 Diesel Exhaust Fluid (DEF) • Check all threaded components for damaged or
4 Bracket (4 used) Tank stripped threads. Repair light damage with thread
Figure 4-15: Diesel Exhaust Fluid (DEF) Tank Cover chasers. Replace parts found to be unserviceable.
3. Remove lock nuts (1), washers (2), and bolts (3). • Check electrical connectors and wire harness for
4. Remove brackets (4) and diesel exhaust fluid (DEF) wear or damage. Replace parts found to be
tank cover (5). unserviceable.
• Clean all parts of dirt and debris.

Installation
Installation is reverse of the removal procedure.

IMPORTANT
Avoid damage to the aftertreatment system. Do not
add any other fluid besides what is specified to the
DEF tank.
• Fill the DEF tank with recommended fluid type. See
the Cummins™ Operation and Maintenance Manual
for more information.

TICO Manufacturing Service Manual 4-9

ENGINE PRO-SPOTTER

FUEL FILTER Inspection

• Inspect filter head for damage or signs of leakage.
Removal Replace parts found to be unserviceable.
See Figure 4-17. • Check hoses, fittings, and clamps for wear or
damage. Replace parts found to be unserviceable.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) • Check wiring harness for wear or damage. Replace
parts found to be unserviceable.
2. Disconnect battery cables. (See “BATTERY” on
page 3-3.) • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
5 • Clean all parts of dirt and debris.
4 6
5
Installation
Installation is reverse of the removal procedure.
• Replace all O-ring seals and apply an approved
lubricant before installation.
9 9
IMPORTANT
7 2 Avoid damage to fuel system components. Do not
pour fuel directly in the center and bypass the filters.
3 This allows unfiltered fuel to enter the system.
• Fill new fuel filter with clean fuel before installation.
8 • Install new fuel filter and tighten to specification.

Specifications
8 N·m
Fuel Filter—Torque Value 71 lb·in
1

NOTE
TPS-043
1 Electrical Connector 6 Lock Nut (2 used)
Priming may need to be repeated until engine starts. Dry
2 Fuel Tank-to-Fuel Filter Hose 7 Filter Head filters may need approximately 140 stokes. Pre-filled
3 Fuel Filter-to-Engine Hose 8 Fuel Filter filters may need 20 to 60 strokes.
4 Cap Screw (2 used) 9 Hose Clamp (2 used) • Use the priming hand pump to prime the fuel system.
5 Washer (4 used)
• Operate the engine and check for leaks.
Figure 4-17: Fuel Filter
3. Install identification tags and disconnect electrical
connector (1).
4. Install identification tags and disconnect hoses (2
and 3). Close all openings using caps and plugs.

NOTE
A SAE 1-in wrench may be used to loosen the fuel filter
(8).
5. Remove fuel filter (8).
6. Remove cap screws (4), washers (5), lock nuts (6),
and filter head (7).
7. Repair or replace components as necessary.

4-10 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

FUEL TANK
Removal
See Figures 4-18 and 4-19. 8 8
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.)

6 9
7 7
TPS-045
6 Fuel Tank 8 Strap (2 used)
7 Nut (2 used) 9 Plug
Figure 4-19: Fuel Tank
5. Remove plug (9) to drain fuel tank.

Specifications
246 L
Fuel Tank—Capacity 65 gal

3 6. Remove grates. (See “LEFT COVERS AND

2
GUARDS” on page 14-8.)
5
5 7. Remove nuts (7) and straps (8).
4 8. Remove fuel tank (6).
5 9. Repair or replace components as necessary.

1 Inspection
• Check hoses, fittings, and clamps for wear or
damage. Replace parts found to be unserviceable.
• Inspect fuel tank and filler cap for damage or signs of
6 leakage. Repair or 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.
• Check wiring harness for wear or damage. Replace
parts found to be unserviceable.
• Clean all parts of dirt and debris.

TPS-044 Installation
1 Electrical Connector 4 Fuel Tank-to-Fuel Filter Hose
Installation is reverse of the removal procedure.
2 Fuel Tank-to-Engine Hose 5 Hose Clamp (3 used)
3 Overflow Hose 6 Fuel Tank • Fill the fuel tank with recommended fuel type. See
Figure 4-18: Fuel Tank Connections the Cummins™ Operation and Maintenance Manual
for more information.
3. Install identification tags and disconnect electrical
connector (1). • Prime the fuel system. See the Cummins™
Operation and Maintenance Manual for more
4. Install identification tags and disconnect hoses (2, 3, information.
and 4). Close all openings using caps and plugs.
• Operate the machine and check for leaks.

TICO Manufacturing Service Manual 4-11

ENGINE PRO-SPOTTER

DRAINING FUEL/WATER RADIATOR

SEPARATOR
See Figure 4-20.
Removal
1. Park and prepare tractor for service. (See “Park See Figures 4-21 and 4-22.
Tractor Safely” on page 1-3.) 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.)

 CAUTION
3
Avoid injury and serious burns from escaping
cooling system fluid under pressure. Stop engine
and allow cooling system temperature to reach
50°C (120°F) or below. Slowly loosen filler cap to
relieve pressure.

3. Drain cooling system into a suitable container. (See

“Cooling System Draining” on page 4-14.)
1
Specifications
Cooling System—Capacity 53 L
14 gal
Radiator—Capacity 38 L
2 10 gal

TPS-046
1 Fuel Filter 2 Drain Valve 3 Priming Hand Pump
Figure 4-20: Fuel/Water Separator
2. Open drain valve (2).
3. Drain the fuel/water separator into a suitable
container until the fuel turns clear.
4. Properly dispose of waste.

IMPORTANT
Avoid damage to the valve threads. Do not
overtighten the drain valve.
5. Hand tighten the drain valve until it is securely
closed.

NOTE
Priming may need to be repeated until engine starts. Dry
filters may need approximately 140 stokes. Pre-filled
filters 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.

4-12 Service Manual TICO Manufacturing

PRO-SPOTTER ENGINE

8. Remove rods (14), rubber mounts (15), washers

1 (16), jamnuts (17), and lock nuts (18).
2

11

8
4
6 7
3

16 22
3 17
18
4
14 10
4 21
5 16
15 20
9 19
TPS-045
19 Lock Nut (2 used) 21 Isolator (2 used)
20 Washer (2 used) 22 Radiator
Figure 4-22: Lower Radiator
9. Remove lock nuts (19), washers (20), and isolators
(21).
10. Remove radiator (22).
11. Repair or replace components as necessary.
13
12
TPS-051 Inspection
1 Hose Clamp 10 Condenser • Check radiator for cracks, broken fins, or other
2 Upper Radiator Hose 11 Charge Air Cooler (CAC) damage. Replace parts found to be unserviceable.
3 Cap Screw (20 used) 12 Transmission Cooler
4 Washer (28 used) 13 Lower Radiator Hose
• Inspect radiator piping, hoses, fittings, and clamps for
5 Lock Nut (8 used) 14 Rod (2 used) leaks, holes, cracks, and loose connections. Replace
6 Washer (12 used) 15 Rubber Mount (8 used) parts found to be unserviceable.
7 Lock Washer (12 used) 16 Washer (8 used) • Clean all parts of dirt and debris.
8 Upper Fan Shroud 17 Jamnut (4 used)
9 Lower Fan Shroud 18 Lock Nut (4 used)
Figure 4-21: Charge Air Cooler (CAC) Installation
(shown removed for clarity) Installation is reverse of the removal procedure.
4. Remove charge air cooler (CAC) (11). (See
“CHARGE AIR COOLER” on page 4-6.)
5. Remove transmission cooler (12). (See
“TRANSMISSION COOLER” on page 5-4.)
6. Loosen hose clamp (1) and disconnect upper
radiator hose (2). Close all openings using caps and
plugs.
7. Remove cap screws (3), washers (4 and 6), lock
washer (7), lock nuts (5), upper fan shroud (8), and
lower fan shroud (9).

TICO Manufacturing Service Manual 4-13

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” on page 1-3.)
Specifications
 CAUTION
Cooling System—Capacity
53 L
14 gal
• To avoid personal injury from escaping
heated coolant under pressure, allow engine
to reach a temperature of 49°C (120°F) or 7. Check cooling system for leaks and damaged hoses
below. Relieve pressure from the coolant and loose or damaged hose clamps.
system by slowly removing the radiator cap. 8. Close drain valve and connect lower radiator hose.
• To prevent skin disorders and bodily injury,
avoid excessive skin contact with used Cooling System Flushing
antifreeze. Wash thoroughly after contact.
Keep out of reach of children. 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
2. Drain cooling system. (See “COOLING SYSTEM
1 MAINTENANCE” 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.

NOTES
2
Adequate venting 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).
TPS-019
1 Filler Cap 2 Surge Tank 4. Wait for 2 to 3 minutes to allow the system to
Figure 4-23: Surge Tank Filler Cap naturally vent air and coolant levels to stabilize.
5. Add plain water to the system to bring the level back
2. Remove filler cap (1) on surge tank (2). to FULL.

 CAUTION
• Avoid personal injury. Do not stand near the
surge tank or radiator while operating the
engine with the filler cap off.
• To prevent skin disorders and bodily injury,
avoid excessive skin contact with used
antifreeze. Wash thoroughly after contact.
Keep out of reach of children.
5
4
3
TPS-058
3 Lower Radiator Hose 5 Radiator
4 Drain Valve
Figure 4-24: Radiator Drain Valve

4-14 Service Manual TICO Manufacturing

 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. Check coolant level.
engine with the pressure cap off at temperatures
above 93°C (200°F). 6. Add coolant as necessary.

NOTES  CAUTION
• Do not install the filler cap. The engine is to be • Avoid personal injury. Do not stand near the
operated without the cap for this process. surge tank or radiator while operating the
• Turn cab heater switches to HIGH and blower engine with the filler cap off.
switches to ON to allow maximum coolant flow • To prevent skin disorders and bodily injury,
throughout the heater core. avoid excessive skin contact with used
6. With the filler cap removed, operate engine at LOW antifreeze. Wash thoroughly after contact.
IDLE for 2 minutes. Keep out of reach of children.
7. Shut off engine and add plain water to the system to
bring the level back to FULL.
8. With the filler cap removed, operate engine at HIGH NOTES
IDLE until thermostat opens. Then allow engine to • Do not install the filler cap. The engine is to be
return to LOW IDLE for 2 minutes. operated without the cap for this process.
9. Shut off engine and add coolant to the system to • Turn cab heater switches to HIGH and blower
bring the level back to FULL. switches to ON to allow maximum coolant flow
10. Install filler cap and operate engine for 1 hour with throughout the heater core.
the coolant temperature above 80°C (176°F). 7. With the filler cap removed, operate engine at LOW
11. Shut off engine. IDLE for 2 minutes.
12. Drain cooling system. (See “COOLING SYSTEM 8. Shut off engine and add 50/50 mixture to the system
MAINTENANCE” on page 4-14.) to bring the level back to FULL cold.
13. Fill the cooling system with clean water. 9. With the filler cap removed, operate engine at HIGH
14. Repeat steps 4 through 8. IDLE until thermostat opens. Then allow engine to
return to LOW IDLE for 2 minutes.
15. Shut off engine.
10. Shut off engine and add coolant to the system to
16. Drain water from cooling system. (See “COOLING bring the level back to FULL hot.
SYSTEM MAINTENANCE” on page 4-14.)
11. Allow the system to cool to 50°C (176°F) and install
17. Fill the cooling system. (See “Cooling System Filling” filler cap.
on page 4-15.)
12. Operate engine until coolant temperature reaches
80°C (176°F).
Cooling System Filling 13. Check cooling system for leaks and damaged hoses
1. Park and prepare tractor for service. (See “Park and loose or damaged hose clamps.
Tractor Safely” on page 1-3.)
2. Drain cooling system. (See “Cooling System
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 use
water alone as a coolant.
\

NOTES
Adequate venting is provided for a fill rate of 19 L (5 gal)
per minute.

TICO Manufacturing Service Manual 4-15

ENGINE PRO-SPOTTER

SURGE TANK Inspection

• Check hoses, fittings, and clamps for wear or
Removal damage. Replace parts found to be unserviceable.
1. Park and prepare tractor for service. (See “Park • Inspect surge tank and filler cap for damage or signs
Tractor Safely” on page 1-3.) of leakage. Repair or replace parts found to be
unserviceable.
2. Disconnect battery cables. (See “BATTERY” on
page 3-3.) • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
 CAUTION
• Check wiring harness for wear or damage. Replace
Avoid injury and serious burns from escaping parts found to be unserviceable.
cooling system fluid under pressure. Stop engine • Clean all parts of dirt and debris.
and allow cooling system temperature to reach
50°C (120°F) or below. Slowly loosen filler cap to
relieve pressure. Installation
Installation is reverse of the removal procedure.
3. Drain cooling system into a suitable container. (See • Properly fill the cooling system with recommended
“Cooling System Draining” on page 4-14.) coolant. See the Cummins™ Operation and
Maintenance Manual for more information.
Specifications • Operate the engine and check for leaks.
53 L
Cooling System—Capacity 14 gal

4 5 6
8
9
7
3 9
2
10
1

11
12

TPS-019
1 Surge Tank 7 Lock Nut (4 used)
2 Electrical Connector 8 Cap Screw (4 used)
3 Engine-to-Surge Tank Hose 9 Hose Clamp (2 used)
4 Overflow Hose 10 Radiator-to-Surge Tank Hose
5 Filler Cap 11 Hose Clamp
6 Washer (4 used) 12 Surge Tank-to-Frame Coupler
Hose
Figure 4-25: Surge Tank
4. Disconnect electrical connector (2).
5. Install identification tags and disconnect hoses (3,
4,10, and 12). Close all openings using caps and
plugs.
6. Remove lock nuts (7), washers (6), and cap screws
(8).
7. Remove surge tank (1).

4-16 Service Manual TICO Manufacturing

 Section 5

TRANSMISSION

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
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 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transmission Fluid Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transmission Fluid Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

TICO Manufacturing Service Manual 5-1

TRANSMISSION PRO-SPOTTER

INTRODUCTION
Standard TICO tractors are equipped with an Allison
Transmission® fully automatic transmission. These 1
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®.
For additional service and maintenance information, see
the Allison Transmission® operator’s manual.

CHECK FLUID LEVEL

TPS-071
Transmission Fluid 1 Dipstick
Periodic transmission fluid level checks help prevent Figure 5-1: Dipstick Location
mechanical failure of a vehicle or transmission
component. Periodic checks also help detect the 6. Clean any dirt or debris from the end of the fill tube
following conditions: before removing the dipstick (1).
• Cooler failures 7. Remove the dipstick and wipe it clean.
• Fluid contamination
• Fluid leaks NOTE
• Fluid overfill Manual transmission fluid level checks should be
performed with the dipstick in the unscrewed or loose
• Fluid underfill
position.
• Incorrect fluid used at last servicing
8. Insert the dipstick into the fill tube. Push down until
Transmission fluid level checks may be completed the dipstick stops while still in an unscrewed or loose
manually by checking the dipstick (1) or electronically via position.
the transmission gear selector.
Transmission fluid level is dependent upon fluid operating
temperatures due to thermal expansion. Procedures vary
FULL
HOT

depending upon transmission fluid temperature.

1
Manual Check—Cold
See Figures 5-1 and 5-2.
ADD
HOT

The cold check band (2) on the dipstick (1) verifies that
COLD
FULL

the transmission has adequate fluid for start-up and

operation until it can be checked at the operating (hot)
temperature. Fluid levels for continued operation should 2
not be adjusted based on a cold check alone. A cold
COLD
ADD

check is the most accurate with fluid temperatures of

TPS-070
16°—49°C (61°—120°F).
1 Dipstick 2 Cold Check Band
1. Park the tractor on a level surface and shift to neutral Figure 5-2: Manual Cold Check
(N).
2. Apply the parking brake. 9. Remove the dipstick and observe the fluid level. If the
transmission fluid is within the cold check band (2),
3. With the engine idling, shift to drive (D) and then to the fluid level is satisfactory.
reverse (R) remove air from hydraulic circuits.
10. If necessary, add or remove transmission fluid until
4. Shift to neutral (N). the transmission fluid level is within the cold check
5. Allow the engine to idle for approximately 1 minute. band.

5-2 Service Manual TICO Manufacturing

PRO-SPOTTER TRANSMISSION

11. Perform a hot manual check once the transmission

fluid has reached 71°—93°C (160°—200°F). 1
For additional service and maintenance information, see

FULL
HOT
the Allison Transmission® operator’s manual.

Manual Check—Hot 3

ADD
HOT
See Figures 5-3 and 5-4.
The hot check band (3) on the dipstick (1) offers the best

COLD
FULL
assurance of maintaining the correct fluid levels. Hot
checks should be performed at normal transmission
operating fluid temperatures of 71°—93°C (160°—
200°F). While a cold check must be performed prior to

COLD
ADD
start-up, fluid levels for continued operation should be TPS-070
adjusted based on hot check results. 1 Dipstick 3 Hot Check Band
1. Ensure transmission fluid has reached a normal Figure 5-4: Manual Hot Check
operating fluid temperature of 71°—93°C (160°— 7. Remove the dipstick and observe the fluid level. If the
200°F). transmission fluid is within the hot check band (3),
2. Park the tractor on a level surface and shift to neutral the fluid level is satisfactory.
(N). 8. If necessary, add or remove transmission fluid until
3. Apply the parking brake. the transmission fluid level is within the hot check
band.
9. Perform a hot manual check once again to ensure
consistent measurements.
1 For additional service and maintenance information, see
the Allison Transmission® operator’s manual.

Electronic Check—Hot
See Figure 5-5.
The electronic hot check offers additional information not
available when performing a manual check. The
transmission gear selector (4) will delay displaying the
fluid level results until the following conditions are met:
• The transmission fluid temperature is above 40°C
(104°F) or below 104°C (220°F).
• Transmission is in neutral (N).
• The tractor has been stationary for approximately 2
TPS-071
minutes to allow the fluid to settle.
1 Dipstick
• The engine is running at idle.
Figure 5-3: Dipstick Location
While an electronic check provides more specific
4. Clean any dirt or debris from the end of the fill tube information regarding the fluid level, a manual check
before removing the dipstick (1). should be performed to verify the electronic check
5. Remove the dipstick and wipe it clean. results.
1. Park the tractor on a level surface and shift to neutral
NOTE (N).
Manual transmission fluid level checks should be 2. Apply the parking brake.
performed with the dipstick in the unscrewed or loose
position. NOTE
6. Insert the dipstick into the fill tube. Push down until The tractor must be completely stopped with a
the dipstick stops while still in an unscrewed or loose transmission output shaft speed of 0 rpm.
position.
3. Allow the engine to idle.
4. Allow the transmission fluid to settle for 2 minutes.

TICO Manufacturing Service Manual 5-3

TRANSMISSION PRO-SPOTTER

1
3
4
5 5

6
6 TPS-180
1 Transmission Cooler 4 Cap Screw (4 used)
2 Transmission Line 5 Washer (8 used)
3 Transmission Line 6 Lock Nut (4 used)
Figure 5-6: Transmission Cooler
TPS-069 4. Position a suitable container below the transmission
4 Transmission Gear 6 Down-Shift Button line connections on the transmission cooler (1).
Selector
5 Up-Shift Button
Figure 5-5: Transmission Gear Selector  CAUTION
5. Request a fluid level measurement and readout by Avoid injury and serious burns from draining
simultaneously pressing the up-shift and down-shift transmission fluid. Avoid contact with hot
buttons (5 and 6) once on the transmission gear transmission fluid.
selector (4).
6. Obtain the reading from the transmission gear 5. Install identification tags and disconnect transmission
selector display. lines (2 and 3). Close all openings using caps and
For additional information, see the Allison Transmission® plugs.
operator’s manual 6. Remove cap screws (4), washers (5), lock nuts (6),
and transmission cooler.
TRANSMISSION COOLER 7. Repair or replace components as necessary.

Removal Inspection
See Figure 5-6. • Check hoses, lines, fittings, and clamps for wear or
damage. Replace parts found to be unserviceable.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
2. Disconnect battery cables. (See “BATTERY” on
chasers. Replace parts found to be unserviceable.
page 3-3.)
• Clean all parts of dirt and debris.
3. Remove brush guard. (See “FRONT COVERS AND
GUARDS” on page 14-3.)
Installation
Installation is reverse of the removal procedure.
• Check transmission fluid level. (See “CHECK FLUID
LEVEL” on page 5-2.)
• Fill transmission fluid as necessary. (See
“Transmission Fluid Filling” on page 5-7.)
For additional information, see the Allison Transmission®
operator’s manual.

5-4 Service Manual TICO Manufacturing

PRO-SPOTTER TRANSMISSION

TRANSMISSION FILTER

1 2
LUBE MAIN

1 2

3
TPS-072
1 Lube Filter Cover 3 Cap Screw (12 used) 5 O-Ring (2 used) 7 Filter (2 used)
2 Main Filter Cover 4 Gasket (2 used) 6 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).
See Figure 5-7.
7. Repair or replace components as necessary.
NOTE
Transmission fluid does not require draining if only filters Inspection
are being replaced. • Check all threaded components for damaged or
1. Park and prepare tractor for service. (See “Park stripped threads. Repair light damage with thread
Tractor Safely” on page 1-3.) chasers. Replace parts found to be unserviceable.
2. Disconnect battery cables. (See “BATTERY” on • Clean all parts of dirt and debris.
page 3-3.)
3. Position a suitable container under the lube and main
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.

TICO Manufacturing Service Manual 5-5

TRANSMISSION PRO-SPOTTER

Installation TRANSMISSION FLUID

1. Lubricate and install new O-rings (5 and 6) on lube MAINTENANCE
and main filter covers (1 and 2).
2. Lubricate O-ring inside filters (7). Transmission Fluid Draining
3. Push filters onto filter covers.
See Figure 5-8.
4. Install new gaskets (4) onto filter covers and align
holes in the gaskets to the holes in the covers. NOTE
Transmission fluid does not require draining if only filters
IMPORTANT are being replaced.
Prevent possible damage to threads. Do not use the 1. Ensure transmission fluid has reached a normal
cap screws to draw in filter covers. Push the operating fluid temperature of 71°—93°C (160°—
assemblies in by hand to seat the seals before 200°F).
installing cap screws.
2. Park and prepare tractor for service. (See “Park
5. Install filter and filter cover assemblies into filter Tractor Safely” on page 1-3.)
compartment. Push the assemblies in by hand to
3. Disconnect battery cables. (See “BATTERY” on
seat the seals.
page 3-3.)
6. Install cap screws (3) and tighten to specification.

Specification
Cap Screw—Torque 51—61 N·m
38—45 lb·ft

7. Check transmission fluid level. (See “CHECK FLUID

LEVEL” on page 5-2.)
8. Fill transmission fluid as necessary. (See
“Transmission Fluid Filling” on page 5-7.) 1
For additional information, see the Allison Transmission®
operator’s manual.

TPS-073
1 Drain Plug
Figure 5-8: Drain Plug
4. Position a suitable container under the transmission
drain plug (1).

 CAUTION
Avoid injury and serious burns from draining
transmission fluid. Avoid contact with hot
transmission fluid.

NOTE
Transmission fluid should be drained while still at normal
operating temperatures. Hot fluid flows quicker and
drains more completely.

5-6 Service Manual TICO Manufacturing

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
2
29 qt

6. Examine the transmission fluid for signs of dirt, water,

or debris.
For additional information, see the Allison Transmission®
operator’s manual.

Transmission Fluid Filling

See Figures 5-9 and 5-10.
1. Park and prepare tractor for service. (See “Park TPS-071
Tractor Safely” on page 1-3.)
2 Dipstick
2. Replace the drain plug O-ring. 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.

Specification
Transmission Fluid—Capacity 27.4 L
29 qt
1
7. Periodically perform a manual cold check to verify the
transmission has adequate fluid for start-up and
operation. (See “Manual Check—Cold” on page 5-2.)
8. Inspect area for leaks before operating the tractor.
9. Operate tractor.
10. Inspect for leaks.
TPS-073
For additional information, see the Allison Transmission®
1 Drain Plug operator’s manual.
Figure 5-9: Drain Plug
3. Install the drain plug (1) and tighten to specification.

Specification
Drain Plug—Torque 25—32 N·m
18—24 lb·ft

TICO Manufacturing Service Manual 5-7

 PRO-SPOTTER

6-0 Service Manual TICO Manufacturing

 Section 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
FRONT END ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
STEERING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
TIE ROD BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

TICO Manufacturing Service Manual 6-1

FRONT AXLE & STEERING PRO-SPOTTER

INTRODUCTION CHECK FLUID LEVEL

The purpose of the FRONT AXLE & STEERING section
is to provide service and maintenance personnel with Front Axle Fluid
guidance on the proper procedures for servicing the front See Figure 6-1.
axle, front suspension, and steering system on TICO
Pro-Spotter terminal trucks. 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
The TICO Pro-Spotter terminal trucks have been
engineered for quick and efficient servicing while
minimizing downtime. For best performance and longer
vehicle life, follow the maintenance procedures provided 3
in this section. 2
For additional information, please contact TICO factory 1
support. (See “CONTACT TICO SUPPORT” on
page 0-15.)

TPS-022
1 FULL Line 3 ADD Line
2 Center Plug 4 Oil Level Line
Figure 6-1: Front Axle Fluid Level
2. Compare oil level line (4) to ADD and FULL lines (3
and 1) to determine proper oil capacity on both sides
of truck.
3. If oil needs to be added, remove center plug (2).

IMPORTANT
Prevent possible machine damage. Do not overfill
hub oil. Oil level line should not exceed specification.
4. Slowly add oil until oil level is level with FULL line. Do
not exceed specification.

Specifications
Oil Level Line—Distance (above 6.4 mm
FULL line, maximum) 0.25 in

5. Compare oil level line to ADD and FULL lines to

verify proper oil capacity on both sides of truck.
6. Install center plug. Tighten to specification.

Specifications
Center Plug—Torque 13.8 N·m
10 lb·ft

6-2 Service Manual TICO Manufacturing

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.) 7 4

 WARNING
8
• Prevent possible crushing injury or death.
6
Use appropriate lifting device. 5 TPS-158
• Support the tractor using properly rated jack 4 Drag Link 7 Drag Link End
stands. Never work under a tractor supported 5 Cotter Pin 8 Steering Arm
only by a jack. 6 Nut
• Do not use wood or concrete blocks to Figure 6-3: Drag Link (rear)
support the tractor. Failure to properly 6. Remove cotter pin (5), nut (6), and drag link end (7).
support the tractor may result in death or
serious injury. 7. Remove drag link (4).
8. Repair or replace components as necessary.
2. Using an appropriate lifting device, raise the front
end of the tractor. (See “Use Lifting Equipment Inspection
Safely” on page 1-4.) • Check all threaded components for damaged or
3. Support the tractor using jack stands. (See “Support stripped threads. Repair light damage with thread
Tractor Securely” on page 1-3.) chasers. Replace parts found to be unserviceable.
• Clean all parts of dirt and debris.
NOTE • Inspect parts for wear or damage. Replace as
Preventing the steering wheel from rotating will make the needed.
steering gear box alignment easier.
4. Lock steering wheel into place. Installation
Installation is the reverse of the removal procedure.
• Perform wheel alignment. (See “FRONT END
3 ALIGNMENT” on page 6-5.)
4

1
2

TPS-157
1 Cotter Pin 3 Drag Link End
2 Nut 4 Drag Link
Figure 6-2: Drag Link (front)

TICO Manufacturing Service Manual 6-3

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.)
11 12
 WARNING
10
• Prevent possible crushing injury or death.
Use appropriate lifting device.
• Support the tractor using properly rated jack
stands. Never work under a tractor supported
only by a jack.
• Do not use wood or concrete blocks to
support the tractor. Failure to properly
support the tractor may result in death or
serious injury.
8 9
7
2. Using an appropriate lifting device, raise the front TPS-159
end of the tractor. (See “Use Lifting Equipment
7 Axle 10 Spacer (4 used)
Safely” on page 1-4.) 8 Lock Nut (8 used) 11 U-Bolt (4 used)
3. Support the tractor using jack stands. (See “Support 9 Washer (8 used) 12 Leaf Spring (2 used)
Tractor Securely” on page 1-3.) Figure 6-5: Axle
4. Release air system pressure. (See “RELIEVING AIR 8. Place jack under axle (7) near the leaf spring (12)
SYSTEM PRESSURE” on page 8-6.) that is to be serviced. (See “Support Tractor
Securely” on page 1-3.)
9. Remove front wheels.
1 10. Remove drag link. (See “DRAG LINK” on page 6-3.)
6
11. Remove lock nuts (8), washers (9), spacers (10), and
5 U-bolts (11).
4
12. Lower and remove axle away from leaf spring.
13. Repair or replace components as necessary.

TPS-163
1 Air Line (2 used) 4 Nut (4 used)
2 Clip (2 used) 5 Washer (4 used)
3 Pin (2 used) 6 Brake Chamber (2 used)
Figure 6-4: 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 chambers
(6).

6-4 Service Manual TICO Manufacturing

PRO-SPOTTER FRONT AXLE & STEERING

Inspection FRONT END ALIGNMENT

• 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. efficient steering and maximum tire life. Check the
• Clean all parts of dirt and debris. alignment at routine intervals or after any heavy impact to
• Inspect parts for wear or damage. Replace as the front axle.
needed.
Preparation
Installation • Properly adjust front end bearings. (See “FRONT
See Figure 6-6. WHEEL BEARINGS” on page 6-8.)
Installation is the reverse of the removal procedure. • 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
13 the rim-to-floor are the same at each wheel. (See
14 “TIRE PRESSURE” on page 2-11.)
• Check the wheel installation.

Checking and Correcting Toe

15 See Figure 6-7.

12

TPS-162
12 Leaf Spring 14 Hole
13 Alignment Pin 15 Upper Plate
Figure 6-6: Alignment Pin
• Verify proper alignment. Locate alignment pin (13)
with hole (14) in frame while installing upper plate
(15). TPS-032
Figure 6-7: Toe (viewed from above)
Toe-in is when the distance between the front wheels is
less at the front of the axle than it is at the rear. Toe-in
can cause excessive tire wear and unstable steering.

Checking the Toe

NOTE
A work bay is needed for this procedure.
1. Slowly drive the truck into the bay.
2. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
3. Apply marks approximately 127 mm (5 in) up on the
front side of both tires. Be sure the mark is parallel to
the center tread rib.
4. Apply marks approximately 127 mm (5 in) up on the
back side of both tires. Be sure the mark is parallel to
the center tread rib.

TICO Manufacturing Service Manual 6-5

 FRONT AXLE & STEERING PRO-SPOTTER

5. Place a trammel bar behind the front tires with the Checking and Correcting Camber
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.
7. With the trammel bar pointers still set, align one
pointer to the outside edge of the center tread rib
mark.
8. Measure and record the distance between the
pointer and the outside edge mark on the opposite
tire.
9. The recorded distance is the toe measurement.
Compare the recorded distance to the specification.
.

Specifications
Toe In—Distance 1.587 mm
0.063 in

10. If measurement exceeds the specification, correct

toe. (See “Correcting the Toe” on page 6-6.)

Correcting the Toe TPS-033

1. If the toe measurement exceeds the specification, Figure 6-8: Wheel Alignment (camber)
loosen both tie rod bar clamps.
Camber is the angle that the front wheels are tilted
2. Rotate the tie rod bar to correct the distance of the outward, or inward for a negative camber condition, at the
toe measurement. top from the vertical position. Camber can cause
3. When the specified distance is reached, tighten the excessive tire wear and unstable steering.
tie rod bar on each end to specification. 1. Park and prepare tractor for service. (See “Park
4. Check the toe measurement before returning the Tractor Safely” on page 1-3.)
tractor to service. (See “Checking the Toe” on
page 6-5.)
 WARNING
• Prevent possible crushing injury or death.
Use appropriate lifting device.
• Support the tractor using properly rated jack
stands. Never work under a tractor supported
only by a jack.
• Do not use wood or concrete blocks to
support the tractor. Failure to properly
support the tractor may result in death or
serious injury.

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. (See “Support
Tractor Securely” on page 1-3.)
4. Using a camber gauge, pull the bottom of the wheel
outward and record the measurement.
5. Using a camber gauge, pull the top of the wheel
outward and record the measurement.

6-6 Service Manual TICO Manufacturing

 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. a. Using a square (1) measure the distance from
. the wheel (6) to the square in two locations as
Specifications shown. Subtract distance A (2) from distance B
(3) to calculate the camber (5).
Camber—Angle 1/4°
b. Measure both wheels. Compare the
measurements to specification.
8. If measurement exceeds the specification, correct
.

toe. (See “Correcting the Toe” on page 6-6.)

Specifications
9. If the calculated angle exceeds the specification,
adjust the wheel bearings. (See “Adjustment” on Camber—Variance 0.24 mm
page 6-8.) 0.094 in

10. Repeat steps 4—7.

15. If the calculated angle continues to exceed the
11. If the readings are within specification, check the toe.
specification, the axle or steering knuckle is bent.
(See “Checking the Toe” on page 6-5.)
(See “FRONT AXLE” on page 6-4 or “STEERING
12. If the calculated angle continues to exceed the KNUCKLE” on page 6-14.)
specification, inspect the steering knuckle bushings
and king pins. (See “STEERING KNUCKLE” on
page 6-14.) Checking Wheels and Tires
13. Perform a wheel and tire check. (See “Checking
Wheels and Tires” on page 6-7.)  WARNING
• Prevent possible crushing injury or death.
Use appropriate lifting device.
5
• Support the tractor using properly rated jack
stands. Never work under a tractor supported
1 only by a jack.
4 • Do not use wood or concrete blocks to
support the tractor. Failure to properly
support the tractor may result in death or
2 serious injury.

1. Using an appropriate lifting device, raise the side of

the tractor. (See “Use Lifting Equipment Safely” on
page 1-4.)
2. Support the tractor using jack stands. (See “Support
3 Tractor Securely” on page 1-3.)
3. Place wheel chocks on rear wheels.
4. Shift the transmission shifter selector in the neutral
6
(N) position. Release parking brake before exiting
cab.
TPS-178
5. Rotate front wheels. Inspect for bulges, broken cords,
1 Square 4 Centerline of Wheel or flat spots.
2 Distance A (from highest 5 Camber (angle)
point of rim) 6. Repair or replace tires as necessary.
3 Distance B (from lowest 6 Wheel
point of rim) 7. Perform front end alignment. (See “FRONT END
Figure 6-9: Manual Camber Measurement ALIGNMENT” on page 6-5.)

TICO Manufacturing Service Manual 6-7

FRONT AXLE & STEERING PRO-SPOTTER

FRONT WHEEL BEARINGS

Adjustment
See Figures 6-10 and 6-11.

15

13

16
10
14
8
6
3 4 12

9 11
7
5

2
1 TPS-166
1 Cap Screw (6 used) 5 Counter Nut 9 Outer Wheel Bearing 13 Inner Bearing Cup
2 Washer (6 used) 6 Lock Washer 10 Outer Bearing Cup 14 Inner Wheel Bearing
3 Hub Cover 7 Lock Ring 11 Hub 15 Sealer Cup
4 Gasket 8 Adjustment Nut 12 Wheel Stud (10 used) 16 Stub Axle
Figure 6-10: Front Wheel Bearing
1. Park and prepare tractor for service. (See “Park 3. Support the tractor using jack stands. (See “Support
Tractor Safely” on page 1-3.) Tractor Securely” on page 1-3.)
4. Remove the cap screws (1), washers (2), hub cover
 WARNING (3), and gasket (4).
5. Verify brake drum and hub fasteners are tight.
• Prevent possible crushing injury or death.
Use appropriate lifting device. 6. Install a magnetic-base dial indicator on the lower
portion of the hub (11) or brake drum.
• Support the tractor using properly rated jack
stands. Never work under a tractor supported
only by a jack. NOTE
• Do not use wood or concrete blocks to Do not push or pull the hub or the brake drum by the
support the tractor. Failure to properly upper part and the lower part. Pulling or pushing by the
support the tractor may result in death or upper and lower part will not give the correct reading.
serious injury. 7. Measure the axial play by pushing and pulling on
each side of the hub or drum while taking the
reading. Record highest and lowest readings.
2. Using an appropriate lifting device, raise the side of
the tractor. (See “Use Lifting Equipment Safely” on
page 1-4.)

6-8 Service Manual TICO Manufacturing

 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. turning the tire in both directions.
9. Compare calculated axial play to specification. If .

calculated play is outside of the specification, adjust Specifications

the wheel bearings.
.0.001-0.005
Adjustment Nut—Torque 136 N·m
100 lb·ft
Specifications
Axial Play—Distance 0.03—0.13 mm 15. Turn the adjustment nut counterclockwise 1/3 turn.
0.001—0.005 in
16. Install the counter nut (5), lock washer (6), and lock
ring (7). Tighten counter nut to specification.
10. If calculated play is within the specification, the wheel
bearings are properly adjusted. No additional
adjustments are required.
Specifications
Counter Nut 28.6—66.7 mm 271—407 N·m
(1-1/8 to 2-5/8 in, 200—300 lb·ft
approximate)—Torque
11 Counter Nut 66.7 mm and 339—407 N·m
larger (2-5/8 in and larger, 250—400 lb·ft
approximate)—Torque
7
17. Install the gasket (4), hub cover (3), washers (2), and
5 cap screws (1). Tighten cap screws to specification.
3

8 Specifications
6 Cap Screw—Torque 27—41 N·m
20—30 lb·ft
4
1 2
TPS-175 18. Lower vehicle to the ground.
1 Cap Screw (6 used) 6 Lock Washer 19. Check vehicle operation.
2 Washer (6 used) 7 Lock Ring
3 Cover Hub 8 Adjustment Nut
4 Gasket 11 Hub
5 Counter Nut
Figure 6-11: Wheel Bearing Adjustment
11. Remove the counter nut (5), lock washer (6), and
lock ring (7).

IMPORTANT
Prevent possible damage to components. Do not
strike the adjustment nut (8) with a metal hammer. Do
not use a chisel or punch to loosen the adjustment
nut. This may cause damage to the nut.
12. Tighten the adjustment nut (8) to specification while
turning the tire in both directions.
.

Specifications
Adjustment Nut—Torque 136 N·m
100 lb·ft

TICO Manufacturing Service Manual 6-9

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.

15

13

16
10
14
8
6
3 4 12

9 11
7
5

2
1 TPS-166
1 Cap Screw (6 used) 5 Counter Nut 9 Outer Wheel Bearing 13 Inner Bearing Cup
2 Washer (6 used) 6 Lock Washer 10 Outer Bearing Cup 14 Inner Wheel Bearing
3 Hub Cover 7 Lock Ring 11 Hub 15 Sealer Cup
4 Gasket 8 Adjustment Nut 12 Wheel Stud (10 used) 16 Stub Axle
Figure 6-12: Front Wheel Bearing Removal
1. Park and prepare tractor for service. (See “Park 3. Support the tractor using jack stands. (See “Support
Tractor Safely” on page 1-3.) Tractor Securely” on page 1-3.)
4. Remove front wheels.
 WARNING 5. Remove drum.
• Prevent possible crushing injury or death. 6. Position a suitable container to receive the drained
Use appropriate lifting device. oil.
• Support the tractor using properly rated jack 7. Remove plug and drain oil.
stands. Never work under a tractor supported 8. Remove cap screws (1), washers (2), hub cover (3)
only by a jack. and gasket (4).
• Do not use wood or concrete blocks to 9. Remove counter nut (5), lock washer (6), and lock
support the tractor. Failure to properly ring (7).
support the tractor may result in death or 10. Using an appropriate lifting device, remove
serious injury. adjustment nut (8), outer wheel bearing (9), and hub
(11).
2. Using an appropriate lifting device, raise the front 11. Remove sealer cup (15) and inner wheel bearing
end of the tractor. (See “Use Lifting Equipment (14).
Safely” on page 1-4.) 12. Repair or replace components as necessary.

6-10 Service Manual TICO Manufacturing

 PRO-SPOTTER FRONT AXLE & STEERING

Inspection LEAF SPRING

• Check all threaded components for damaged or
stripped threads. Repair light damage with thread Removal
chasers. Replace parts found to be unserviceable.
See Figures 6-13, 6-14, and 6-15.
• Clean all parts of dirt and debris.
• Inspect parts for wear or damage. Replace as NOTE
needed. Procedure is written for the left side cab latch. Right side
• Check all bearings and seals for damage. Replace cab latch procedure is similar.
parts found to be unserviceable. 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
Installation
Installation is the reverse of the removal procedure.  WARNING
• Rotate drum in both directions when tightening the • Prevent possible crushing injury or death.
adjusting nut to ensure bearing surfaces are in Use appropriate lifting device.
contact. • Support the tractor using properly rated jack
• Back off adjusting nut 1/6 turn. Allowable play is stands. Never work under a tractor supported
within 0.03—0.30 mm (0.001—0.010 in). only by a jack.
-
• Do not use wood or concrete blocks to
Specifications support the tractor. Failure to properly
support the tractor may result in death or
Cap Screw—Torque 33 N·m
serious injury.
24 lb·ft
Adjusting Nut—Torque 67.8 N·m
50 lb·ft 2. Using an appropriate lifting device, raise the front
end of the tractor. (See “Use Lifting Equipment
Jam Nut 28.6—66.8 mm 135.6—203.4 N·m
Safely” on page 1-4.)
(1-1/8—2-5/8 in)—Torque 100—150 lb·ft
3. Support the tractor using jack stands. (See “Support
Jam Nut 66.8 mm and larger 135.6—271.2 N·m
Tractor Securely” on page 1-3.)
(2-5/8 in and larger)—Torque 100—200 lb·ft

6
4 5

2 3
1
TPS-159
1 Axle 4 Spacer (2 used)
2 Lock Nut (4 used) 5 U-Bolt (2 used)
3 Washer (4 used) 6 Leaf Spring
Figure 6-13: Axle
4. Place jack under axle (1) near the leaf spring (6) that
is to be serviced. (See “Support Tractor Securely” on
page 1-3.)

TICO Manufacturing Service Manual 6-11

FRONT AXLE & STEERING PRO-SPOTTER

5. Remove front wheel. 10. Remove bolt (10), washer (11), lock nut (12), and leaf
6. Remove lock nuts (2), washers (3), spacers (4), and spring.
U-bolts (5). 11. Repair or replace components as necessary.
7. Lower axle away from leaf spring.
Inspection
 WARNING • Inspect leaf springs for cracks or damage. Replace
Prevent possible crushing injury or death. Use as needed.
appropriate lifting device. • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
8. Using an appropriate lifting device, support leaf
spring. • Clean all parts of dirt and debris.
• Inspect parts for wear or damage. Replace as
needed.

Installation
See Figure 6-16.
Installation is the reverse of the removal procedure.
9 • Tighten lock nut (9) to specification.

7 Specification
Lock Nut (9)—Torque 461 N·m
340 lb·ft
8
6

13
TPS-160
6 Leaf Spring 8 Washer 14
7 Bolt 9 Lock Nut
Figure 6-14: Leaf Spring
9. Remove bolt (7), washer (8), and lock nut (9) from
leaf spring.
15

12
12
10
TPS-162
12 Leaf Spring 14 Hole
11 13 Alignment Pin 15 Upper Plate
Figure 6-16: Alignment Pin
• Verify proper alignment. Locate alignment pin (13)
with hole (14) in frame while installing upper plate
(15).
6
TPS-161
6 Leaf Spring 11 Washer
10 Bolt 12 Lock Nut
Figure 6-15: Leaf Spring

6-12 Service Manual TICO Manufacturing

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 7
Tractor Safely” on page 1-3.)

 WARNING
• Prevent possible crushing injury or death. 5
Use appropriate lifting device.
• Support the tractor using properly rated jack
stands. Never work under a tractor supported 13 6
only by a jack.
• Do not use wood or concrete blocks to 12 9
support the tractor. Failure to properly
support the tractor may result in death or
serious injury. 11

2. Using an appropriate lifting device, raise the front

end of the tractor. (See “Use Lifting Equipment 8
Safely” on page 1-4.)
3. Support the tractor using jack stands. (See “Support 10
Tractor Securely” on page 1-3.)

NOTE
Preventing the steering wheel from rotating will make the 4
steering gear box alignment easier. TPS-165
4. Lock steering wheel into place. 4 Steering Arm 9 Hydraulic Line
5 Nut 10 Steering Gear Box
6 Cap Screw 11 Cap Screw (3 used)
7 Steering Shaft 12 Washer (6 used)
8 Hydraulic Line 13 Nut (3 used)
Figure 6-18: Steering Gear Box
7. Remove nut (5), cap screw (6), and steering shaft
(7).
8. Remove hydraulic lines (8 and 9) from steering gear
box (10). Close all openings using caps and plugs.

3
4  WARNING
Prevent possible crushing injury or death. Use
appropriate lifting device.

1 9. Using an appropriate lifting device, support the

2
TPS-164 steering gear box.
1 Cotter Pin 3 Drag Link 10. Remove cap screws (11), washers (12), nuts (13),
2 Nut 4 Steering Arm and steering gear box.
Figure 6-17: Steering Arm 11. Repair or replace components as necessary.
5. Remove cotter pin (1) and nut (2) from drag link (3).

TICO Manufacturing Service Manual 6-13

FRONT AXLE & STEERING PRO-SPOTTER

Inspection
1
• Check all threaded components for damaged or 6
stripped threads. Repair light damage with thread
5
chasers. Replace parts found to be unserviceable.
4
• Inspect hydraulic lines and fittings for leaks, holes,
cracks, and loose connections. Replace parts found
to be unserviceable.
• Clean all parts of dirt and debris. 2
• Inspect parts for wear or damage. Replace as
needed.
3
Installation
Installation is the reverse of the removal procedure.
TPS-163
• Perform wheel alignment. (See “FRONT END
1 Air Line (2 used) 4 Nut (4 used)
ALIGNMENT” on page 6-5.)
2 Clip (2 used) 5 Washer (4 used)
3 Pin (2 used) 6 Brake Chamber (2 used)
STEERING KNUCKLE Figure 6-19: Brake Chamber (left side shown)
5. Install identification tags and disconnect air lines (1).
Removal Close all openings using caps and plugs.
See Figures 6-19 and 6-20. 6. Remove clips (2) and pins (3).
7. Remove nuts (4), washers (5), and brake chambers
NOTE (6).
Procedure is written for the left side steering knuckle. 8. Remove wheel bearing and hub assembly. (See
Right side steering knuckle procedure is similar. “FRONT WHEEL BEARINGS” on page 6-8.)
1. Park and prepare tractor for service. (See “Park 9. Remove drag link. (See “DRAG LINK” on page 6-3.)
Tractor Safely” on page 1-3.) 10. Remove tie rod bar. (See “TIE ROD BAR” on
page 6-16.)
 WARNING 11. Remove cap screws (7), washers (8), upper cap (9),
• Prevent possible crushing injury or death. and gasket (10).
Use appropriate lifting device. 12. Remove cap screws (11), washers (12), lower cap
• Support the tractor using properly rated jack (13), and gasket (14).
stands. Never work under a tractor supported
only by a jack.  WARNING
• Do not use wood or concrete blocks to Prevent possible crushing injury or death. Use
support the tractor. Failure to properly appropriate lifting device.
support the tractor may result in death or
serious injury.
13. Using appropriate lifting device, support steering
knuckle (15).
2. Using an appropriate lifting device, raise the front
end of the tractor. (See “Use Lifting Equipment NOTE
Safely” on page 1-4.)
Use a brass hammer and drift to drive out draw key and
3. Support the tractor using jack stands. (See “Support king pin. Do not use heat on any axle parts.
Tractor Securely” on page 1-3.)
14. Remove king pin (16), shims (17), and steering
4. Release air system pressure. (See “RELIEVING AIR knuckle.
SYSTEM PRESSURE” on page 8-6.)
15. Repair or replace components as necessary.

6-14 Service Manual TICO Manufacturing

PRO-SPOTTER FRONT AXLE & STEERING

8 7
18
24
23
9
10
20
19 22
24

15
23

17

23
24

16 21

19

14
13
12
18
11 TPS-179
7 Cap Screw (3 used) 12 Washer (3 used) 17 Shim (as required) 22 Front Axle
8 Washer (3 used) 13 Lower Cap 18 Grease Fitting (2 used) 23 Nut (3 used)
9 Upper Cap 14 Gasket 19 Bushing (2 used) 24 Cotter Pin (3 used)
10 Gasket 15 Steering Knuckle 20 Arm
11 Cap Screw (3 used) 16 King Pin 21 Arm
Figure 6-20: Steering Knuckle

Inspection Installation
• Check all threaded components for damaged or Installation is the reverse of the removal procedure.
stripped threads. Repair light damage with thread • Perform wheel alignment. (See “FRONT END
chasers. Replace parts found to be unserviceable. ALIGNMENT” on page 6-5.)
• Clean all parts of dirt and debris.
• Inspect parts for wear or damage. Replace as
needed.
• Check all bushings (19) and shims (17) for damage.
Replace parts found to be unserviceable.

TICO Manufacturing Service Manual 6-15

FRONT AXLE & STEERING PRO-SPOTTER

TIE ROD BAR

Removal
See Figures 6-21 and 6-22. 6
5
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) 7
4

 WARNING
• Prevent possible crushing injury or death.
Use appropriate lifting device.
• Support the tractor using properly rated jack
stands. Never work under a tractor supported TPS-156
only by a jack. 4 Tie Rod Bar 6 Nut
• Do not use wood or concrete blocks to 5 Cotter Pin 7 Tie Rod End
support the tractor. Failure to properly Figure 6-22: Tie Rod Bar (right side shown)
support the tractor may result in death or 6. Remove cotter pin (5), nut (6), and tie rod end (7).
serious injury.
7. Remove tie rod bar (4).
8. Repair or replace components as necessary.
2. Using an appropriate lifting device, raise the front
end of the tractor. (See “Use Lifting Equipment
Safely” on page 1-4.) Inspection
3. Support the tractor using jack stands. (See “Support • Check all threaded components for damaged or
Tractor Securely” on page 1-3.) stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
NOTE • Clean all parts of dirt and debris.
Preventing the steering wheel from rotating will make the • Inspect parts for wear or damage. Replace as
steering gear box alignment easier. needed.
4. Lock steering wheel into place.
Installation
Installation is the reverse of the removal procedure.
• Perform wheel alignment. (See “FRONT END
1 ALIGNMENT” on page 6-5.)

3
4

TPS-155
1 Cotter Pin 3 Tie Rod End
2 Nut 4 Tie Rod Bar
Figure 6-21: Tie Rod Bar (left side shown)
5. Remove cotter pin (1), nut (2), and tie rod end (3).

6-16 Service Manual TICO Manufacturing

 Section 7

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 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Rear Drive Axle Fluid Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

TICO Manufacturing Service Manual 7-1

REAR AXLE PRO-SPOTTER

INTRODUCTION 6. If overfilled, excess fluid will drain from fill port. Allow
excess fluid to drain until fluid slowly seeps.
The purpose of the REAR AXLE section is to provide 7. Install fill plug and tighten to specification.
service and maintenance personnel with guidance on the
proper procedures for servicing the rear axles and Specification
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
engineered for quick and efficient servicing while
minimizing downtime.
For additional information, please contact TICO factory REAR DRIVE AXLE
support. (See “CONTACT TICO SUPPORT” on
page 0-15.) Removal
See Figures 7-2 and 7-3.
CHECK FLUID LEVEL 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
Rear Drive Axle Fluid
See Figure 7-1.  CAUTION
1. Park and prepare tractor for service. (See “Park Prevent possible crushing injury from heavy
Tractor Safely” on page 1-3.) component. Use appropriate lifting device.

2. Using appropriate lifting device, raise rear of tractor

and support using jack stands. (See “Support Tractor
Securely” on page 1-3.)
2 3. Release air system pressure. (See “RELIEVING AIR
SYSTEM PRESSURE” on page 8-6.)
4. Remove left and right side rear fender and mud flap
assemblies. (See “LEFT COVERS AND GUARDS”
on page 14-8.)

3 1

TPS-123
5
1 Rear Drive Axle 3 Drain Plug
2 Fill Plug 4
Figure 7-1: Rear Drive Axle Plugs
2. Position a suitable container below the fill plug (2) of
the rear drive axle (1).

3
 CAUTION
2 1 TPS-120
Avoid injury and serious burns from draining rear
1 Cap Screw (4 used) 4 Drive Shaft
drive axle fluid. Avoid contact with hot rear drive
2 Spacer (4 used) 5 Rear Drive Axle
axle fluid. 3 Cap (2 used)
Figure 7-2: Drive Shaft
3. Remove fill plug.
5. Remove cap screws (1), spacers (2), and caps (3).
4. Rear drive axle fluid should slowly seep from the
6. Separate drive shaft (4) from rear drive axle (5).
bottom of the fill port if properly filled.
5. If no seepage occurs, insert a finger into the fill port
to feel if the fluid level is just below. Add proper fluid.
(See “Rear Drive Axle Fluid Filling” on page 7-5.)

7-2 Service Manual TICO Manufacturing

 PRO-SPOTTER REAR AXLE

21 20
9

8
22

19
18 14
11
10

12
15 13
7
16
17

TPS-121
5 Rear Drive Axle 10 Clip (2 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 Washer (4 used) 18 Cap Screw (4 used)
9 Air Line 14 Cap Screw (4 used) 19 Washer (8 used)
Figure 7-3: Inner Rear Drive Axle (right side shown)

TICO Manufacturing Service Manual 7-3

REAR AXLE PRO-SPOTTER

7. Remove wheels (6). Inspection

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; however, removing the brake
chasers. Replace parts found to be unserviceable.
chambers will ease handling of the rear drive axle.
8. Install identification tags and disconnect air lines (8
and 9). Close all openings using caps and plugs. Installation
9. Remove clips (10) and pins (11). See Figure 7-4.
10. Remove nuts (12), washers (13), and brake Installation is the reverse of the removal procedure.
chambers (7).
11. Remove cap screws (14), washers (15), lock nuts
(16), and links (17). 23 24
5

 CAUTION
Prevent possible crushing injury from heavy
component. Use appropriate lifting device.
21
12. Using appropriate lifting device, support rear drive
axle.
13. Remove cap screws (18), washers (19), lock nuts
(20), and upper and lower plates (21 and 22).
14. Using appropriate lifting device, remove rear drive TPS-122
axle. 5 Rear Drive Axle 23 Alignment Pin (2 used)
15. Repair or replace components as necessary. 21 Upper Plate (2 used) 24 Hole (4 used)
Figure 7-4: Rear Drive Axle Alignment
• Verify proper alignment. Locate alignment pins (23)
with holes (24) in frame while installing upper plates
(21).

7-4 Service Manual TICO Manufacturing

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” on page 1-3.)

3 1

TPS-123
3 1 1 Rear Drive Axle 3 Drain Plug
2 Fill Plug
Figure 7-6: Rear Drive Axle Plugs
TPS-123
2. Install drain plug (3) if removed. Tighten drain plug to
1 Rear Drive Axle 3 Drain Plug
specification.
2 Fill Plug
Figure 7-5: Rear Drive Axle Plugs Specification
2. Position a suitable container below the drain plug (3) Drain Plug—Torque 34 N·m
of the rear drive axle (1). 25 lb·ft
Specification
3. Remove fill plug (2).
Rear Drive Axle Fluid—Capacity 39.7 L
4. Fill rear drive axle until fluid seeps from the bottom of
42 qt
the fill port.

Specification
 CAUTION Rear Drive Axle Fluid—Capacity 39.7 L
Avoid injury and serious burns from draining rear 42 qt
drive axle fluid. Avoid contact with hot rear drive
axle fluid. 5. Install fill plug and tighten to specification.

Specification
3. Remove fill and drain plugs (2 and 3).
Fill Plug—Torque 47.5 N·m
4. Inspect and clean drain plug magnet of any metal
35 lb·ft
debris.
5. Inspect condition of oil for containments, texture, and
sediment particles. Contaminated fluid can be a sign
of internal damage.
6. Fill rear drive axle. (See “Rear Drive Axle Fluid
Filling” on page 7-5.)

TICO Manufacturing Service Manual 7-5

 PRO-SPOTTER

8-0 Service Manual TICO Manufacturing

 Section 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 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 TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
BRAKE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
RELIEVING AIR SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
WET AIR TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

TICO Manufacturing Service Manual 8-1

AIR SYSTEM PRO-SPOTTER

INTRODUCTION Air System Maximum Pressure Test

The purpose of the AIR SYSTEM section is to provide 1. Start engine and run at fast idle.
service and maintenance personnel with guidance on the 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,
which supply air pressure to pneumatic subsystems
including brakes, cab and seat suspension, and trailer
Specification
connections. Maximum System Pressure 896 kPa
The TICO Pro-Spotter terminal trucks have been 9.0 bar
engineered for quick and efficient servicing while 130 psi
minimizing downtime. Governor Cutout Pressure 827 kPa
For additional information, please contact TICO factory 8.3 bar
support. (See “CONTACT TICO SUPPORT” on 120 psi
page 0-15.)
Air System Leak Down Test
AIR BRAKE SYSTEM TESTS 1. Disconnect the glad hands from the trailer.
The following air brake system tests should be performed 2. Run engine at fast idle.
periodically to determine the condition of the system. 3. Allow air pressure to stabilize at operating pressure
These tests are designed to help discover sluggish for at least 1 minute.
performance and/or system leaks before they become a 4.

major problem. Performing these tests does NOT rule out Specification
the importance and necessity of functional, dynamic
Operating Pressure 827 kPa
controllability tests and other tests required in assuring
vehicle safety and performance. 8.3 bar
120 psi

Low Air Buzzer and Light Test 5. Shut off engine and observe pressure gauge for 2
1. Apply and release the brake pedal until air pressure minutes.
drops below specification. 6. Pressure drop should not exceed specification.
7.

Specification Specification
Low Pressure Alarm (maximum 483 kPa Pressure Drop (2-minute period) 14 kPa
pressure) 4.8 bar 0.1 bar
70 psi 2 psi

2. The low air buzzer and dash warning light should

come on.

8-2 Service Manual TICO Manufacturing

PRO-SPOTTER AIR SYSTEM

Pressure Buildup, Low-Pressure AIR DRYER

Warning Cutoff, and Governor Cutout
Test Removal
1. Open reservoir drain valves and drain system. See Figure 8-1.
2. Start engine and run at fast idle. Low-pressure 1. Park and prepare tractor for service. (See “Park
warning should be active. Tractor Safely” on page 1-3.)
3. Begin timing pressure buildup when system pressure
reaches 345 kPa/3.45 bar (50 psi). Record the  CAUTION
following data;
• Avoid personal injury from explosion. Air
— The pressure at which low-pressure warning cuts system components may contain pressurized
off. gases. Exposure to excessive heat may
— The time at which system pressure has reached cause components to explode.
621kPa/6.21 bar (90 psi). Elapsed time should • Avoid personal injury from high-pressure
not exceed specification. gases or debris. High-pressure release of
—

gases or debris from a pressurized system

Specification can cause penetrating injuries. Relieve
Low-Pressure Warning Cutoff 414 kPa system pressure from air system before
4.1 bar servicing.
60 psi
System Pressure Buildup (time) 5 min 2. Release air system pressure. (See “RELIEVING AIR
SYSTEM PRESSURE” on page 8-6.)
4. Continue observing gauge. The governor cutout
should limit system air pressure to specification.

Specification
9
Maximum System Pressure 896 kPa
9.0 bar
130 psi
Governor Cutout Pressure 827 kPa 8
6
8.3 bar
7
120 psi 2
3
4 5
1
TPS-087
1 Supply Air Line 6 Cap Screw (2 used)
2 Control Air Line 7 Washer (4 used)
3 Discharge Air Line 8 Lock Nut (2 used)
4 Electrical Connector 9 Air Dryer
5 Band
Figure 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), lock nuts (8),
and air dryer (9).
7. Repair or replace components as necessary.

TICO Manufacturing Service Manual 8-3

AIR SYSTEM PRO-SPOTTER

Inspection
• Clean all parts of dirt and debris.
 CAUTION
• Inspect air lines, fittings, and valves for leaks, holes, • Avoid personal injury from explosion. Air
cracks, and loose connections. Replace parts found system components may contain pressurized
to be unserviceable. gases. Exposure to excessive heat may
cause components to explode.
• Check all threaded components for damaged or
stripped threads. Repair light damage with thread • Avoid personal injury from high-pressure
chasers. Replace parts found to be unserviceable. gases or debris. High-pressure release of
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
Installation system pressure from air system before
Installation is the reverse of the removal procedure. servicing.

AIR SYSTEM SCHEMATIC 3. Release air system pressure. (See “RELIEVING AIR
SYSTEM PRESSURE” on page 8-6.)
Air system schematics are used to aid in servicing and
troubleshooting pneumatic equipment. These schematics
my differ greatly depending on the optional equipment 2
installed. To view the most accurate applicable system
2 3
schematic, contact TICO support. (See “CONTACT TICO
SUPPORT” on page 0-15.) 1

6
AIR TANK 4
5
Removal
See Figures 8-2, 8-3, 8-4, and 8-5. TPS-094

NOTE 1 Cap Screw 4 Air Release Cable

2 Washer (2 used) 5 Air Release Cable
Procedure is written for the left side air tank. Right side 3 Lock Nut 6 Clamp
air tank procedure is similar. Figure 8-2: Air Release Cables and Clamp
1. Park and prepare tractor for service. (See “Park
4. Remove cap screw (1), washers (2), and lock nut (3).
Tractor Safely” on page 1-3.)
5. Remove air release cables (4 and 5) from clamp (6)
2. Remove rear grate. (See “GRATES AND COVERS”
and set aside.
on page 14-5.)

12 11
10

9
7

TPS-095
7 Air Line 10 Lock Nut (2 used)
8 Air Line 11 Cap Screw (2 used)
9 Washer (4 used) 12 Air Tank
Figure 8-3: Air Tank (rear view)

8-4 Service Manual TICO Manufacturing

PRO-SPOTTER AIR SYSTEM

6. Disconnect air lines (7 and 8). Close all openings Inspection

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.
• Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.

Installation
10
Installation is the reverse of the removal procedure.
9 13
11 • Loosely apply bands (14 and 19) to air tank (12) to
aid in alignment.
14 12 • Position air release valve (15) for proper operation of
air release cable (5) and tighten bands.
TPS-096
• Verify operation of air release cables.
9 Washer (4 used) 12 Air Tank
10 Lock Nut (2 used) 13 Air Line
11 Cap Screw (2 used) 14 Inside Band (2 used) BRAKE MAINTENANCE
Figure 8-4: Air Tank (front view)
A schedule for the periodic cleaning, inspection, and
7. Disconnect air line (13). Close all openings using lubrication of brake equipment should be established.
caps and plugs. Brake linings and drums are subject to wear.
8. Using an appropriate lifting device, support air tank To compensate for this wear, the brakes are equipped
(12). with automatic slack adjusters to maintain proper
operation. The adjusters should be routinely checked to
provide uniform lining clearance, correct travel of levers,
12 and proper equalization.
Brakes should be cleaned, inspected, lubricated, and
17
19 adjusted every time the hubs are removed.
19

16

15
18

14

TPS-097
12 Air Tank 17 Washer (12 used)
14 Inside Band (2 used) 18 Lock Nut (2 used)
15 Air Release Valve 19 Outside Band (2 used)
16 Cap Screw (2 used)
Figure 8-5: Air Release Valve
9. Remove air release valve (15) as necessary.
10. Remove cap screws (11 and 16), washers (9 and
17), lock nuts (10 and 18), inside bands (14), and air
tank (12).
11. Repair or replace components as necessary.

TICO Manufacturing Service Manual 8-5

AIR SYSTEM PRO-SPOTTER

RELIEVING AIR SYSTEM WET AIR TANK

PRESSURE
See Figure 8-6.
Removal
1. Park and prepare tractor for service. (See “Park See Figures 8-7, 8-8, and 8-9.
Tractor Safely” on page 1-3.) 1. Park and prepare tractor for service. (See “Park
2. Disconnect batteries. (See “BATTERY” on page 3-3.) Tractor Safely” on page 1-3.)
3. Pump brake pedal 30 times.
 CAUTION
• Avoid personal injury from explosion. Air
system components may contain pressurized
gases. Exposure to excessive heat may
cause components to explode.
• Avoid personal injury from high-pressure
gases or debris. High-pressure release of
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
system pressure from air system before
1 servicing.

2. Release air system pressure. (See “RELIEVING AIR

SYSTEM PRESSURE” on page 8-6.)

TPS-086
1 Air Reservoir Drain Pull 2
Cord (3 used) 2 3
Figure 8-6: Air Reservoir Drain Pull Cord
1
 CAUTION
6
• Avoid personal injury from explosion. Air 4
system components may contain pressurized
gases. Exposure to excessive heat may
5
cause components to explode.
• Avoid personal injury from high-pressure TPS-094
gases or debris. High-pressure release of 1 Cap Screw 4 Air Release Cable
gases or debris from a pressurized system 2 Washer (2 used) 5 Air Release Cable
can cause penetrating injuries. Relieve 3 Lock Nut 6 Clamp
system pressure from air system before Figure 8-7: Air Release Cables and Clamp
servicing. 3. Remove cap screw (1), washers (2), and lock nut (3).
4. Remove air release cables (4 and 5) from clamp (6)
4. Release air pressure using air reservoir drain pull and set aside.
cords (1).

8-6 Service Manual TICO Manufacturing

PRO-SPOTTER AIR SYSTEM

7. Disconnect air line (17). Close all openings using

caps and plugs.
7 8. Using an appropriate lifting device, support wet air
9 tank (16).
15 9. Remove cap screws (13 and 18), washers (14 and
11 19), lock nuts (15 and 20), lower bands (12), and wet
air tank.
8 10. Repair or replace components as necessary.

12
Inspection
14 • Clean all parts of dirt and debris.
13
• Inspect air lines, fittings, and valves for leaks, holes,
16 10 TPS-098
cracks, and loose connections. Replace parts found
to be unserviceable.
7 Air Line 12 Lower Band (2 used)
8 Air Line 13 Cap Screw (2 used) • Check all threaded components for damaged or
9 Air Line 14 Washer (12 used) stripped threads. Repair light damage with thread
10 Air Release Valve 15 Lock Nut (2 used) chasers. Replace parts found to be unserviceable.
11 Upper Band (2 used) 16 Wet Air Tank
Figure 8-8: Wet Air Tank (rear view)
Installation
5. Disconnect air lines (7—9). Close all openings using
Installation is the reverse of the removal procedure.
caps and plugs.
• Loosely apply bands (11 and 12) to wet air tank (16)
6. Remove air release valve (10) as necessary.
to aid in alignment.
• Position air release valve (10) for proper operation of
air release cable (4) and tighten bands.
17 • Verify operation of air release cables.

16
19

18 20
13
12
TPS-099
12 Lower Band (2 used) 18 Cap Screw (2 used)
13 Cap Screw (2 used) 19 Washer (4 used)
16 Wet Air Tank 20 Lock Nut (2 used)
17 Air Line
Figure 8-9: Wet Air Tank (front view)

TICO Manufacturing Service Manual 8-7

 PRO-SPOTTER

9-0 Service Manual TICO Manufacturing

 Section 9

ABS/ATC SYSTEM

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ANTILOCK BRAKE SYSTEM (ABS) CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
BOBTAIL 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
REAR MODULATOR VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
REAR QUICK RELEASE BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

TICO Manufacturing Service Manual 9-1

ABS/ATC SYSTEM PRO-SPOTTER

INTRODUCTION
The purpose of the ABS/ATC SYSTEM section is to
provide service and maintenance personnel with
guidance on the proper procedures for servicing the
electronic control unit and pneumatic braking equipment 3
on 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.
The TICO Pro-Spotter terminal trucks have been
engineered for quick and efficient servicing while 4
minimizing downtime. 3
For additional information, please contact TICO factory
support. (See “CONTACT TICO SUPPORT” on 1
page 0-15.) 2

ANTILOCK BRAKE SYSTEM

(ABS) CONTROLLER
Removal TPS-182
1 Electrical Connector 3 Cap Screw (2 used)
See Figure 9-1. 2 Electrical Connector 4 Antilock Brake System (ABS)
Controller
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) Figure 9-1: Antilock Brake System (ABS) Controller
2. Disconnect batteries. (See “BATTERY” on page 3-3.) 4. Install identification tags and disconnect electrical
3. Remove front left cover. (See “FRONT COVERS connectors (1 and 2).
AND GUARDS” on page 14-3.) 5. Remove cap screws (3) and antilock brake system
(ABS) controller (4).
6. Repair or replace components as necessary.

Inspection
• Clean all parts of dirt and debris.
• Inspect electrical connectors, wire insulation, and
retainers for damage or corrosion. Replace as
needed.
• 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.
• Test operation of brake system.

9-2 Service Manual TICO Manufacturing

PRO-SPOTTER ABS/ATC SYSTEM

BOBTAIL PROPORTIONING
VALVE  CAUTION
• Avoid personal injury from explosion. Air
Removal system components may contain pressurized
See Figure 9-2. gases. Exposure to excessive heat may
cause components to explode.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) • Avoid personal injury from high-pressure
gases or debris. High-pressure release of
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
system pressure from air system before
servicing.

2. Release air system pressure. (See “RELIEVING AIR

SYSTEM PRESSURE” on page 8-6.)

7
2
8
10
9 6
1

5
TPS-112
1 Air Line 4 Air Line 7 Cap Screw (2 used) 10 Bobtail Proportioning Valve
2 Air Line 5 Air Line 8 Washer (4 used)
3 Air Line 6 Air Line 9 Lock Nut (2 used)
Figure 9-2: Bobtail Proportioning Valve
3. Install identification tags and disconnect air lines (1— • Check all threaded components for damaged or
6). Close all openings using caps and plugs. stripped threads. Repair light damage with thread
4. Remove cap screws (7), washers (8), lock nuts (9), chasers. Replace parts found to be unserviceable.
and bobtail proportioning valve (10).
5. Repair or replace components as necessary. Installation
Installation is the reverse of the removal procedure.
Inspection • Test operation of brake system.
• 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.

TICO Manufacturing Service Manual 9-3

ABS/ATC SYSTEM PRO-SPOTTER

FRONT MODULATOR VALVE (IF

EQUIPPED) 6 4
2 5
Removal 1
See Figure 9-3.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
3 7
 CAUTION
• Avoid personal injury from explosion. Air
system components may contain pressurized
gases. Exposure to excessive heat may TPS-115
cause components to explode. 1 Air Line 5 Washer (4 used)
• Avoid personal injury from high-pressure 2 Air Line 6 Lock Nut (2 used)
gases or debris. High-pressure release of 3 Electrical Connector 7 Front Modulator Valve (if
4 Cap Screw (2 used) equipped)
gases or debris from a pressurized system
can cause penetrating injuries. Relieve Figure 9-3: Front Modulator Valve (if equipped)
system pressure from air system before
servicing. NOTE
Procedure addresses the right side front modulator valve
2. Release air system pressure. (See “RELIEVING AIR (if equipped) (7). The left side procedure is similar.
SYSTEM PRESSURE” on page 8-6.) Technicians should only address the units which are
malfunctioning.
3. Install identification tags and disconnect air lines (1
and 2). Close all openings using caps and plugs.
4. Install identification tags and disconnect electrical
connector (3).
5. Remove cap screws (4), washers (5), lock nuts (6),
and front modulator valve (if equipped) (7).
6. Repair 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 unserviceable.
• 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.
• Test operation of brake system.

9-4 Service Manual TICO Manufacturing

PRO-SPOTTER ABS/ATC SYSTEM

FRONT QUICK RELEASE BRAKE

VALVE
Removal
See Figures 9-4 and 9-5.
4
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) 5

 CAUTION
• Avoid personal injury from explosion. Air
system components may contain pressurized
gases. Exposure to excessive heat may
cause components to explode.
• Avoid personal injury from high-pressure TPS-116
gases or debris. High-pressure release of 4 Cap Screw (2 used) 5 Washer (4 used)
gases or debris from a pressurized system Figure 9-5: Cap Screws and Washers
can cause penetrating injuries. Relieve 5. Remove cap screws (4), washers (5), lock nuts (6),
system pressure from air system before and front quick release brake valve (7).
servicing.
6. Repair or replace components as necessary.

2. Release air system pressure. (See “RELIEVING AIR

SYSTEM PRESSURE” on page 8-6.)
Inspection
3. Remove brush guard. (See “FRONT COVERS AND • Clean all parts of dirt and debris.
GUARDS” on page 14-3.) • Inspect air lines, fittings, and valves for leaks, holes,
cracks, and loose connections. Replace parts found
to be unserviceable.
4
• Check all threaded components for damaged or
5 stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
2 6
1 Installation
7 Installation is the reverse of the removal procedure.
• Test operation of brake system.

TPS-113
1 Air Line 5 Washer (4 used)
2 Air Line 6 Lock Nut (2 used)
3 Air Line 7 Front Quick Release Brake
4 Cap Screw (2 used) Valve
Figure 9-4: Front Quick Release Brake Valve
4. Install identification tags and disconnect air lines (1—
3). Close all openings using caps and plugs.

TICO Manufacturing Service Manual 9-5

ABS/ATC SYSTEM PRO-SPOTTER

REAR MODULATOR VALVE (IF

EQUIPPED)  CAUTION
• Avoid personal injury from explosion. Air
system components may contain pressurized
Removal gases. Exposure to excessive heat may
See Figure 9-6. cause components to explode.
1. Park and prepare tractor for service. (See “Park • Avoid personal injury from high-pressure
Tractor Safely” on page 1-3.) gases or debris. High-pressure release of
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
system pressure from air system before
servicing.

2. Release air system pressure. (See “RELIEVING AIR

SYSTEM PRESSURE” on page 8-6.)

6 7
7 4 5 4
5 6

1
3 3

2
TPS-112
1 Air Line (2 used) 3 Electrical Connector (2 5 Washer (8 used) 7 Rear Modulator Valve (2
used) used) (if equipped)
2 Air Line (2 used) 4 Cap Screw (4 used) 6 Lock Nut (4 used)
Figure 9-6: Rear Modulator Valve (if equipped)

NOTE
Inspection
• Clean all parts of dirt and debris.
Procedure includes servicing of both rear modulator
valves (if equipped) (7). Technicians should only address • Inspect air lines, fittings, and valves for leaks, holes,
the units which are malfunctioning. cracks, and loose connections. Replace parts found
to be unserviceable.
3. Install identification tags and disconnect air lines (1
and 2). Close all openings using caps and plugs. • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
4. Install identification tags and disconnect electrical
chasers. Replace parts found to be unserviceable.
connectors (3).
5. Remove cap screws (4), washers (5), lock nuts (6),
and rear modulator valves (if equipped) (7). Installation
6. Repair or replace components as necessary. Installation is the reverse of the removal procedure.
• Test operation of brake system.

9-6 Service Manual TICO Manufacturing

PRO-SPOTTER ABS/ATC SYSTEM

REAR QUICK RELEASE BRAKE

VALVE
Removal 1
See Figure 9-7.
1. Park and prepare tractor for service. (See “Park 6
Tractor Safely” on page 1-3.) 7
2

 CAUTION
• Avoid personal injury from explosion. Air
5
system components may contain pressurized
gases. Exposure to excessive heat may 6
cause components to explode. 8
• Avoid personal injury from high-pressure
gases or debris. High-pressure release of 4
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
system pressure from air system before
servicing. 3

2. Release air system pressure. (See “RELIEVING AIR TPS-114

SYSTEM PRESSURE” on page 8-6.) 1 Air Line 5 Cap Screw (2 used)
2 Air Line 6 Washer (4 used)
3 Air Line 7 Lock Nut (2 used)
4 Air Line 8 Rear Quick Release Brake Valve
Figure 9-7: Rear Quick Release Brake Valve
3. Install identification tags and disconnect air lines (1—
4). Close all openings using caps and plugs.
4. Remove cap screws (5), washers (6), lock nuts (7),
and rear quick release brake valve (8).
5. Repair 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 unserviceable.
• 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.
• Test operation of brake system.

TICO Manufacturing Service Manual 9-7

 PRO-SPOTTER

10-0 Service Manual TICO Manufacturing

 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

TICO Manufacturing Service Manual 10-1

CHASSIS LUBRICATION SYSTEM PRO-SPOTTER

INTRODUCTION 3. Clean and inspect male filler coupler (3) on the

automatic lubrication system. Verify coupler is free of
The purpose of the CHASSIS LUBRICATION SYSTEM dirt and debris.
section is to provide service and maintenance personnel
with guidance on the proper procedures for servicing IMPORTANT
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.
engineered for quick and efficient servicing while
4. With the male and female couplers of the filler pump
minimizing downtime.
connected, operate the filler pump for at least 3
Automatic lubrication systems reduce service times strokes. Circulating the grease ensures there are no
further by ensuring components are kept properly air pockets in the filler hose. This is especially
lubricated during operation without requiring direct important when exchanging buckets of grease.
service labor.
5. Clean and inspect female filler coupler. Verify coupler
For additional information, please contact TICO factory is free of dirt and debris.
support. (See “CONTACT TICO SUPPORT” on
6. Connect the male filler coupler of the automatic
page 0-15.)
lubrication system to the female couple of the filler
pump.
AUTOMATIC LUBRICATION
IMPORTANT
SYSTEM
Prevent possible damage to automatic lubrication
Filling the Reservoir system. Do not overfill reservoir. Reservoir should be
filled only to maximum level mark.
See Figure 10-1.
If during a system inspection when it is visible that the NOTE
reservoir has reached minimum level, the pump needs to
If automatic lubrication system is filled to the maximum
be filled with an appropriate NLGI - grade lubricant. (See
level mark, the system may release excess lubricant or
“RECOMMENDED LUBRICANTS AND CAPACITIES” on
trapped air from underneath the follower plate through
page 2-6.)
the system vent.
For filling the reservoir, follow the steps as described
7. Fill reservoir with grease until top of follower plate
below to ensure that no contaminants and/or air enter the
reaches the maximum level mark on reservoir.
lubrication system.
8. Install dust cap.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) Removal
See Figures 10-2 and 10-3.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
3 2. Disconnect batteries. (See “BATTERY” on page 3-3.)

TPS-037

TPS-035 1 Electrical Connector

2 Dust Cap 3 Male Filler Coupler Figure 10-2: Automatic Lubrication System
Figure 10-1: Dust Cap Electrical Connector

2. Remove dust cap (2). 3. Install identification tags and disconnect electrical
connector (1).

10-2 Service Manual TICO Manufacturing

PRO-SPOTTER CHASSIS LUBRICATION SYSTEM

10
3
6

7
8
2
9

1 11

13 12
TPS-035
1 Electrical Connector 5 Magnetic Key 9 Grommet (4 used) 13 Digital Display
2 Dust Cap 6 Cap Screw (4 used) 10 Backer Plate (2 used)
3 Male Filler Coupler 7 Lock Washer (4 used) 11 Pump Element (24 used)
4 Automatic Lubrication System 8 Washer (4 used) 12 Lubrication Line (24 used)
Figure 10-3: Automatic Lubrication System
4. Install identification tags and disconnect lubrication • Verify magnetic key (5) is present. Replace magnetic
lines (12). Close all openings using caps or plugs. key if missing.
5. Support automatic lubrication system (4).
6. Remove cap screws (6), lock washers (7), washers Installation
(8), grommets (9), and backer plates (10). Installation is reverse of removal procedure.
7. Remove automatic lubrication system.
8. 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. Replace parts found to be unserviceable.
• Check all lubrication lines for signs of leakage or
damage. Replace parts found to be unserviceable.
• Check all pump elements (11) for signs of leakage or
damage. Replace parts found to be unserviceable.

TICO Manufacturing Service Manual 10-3

 PRO-SPOTTER

11-0 Service Manual TICO Manufacturing

 Section 11

HYDRAULIC SYSTEM

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
DIRECTIONAL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
HYDRAULIC SYSTEM SHUT OFF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

TICO Manufacturing Service Manual 11-1

HYDRAULIC SYSTEM PRO-SPOTTER

INTRODUCTION CHECK FLUID LEVEL

The purpose of the HYDRAULIC SYSTEM section is to
provide service and maintenance personnel with Hydraulic Fluid
guidance on the proper procedures for removing and See Figure 11-1.
replacing the various hydraulic components on the TICO
Pro-Spotter terminal trucks. 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
The TICO Pro-Spotter terminal trucks have been
engineered for quick and efficient servicing while NOTE
minimizing downtime. The hydraulic system is
responsible for the fifth wheel boom and power steering Fifth wheel boom should be powered down to fully
operation. lowered position whenever checking and servicing the
hydraulic reservoir.
Service and maintenance personnel should inspect the
entire hydraulic system frequently for leaks, loose fittings, 2. Lower fifth wheel boom to fully down position.
or damage.
For additional information, please contact TICO factory
2
support. (See “CONTACT TICO SUPPORT” on
page 0-15.)

TPS-018
1 Hydraulic Reservoir Sight 3 Hydraulic Reservoir
Glass
2 Filler Cap
Figure 11-1: Hydraulic Reservoir
3. Check hydraulic reservoir sight glass (1) to determine
hydraulic fluid level.
4. If necessary, remove filler cap (2) and add approved
hydraulic oil to hydraulic reservoir (3).
5. Check hydraulic reservoir sight glass to verify
hydraulic fluid level.
6. Install the filler cap.
7. Verify fifth wheel boom operation.

11-2 Service Manual TICO Manufacturing

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. Remove cap screws (7), washers (8 and 9), lock nut
Tractor Safely” on page 1-3.) (10), and directional control valve (12).
8. Repair or replace components as necessary.
NOTE
Fifth wheel boom should be powered down to fully Inspection
lowered position whenever checking and servicing the
hydraulic reservoir. • Clean all parts of dirt and debris.
2. Lower fifth wheel boom to fully down position. • Inspect hydraulic lines and fittings for leaks, holes,
cracks, and loose connections. Replace parts found
3. Remove boom grate and boom heat shield. (See
to be unserviceable.
“GRATES AND COVERS” on page 14-5.)
• Inspect electrical connectors and wiring for damage,
4. Close hydraulic tank shut offs. (See “HYDRAULIC
corrosion, or loose connections. Replace parts found
SYSTEM SHUT OFF VALVES” on page 11-6.)
to be unserviceable.
• Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
7 9
8 10
12 6 Installation
Installation is the reverse of the removal procedure.
2
• Test boom operation.

1
5

4
3
11

TPS-093
1 Directional Control 7 Cap Screw (2 used)
Valve-to-Tee Hydraulic Line
2 Hydraulic 8 Washer (2 used)
Pump-to-Directional
Control Valve Hydraulic
Line
3 Tee-to-Directional Control 9 Washer (2 used)
Valve Hydraulic Line
4 Tee-to-Directional Control 10 Lock Nut (2 used)
Valve Hydraulic Line
5 Directional Control 11 Solenoid (2 used)
Valve-to-Tee Hydraulic Line
6 Hydraulic 12 Directional Control Valve
Filter-to-Directional Control
Valve Hydraulic Line
Figure 11-2: Directional Control Valve

TICO Manufacturing Service Manual 11-3

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. Remove U-bolts (8), washers (9), lock nuts (7), and
Tractor Safely” on page 1-3.) clamp (6). Move clamp and air release cord (5) aside.
7. Remove cap screws (10), washers (11), and
NOTE hydraulic filter assembly.
Fifth wheel boom should be powered down to fully 8. Position a suitable container below the hydraulic filter
lowered position whenever checking and servicing the assembly. Remove and discard the hydraulic filter
hydraulic reservoir. (2).
2. Lower fifth wheel boom to fully down position. 9. Repair or replace components as necessary.
3. Close hydraulic tank shut offs. (See “HYDRAULIC
SYSTEM SHUT OFF VALVES” on page 11-6.) Inspection
• Clean all parts of dirt and debris.
7 8 10 • Inspect hydraulic lines and fittings for leaks, holes,
9 cracks, and loose connections. Replace parts found
6 11
to be unserviceable.
5
• Check all threaded components for damaged or
stripped threads. Repair light damage with thread
4 chasers. Replace parts found to be unserviceable.

Installation
Installation is the reverse of the removal procedure.
3 • Apply a thin film of clean hydraulic fluid to the filter
1 gasket.
• Tighten hydraulic filter (2) by hand approximately 1/2
2 TPS-107 to 3/4 turn after filter gasket makes contact with the
1 Hydraulic Filter Assembly 7 Lock Nut (4 used) filter head.
2 Hydraulic Filter 8 U-Bolt (2 used)
• Test boom and steering operation.
3 Hydraulic 9 Washer (4 used)
Filter-to-Directional Control
Valve Hydraulic Line
4 Hydraulic 10 Cap Screw (2 used)
Filter-to-Hydraulic Tank
Hydraulic Line
5 Air Release Cord 11 Washer (2 used)
6 Clamp
Figure 11-3: Hydraulic Filter Assembly

11-4 Service Manual TICO Manufacturing

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.)

See Figure 11-4. NOTE

1. Park and prepare tractor for service. (See “Park Fifth wheel boom should be powered down to fully
Tractor Safely” on page 1-3.) lowered position whenever checking and servicing the
hydraulic reservoir.
NOTE
2. Lower fifth wheel boom to fully down position.
Fifth wheel boom should be powered down to fully
lowered position whenever checking and servicing the
hydraulic reservoir. 2
2. Lower fifth wheel boom to fully down position.
3. Position a suitable container to receive the drained
oil.

4 3

TPS-018
1 Hydraulic Reservoir Sight 3 Hydraulic Reservoir
Glass
2 Filler Cap
TPS-090
Figure 11-5: Hydraulic Reservoir
4 Drain Plug
Figure 11-4: Drain Plug 3. Remove filler cap (2) and add approved hydraulic oil to
hydraulic reservoir (3).
4. Check hydraulic fluid level. (See “CHECK FLUID
 CAUTION LEVEL” on page 11-2.)
Avoid injury and serious burns from hydraulic 5. Install the filler cap.
fluid. Avoid contact with hot hydraulic fluid. 6. Test boom and steering operation.

4. Remove drain plug (4) and drain hydraulic oil.

TICO Manufacturing Service Manual 11-5

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.
1. Park and prepare tractor for service. (See “Park HYDRAULIC SYSTEM SHUT OFF
Tractor Safely” on page 1-3.)
VALVES
2. Raise the cab.
3. Close hydraulic tank shut offs. (See “HYDRAULIC See Figures 11-7 and 11-8.
SYSTEM SHUT OFF VALVES” on page 11-6.) 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)

5 2 3

TPS-118
1 3
2 1 Hydraulic Tank 3 Suction Line Shut Off Valve
2 Suction Line
TPS-092
Figure 11-7: Hydraulic Tank (rear)
1 Hydraulic 4 Cap Screw (2 used)
Pump-to-Steering Gear 2. Close suction line shut off valve (3).
Box Hydraulic Line
2 Hydraulic 5 Washer (2 used)
Pump-to-Directional
Control Valve Hydraulic
Line
3 HydraulicTank-to-Hydraulic 6 Hydraulic Pump
Pump Hydraulic Line
Figure 11-6: Hydraulic Pump
4. Install identification tags and disconnect hydraulic
lines (1—3). Close all openings using caps and
plugs.
5. Remove cap screws (4), washers (5), and hydraulic 4 5
pump (6).
6. Repair or replace components as necessary.

Inspection 1
TPS-119
• Clean all parts of dirt and debris.
1 Hydraulic Tank 5 HydraulicTank-to-Hydraulic
• Inspect hydraulic lines and fittings for leaks, holes, 4 HydraulicTank-to-Hydraulic Pump Line Shut Off Valve
cracks, and loose connections. Replace parts found Pump Line
to be unserviceable. Figure 11-8: Hydraulic Tank (bottom)
• Check all threaded components for damaged or 3. Close hydraulic tank-to-hydraulic pump line shut off
stripped threads. Repair light damage with thread valve (5).
chasers. Replace parts found to be unserviceable.

11-6 Service Manual TICO Manufacturing

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”
on page 11-5.
Suction filter restricted Clean or replace suction See “HYDRAULIC FILTER
filter. ASSEMBLY” on page 11-4.
Suction line restricted or Install new suction line.
collapsed
Improper viscosity hydraulic Drain and refill with proper See “LUBRICATION
oil (too heavy) oil to specified level. CHART” on page 2-9 or see
“Hydraulic Fluid Draining” on
page 11-5.
Hydraulic oil Hydraulic oil level is low. Fill reservoir with proper oil See “CHECK FLUID LEVEL”
temperature is too to specified level. on page 11-2 or
high see “Hydraulic Fluid Filling”
on page 11-5.
Machine overloaded Remove overload from
machine.
Improper viscosity hydraulic Drain and refill with proper See “LUBRICATION
oil (too light) oil to specified level. CHART” on page 2-9 or see
“Hydraulic Fluid Draining” on
page 11-5.
Boom operation Hydraulic oil level is low Fill reservoir with proper oil See “CHECK FLUID LEVEL”
slow or sluggish to specified level. on page 11-2 or
see “Hydraulic Fluid Filling”
on page 11-5.
Hydraulic pump pressure is Repair or replace hydraulic See “HYDRAULIC PUMP”
low pump. on page 11-6.
Boom leaks down Cylinder piston packing Repair or replace boom See “BOOM CYLINDERS”
leaking cylinder. on page 12-4.
Directional control valve Repair or replace directional See “DIRECTIONAL
leaking internally control valve. CONTROL VALVE” on
page 11-3.
Boom cylinder Damaged or worn rod seal Repair or replace boom See “BOOM CYLINDERS”
leaking externally and wiper cylinder. on page 12-4.
Hydraulic pump Worn or damaged shaft seal Repair or replace hydraulic See “HYDRAULIC PUMP”
leaking at shaft Worn or damaged bearings pump. on page 11-6.

TICO Manufacturing Service Manual 11-7

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”
proper oil to specified level. on page 11-2 or
see “Hydraulic Fluid Filling”
on page 11-5.
Improper viscosity hydraulic Drain and refill with proper See “LUBRICATION
oil oil to specified level. CHART” on page 2-9 or see
“Hydraulic Fluid Draining” on
page 11-5.

HYDRAULIC TANK 4. Remove U-bolts (7), washers (8), lock nuts (6), and
clamp (5). Move clamp and air release cord (4) aside.

Removal NOTE
See Figures 11-9, 11-10, 11-11, and 11-12. The hydraulic lines (2 and 3) do not need to be removed
1. Park and prepare tractor for service. (See “Park from the hydraulic filter assembly (1).
Tractor Safely” on page 1-3.) 5. Remove cap screws (9) and washers (10) and set
2. Close hydraulic tank shut offs. (See “HYDRAULIC hydraulic filter assembly (1) aside.
SYSTEM SHUT OFF VALVES” on page 11-6.)
3. Drain hydraulic tank. (See “Hydraulic Fluid Draining”
on page 11-5.)

13 12 2
11 6 7 9
8
10
13 11
5 3
12
17
4
15

3
14 16
2 TPS-118
2 Suction Hydraulic Line 14 Cap Screw
1 3 Hydraulic 15 Washer (2 used)
Filter-to-Hydraulic Tank
TPS-107 Hydraulic Line
11 Hydraulic Tank 16 Lock Nut
1 Hydraulic Filter Assembly 8 Washer (4 used)
12 Cap Screw (4 used) 17 Clamp
2 Hydraulic 9 Cap Screw (2 used)
Filter-to-Directional Control 13 Washer (8 used)
Valve Hydraulic Line Figure 11-10: Hydraulic Tank (rear)
3 Hydraulic 10 Washer (2 used)
Filter-to-Hydraulic Tank 6. Install identification tags and disconnect hydraulic
Hydraulic Line
4 Air Release Cord 11 Hydraulic Tank line (3). Close all openings using caps and plugs.
5 Clamp 12 Cap Screw (4 used) 7. Remove cap screw (14), washers (15), lock nut (16),
6 Lock Nut (4 used) 13 Washer (8 used) and clamp (7).
7 U-Bolt (2 used)
Figure 11-9: Hydraulic Filter Assembly

11-8 Service Manual TICO Manufacturing

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.

18 10. Using an appropriate lifting device, support hydraulic

11 tank (11).
11. Remove cap screws (12), washers (13), lock nuts
(19), and hydraulic tank.
12. Repair or replace components as necessary.
TPS-119
11 Hydraulic Tank 18 HydraulicTank-to-Hydraulic
Pump Hydraulic Line Inspection
Figure 11-11: Hydraulic Tank (bottom)
• Clean all parts of dirt and debris.
8. Install identification tags and disconnect hydraulic • Inspect hydraulic lines and fittings for leaks, holes,
line (18). Close all openings using caps and plugs. 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 to be unserviceable.

Installation
Installation is the reverse of the removal procedure.
• Fill hydraulic tank (11). (See “Hydraulic Fluid Filling”
20 on page 11-5.)
• Test boom and steering operation.

19

13

12

21

11
TPS-117
11 Hydraulic Tank 19 Lock Nut (4 used)
12 Cap Screw (4 used) 20 Hydraulic Tank-to-Tee Hydraulic
Line
13 Washer (8 used) 21 Steering Gear Box-to-Hydraulic
Tank Hydraulic Line
Figure 11-12: Hydraulic Tank (front)

TICO Manufacturing Service Manual 11-9

 PRO-SPOTTER

12-0 Service Manual TICO Manufacturing

 Section 12

BOOM AND FIFTH WHEEL

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
FIFTH WHEEL TOP PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

TICO Manufacturing Service Manual 12-1

BOOM AND FIFTH WHEEL PRO-SPOTTER

INTRODUCTION BOOM
The purpose of the BOOM AND FIFTH WHEEL section
is to provide service and maintenance personnel with Removal
guidance on the proper service procedures for boom and See Figures 12-1 and 12-2.
fifth wheel systems on the TICO Pro-Spotter terminal
trucks. 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
The TICO Pro-Spotter terminal trucks have been
engineered for quick and efficient servicing while NOTE
minimizing downtime.
The boom may be removed with the fifth wheel installed:
Service and maintenance personnel must inspect,
however, removing the fifth wheel will ease handling the
lubricate, and service the hydraulic boom and fifth wheel
boom.
systems regularly to maintain proper operation.
2. Remove fifth wheel top plate. (See “FIFTH WHEEL
For additional information, please contact TICO factory
TOP PLATE” on page 12-8.)
support. (See “CONTACT TICO SUPPORT” on
page 0-15.) 3. Remove boom grate and boom heat shield covers.
(See “GRATES AND COVERS” on page 14-5.)

18
14

15
16
20 4
1

3
18
15 2

16
17
19
1

2
TPS-091
1 Cap Screw (2 used) 4 Boom 16 Washer (as required) 19 Lock Plate
2 Nut (2 used) 14 Nut 17 Washer (2 used) 20 Boom Pin
3 Boom Cylinder Pin (2 used) 15 Washer (as required) 18 Bushing (4 used)
Figure 12-1: Boom (exploded view)
4. Remove cap screws (1) and nuts (2) to allow removal
of boom cylinder pins (3).

12-2 Service Manual TICO Manufacturing

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.
5. Using an appropriate lifting device, support boom (4). • 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 or
12 13 12 13 stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
8
9 10 Installation
7 11 Installation is the reverse of the removal procedure.
• Service all grease fittings.

6 • Test operation of boom and fifth wheel top plate.

5
TPS-100
5 Tee-to-Boom Cylinder 10 Tee-to-Boom Cylinder
(retract) Hydraulic Line (retract) Hydraulic Line
6 Tee-to-Boom Cylinder 11 Jam Nut (2 used)
(extend) Hydraulic Line
7 Directional Control 12 Clamp (2 used)
Valve-to-Tee Hydraulic Line
8 Directional Control 13 Clamp (2 used)
Valve-to-Tee Hydraulic Line
9 Tee-to-Boom Cylinder
(extend) Hydraulic Line
Figure 12-2: Hydraulic Lines
6. Install identification tags and disconnect hydraulic
lines (5—10). Remove jam nuts (11). Close all
openings using caps and plugs.
7. Remove clamps (12) securing hydraulic lines to
boom.
8. Remove clamps (13) securing release cylinder air
hose to boom.
9. Remove nut (14).
10. Support bushings (18) and washers (15—17). Drive
out and remove boom pin (20).

 CAUTION
Prevent possible crushing injury from heavy
component. Use appropriate lifting device.

11. Using appropriate lifting device, lift boom clear of

frame.
12. With boom removed, position boom cylinders against
drive axle.
13. Repair or replace components as necessary.

TICO Manufacturing Service Manual 12-3

BOOM AND FIFTH WHEEL PRO-SPOTTER

BOOM CYLINDERS
12
11 10
Removal 13
See Figures 12-3 and 12-4.
1. Raise boom approximately 15.2 cm (6 in).
5
2. Park and prepare tractor for service. (See “Park 14
Tractor Safely” on page 1-3.) 9
3. Remove boom grate and boom heat shield covers.
8
(See “GRATES AND COVERS” on page 14-5.)

TPS-104
7 5 Boom Cylinder (2 used) 11 Washer (4 used)
5 8 Tee-to-Boom Cylinder
(retract) Hydraulic Line
12 Lock Nut (2 used)

9 Tee-to-Boom Cylinder 13 Cylinder Pin (2 used)

1 (extend) Hydraulic Line
10 Cap Screw (2 used) 14 Bushing (4 used)
Figure 12-4: Boom Cylinder (upper end, right side
3 shown)
6
4 2 7. Install identification tags and disconnect hydraulic
lines (8 and 9). Close all openings using caps and
plugs.
TPS-106
8. Remove cap screws (10), washers (11), and lock
1 Cap Screw (8 used) 5 Boom Cylinder (2 used)
nuts (12).
2 Washer (8 used) 6 Rear Drive Axle
3 Lock Nut (8 used) 7 Boom
4 Cap (2 used)  CAUTION
Figure 12-3: Boom Cylinders (lower end)
Prevent possible crushing injury from heavy
4. Remove cap screws (1), washers (2), lock nuts (3), component. Use appropriate lifting device.
and both caps (4).
9. Using an appropriate lifting device, support boom
 CAUTION cylinders.
Prevent possible crushing injury from heavy 10. Remove cylinder pins (13) and lower boom cylinders
component. Use appropriate lifting device. to floor.
11. Repair or replace components as necessary.
5. Using an appropriate lifting device, support boom (7).
6. Retract both boom cylinders (5) completely. Inspection
• Check all welds for cracks and have any cracks
welded.
• Check cylinder pins (13) for excessive wear. Replace
pins found unserviceable.
• Check bushings (14) for wear. Press worn bushings
out.
• 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.
• Service all grease fittings.
• Test operation of boom cylinders.

12-4 Service Manual TICO Manufacturing

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
minimum of every 60,000 miles or if excessive movement
between the kingpin and fifth wheel is noticed while
driving the vehicle.
13
 WARNING
Failure to maintain proper fifth wheel adjustment
could result in loss of vehicle control, which if not
1 TPS-102
avoided, could result in death or serious injury.
1 Fifth Wheel Top Plate 13 Adjustment Nut
Figure 12-6: Compressing the Rubber Washer
IMPORTANT 4. With the locks closed around the lock tester, position
Excessive movement between the tractor and trailer the adjustment nut on yoke shaft so it is slightly
can affect vehicle handling. compressing the rubber washer. This will make it
difficult to turn the adjustment nut by hand.
NOTE
To obtain proper fifth wheel adjustment,
SAF-HOLLAND™ recommends the use of the
HOLLAND lock tester (part number TF-TLN-5001). The
HOLLAND lock tester is available from a local HOLLAND
distributor.
1

13
TPS-103
1 1 Fifth Wheel Top Plate 13 Adjustment Nut
Figure 12-7: Clockwise Adjustment
5. Turn the adjustment nut 1 additional turn clockwise to
further compress the rubber washer.
13
TPS-101 IMPORTANT
1 Fifth Wheel Top Plate 13 Adjustment Nut Over-compressing the rubber washer with additional
Figure 12-5: Loosening the Adjustment Nut turns will take the fifth wheel out of proper
adjustment and degrade the performance of the fifth
1. Loosen the adjustment nut (13) 5 or 6 turns.
wheel.
2. If the fifth wheel is locked, pull the release handle to
6. Repeat the coupling and uncoupling process with the
unlock the fifth wheel. If equipped with a manual
lock tester at least twice to help “seat” the yoke.
secondary lock, first pull the secondary release
handle and hook on the top plate casting. 7. Confirm that the rubber washer cannot be turned by
hand. If it can, repeat the adjustment procedures.
NOTE 8. Remove the lock tester from the fifth wheel.
For specific lock tester instructions, visit SAF-HOLLAND
online (www.safholland.us) and refer to SAF-HOLLAND
document number XL-FW10082ST-en-US.

TICO Manufacturing Service Manual 12-5

BOOM AND FIFTH WHEEL PRO-SPOTTER

Lubrication Contact Surface

See Figure 12-9.
Air Cylinder
See Figure 12-8.

11

12
9 TPS-025
TPS-028 11 Lubrication Surface (as
necessary)
8 Air Cylinder Tube 12 Supply Fitting Figure 12-9: Fifth Wheel Lubrication Surface
9 Piston Shaft
Figure 12-8: Air Cylinder 1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)
1. Inspect air cylinder tube (8) and piston shaft (9) for
2. Remove old grease and debris from the fifth wheel
dents, bending, or other damage. Replace as
lubrication surface (11).
necessary.
3. Apply new water-resistant, lithium-based grease to
2. Engage air cylinder control to extend the piston shaft
the fifth wheel lubrication surface.
fully.
4. Clean grease grooves if a large amount of debris is
3. Clean exposed piston shaft with penetrating oil and a
present.
clean shop towel. Do not use abrasives on the
exposed shaft as they could damage the piston shaft.
4. Disengage air cylinder control to retract the piston
and shaft.
5. Remove the supply 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 cylinder and onto the
piston.
8. Verify proper operation.

12-6 Service Manual TICO Manufacturing

PRO-SPOTTER BOOM AND FIFTH WHEEL

Locking Mechanism
See Figure 12-10.

3
2
7
8
4

9
1
10

11
TPS-027
1 Yoke Tip (2 used) 4 Secondary Lock 7 Cam Pivot Point 10 Fifth Wheel Top Plate
2 Cam Profile 5 Release Handle 8 Air Cylinder Tube 11 Lubrication Surface (as
3 Yoke Shaft 6 Lock Jaw (2 used) 9 Piston Shaft necessary)
Figure 12-10: Fifth Wheel Lubrication Locations
1. Park and prepare tractor for service. (See “Park 6. Using water-resistant, lithium-based grease,
Tractor Safely” on page 1-3.) lubricate secondary lock (4) where it contacts the
2. Using an appropriate lifting device, remove fifth cam plate.
wheel top plate (10). (See “FIFTH WHEEL TOP 7. Using water-resistant, lithium-based grease,
PLATE” on page 12-8.) lubricate release handle (5).
3. Using water-resistant, lithium-based grease, 8. Using water-resistant, lithium-based grease,
lubricate the yoke tips (1) where it contacts the locks lubricate lock jaws (6) where it contacts the kingpin.
and top plate casting. 9. Using a light oil, lubricate the cam pivot point (7).
4. Using water-resistant, lithium-based grease,
lubricate cam profile (2).
5. Using water-resistant, lithium-based grease,
lubricate yoke shaft (3) along the sliding surface.

TICO Manufacturing Service Manual 12-7

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
Tractor Safely” on page 1-3.) 6. Using an appropriate lifting device, remove the top
plate.
2. Raise boom approximately 15.24 cm (6 in) to
increase access to underside of fifth wheel. 7. Place the fifth wheel top plate on a flat, clean working
area.

Inspection
See Figure 12-13.
• Clean all parts of dirt and debris.
1 • Inspect air lines, fittings, and valves for leaks, holes,
cracks, and loose connections. Replace parts found
to be unserviceable.
8 • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
13 chasers. Replace parts found to be unserviceable.

TPS-105 1
1 Fifth Wheel Top Plate 13 Air Line
8 Air Cylinder Tube 5
Figure 12-11: Air Line
3. Disconnect air line (13) from air cylinder tube (8).
Close all openings using caps and plugs.

1 6

TPS-031
2
1 Fifth Wheel Top Plate 6 Free Vertical Movement of
5 Pocket Insert Thickness Top Plate
3 Figure 12-13: Pocket Insert Inspection
• Inspect pocket inserts and replace if:
a. Pocket insert thickness (5) is less than
specification.
4
TPS-029 Specification
1 Fifth Wheel Top Plate 3 Nut (2 used) Pocket Insert—Thickness 1.6 mm
2 Cap Screw (2 used) 4 Bracket Pin (2 used) (minimum) 0.063 in
Figure 12-12: Fifth Wheel Top Plate
4. Remove nuts (3) and cap screws (2). b. Free vertical movement of top plate (6) on
bracket exceeds specification without
5. Using a pry bar, pull the bracket pins (4) out of the
compressing rubber bushings.
fifth wheel top plate (1).

12-8 Service Manual TICO Manufacturing

PRO-SPOTTER BOOM AND FIFTH WHEEL

Specification
Top Plate Vertical Movement— 12.7 mm
Distance (maximum) 0.5 in 1

c. Pocket inserts are severely chipped, cracked, or

gouged. 2

Installation 3
See Figures 12-14 and 12-15. 10

4
TPS-029
1 Fifth Wheel Top Plate 4 Bracket Pin (2 used)
2 Cap Screw (2 used) 10 Mounting Base
7
3 Nut (2 used)
Figure 12-15: Fifth Wheel Top Plate

 CAUTION
8 Prevent possible crushing injury from heavy
component. Use appropriate lifting device.

4. Using an appropriate lifting device, install fifth wheel

9 TPS-030
top plate (1) onto mounting base (10).
5. Install bracket pins (4) through the fifth wheel top
7 Pocket Insert (2 used) 9 Pocket Area (2 used)
8 Double-Face Tape (as
plate and mounting base.
necessary) 6. Install cap screws (2) and nuts (3). Tighten nuts to
Figure 12-14: Pocket Area specification.
1. If pocket inserts (7) are dislodged, clean pocket
areas (9). Specification
2. Apply double-face tape (8) to bottom of each pocket Nut—Torque 68—81 N·m
area. 50—60 ft·lb
3. Install pocket inserts by pressing down firmly into
pocket areas.

TICO Manufacturing Service Manual 12-9

 PRO-SPOTTER

13-0 Service Manual TICO Manufacturing

 Section 13

CAB

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
CAB AIR BAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
CAB DOOR AIR PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CAB LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
CAB LEVELING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Hydraulic Fluid Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Cab Tilt Hydraulic Fluid Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
CAB TILT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
CHECK FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
Cab Tilt Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
TRAINER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15

TICO Manufacturing Service Manual 13-1

CAB PRO-SPOTTER

WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16

13-2 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

INTRODUCTION CAB AIR BAG

The purpose of the CAB section is to provide service and
maintenance personnel with guidance on the proper Adjustment
procedures for removing and replacing of the various cab See Figures 13-1 and 13-2.
components and the cab hydraulic tilt system on the
TICO Pro-Spotter terminal trucks. NOTE
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.
minimizing downtime.
1. Park and prepare tractor for service. (See “Park
Service and maintenance personnel should only remove Tractor Safely” on page 1-3.)
components deemed necessary for the service or
maintenance procedure being performed.
For additional information, please contact TICO factory
support. (See “CONTACT TICO SUPPORT” on
page 0-15.)

TPS-083
1 Detent Position 1 (full open) 3 Detent Position 3 (minimum
open)
2 Detent Position 2 (half 4 Lock Bar
open)
Figure 13-1: Lock Bar
2. Raise cab completely and allow it to settle into detent
position 1 (full open) (1) of the lock bar (4).

TICO Manufacturing Service Manual 13-3

CAB 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
5 Tractor Safely” on page 1-3.)

TPS-150 2
5 Lock Nut (4 used) 6 Cab Air Bag
Figure 13-2: Cab Latch (right side shown) 1
3. Apply alignment marks to cab frame and cab air bag
(6) to aid when adjusting. TPS-083

4. Loosen lock nuts (5). 1 Detent Position 1 (full open) 3 Detent Position 3 (minimum
open)
5. Adjust cab air bag by repositioning cab air bag on the 2 Detent Position 2 (half 4 Lock Bar
cab frame as necessary. open)
Figure 13-3: Lock Bar
6. Tighten lock nuts.
7. Slowly lower cab. Check alignment between cab air 2. Raise cab completely and allow it to settle into detent
bag striker and cab latch. (See “CAB LATCH” on position 1 (full open) (1) of the lock bar (4).
page 13-7.)
 CAUTION
• Avoid personal injury from explosion. Air
system components may contain pressurized
gases. Exposure to excessive heat may
cause components to explode.
• Avoid personal injury from high-pressure
gases or debris. High-pressure release of
gases or debris from a pressurized system
can cause penetrating injuries. Relieve
system pressure from air system before
servicing.

3. Release air system pressure. (See “RELIEVING AIR

SYSTEM PRESSURE” on page 8-6.)

13-4 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

13
11
14

12 17
10

15
9 11 16
7
8
TPS-152
11 Housing 16 Cab Air Bag Striker
5 15 Lock Nut (2 used) 17 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).
6

11

TPS-151
5 Nut 10 Air Line
6 Linkage 11 Housing
7 Lock Nut (2 used) 12 Cap Screw (4 used)
8 Washer (2 used) 13 Washer (8 used) 18
9 Cab Leveling Valve 14 Lock Nut (4 used)
Figure 13-4: Housing (left side shown) TPS-153
4. Remove nut (5) and disconnect linkage (6). 11 Housing 18 Nut (2 used)

5. Remove lock nuts (7) and washers (8). Set cab Figure 13-6: Housing (upper)
leveling valve (9) aside. 10. Remove nuts (18) and cab air bag from housing.
6. Install identification tags and disconnect air line (10) 11. Repair or replace components as necessary.
at housing (11).
7. Apply alignment marks to housing and cab frame to Inspection
aid when installing.
• Clean all parts of dirt and debris.
8. Remove cap screws (12), washers (13), lock nuts
(14), and housing. • Inspect air lines, fittings, and connections 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 with thread
chasers. Replace parts found to be unserviceable.

Installation
Installation is the reverse of the removal procedure.
• Check cab air bag alignment with cab latch. (See
“Adjustment” on page 13-3.)

TICO Manufacturing Service Manual 13-5

CAB PRO-SPOTTER

CAB DOOR AIR PRESSURE

ADJUSTMENT
See Figures 13-7 and 13-8.
1. Park and prepare tractor for service. (See “Park 6
Tractor Safely” on page 1-3.)
5

4 7

TPS-181

3 5 Air Pressure Gauge 7 Air Regulator Valve

6 Adjustment Knob
Figure 13-8: Air Regulator Valve
2
3. Read air pressure gauge (5) and determine if
1 adjustment is necessary.
4. Lift adjustment knob (6).
TPS-083
1 Detent Position 1 (full open) 3 Detent Position 3 (minimum
IMPORTANT
open) Prevent possible component damage. Cab door air
2 Detent Position 2 (half 4 Lock Bar
open) pressure must be set between 207—345 kPa (30—50
Figure 13-7: Lock Bar psi). Exceeding or reducing beyond this range can
cause damage to the air closure or operating
2. Raise cab completely and allow it to settle into detent mechanism.
position 1 (full open) (1) of the lock bar (4).
5. Turn adjustment knob clockwise to increase cab door
air pressure.
6. Turn adjustment knob counterclockwise to decrease
cab door air pressure.
7. Read air pressure gauge after adjustment. Verify new
pressure is within specification.

Specification
Cab Door Air Pressure Range— 207—345 kPa
Pressure 30—50 psi

8. Lower the cab.

9. Start engine. Run engine at fast idle.
10. Allow air pressure to stabilize at normal operating
pressure for at least 1 minute.
11. Operate cab door and verify adjustments.

13-6 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

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 10
Tractor Safely” on page 1-3.)
9

TPS-149
9 Lock Nut (4 used) 10 Cab Latch
Figure 13-10: Cab Latch (left side shown)
3. Apply alignment marks to bracket and adjuster to aid
when adjusting.
4 4. Loosen lock nuts (9).
5. Adjust cab latch (10) by repositioning cab latch on
the frame as necessary.
6. Tighten lock nuts.
3 7. Slowly lower cab. Check alignment between cab
latch and cab air bag striker. (See “CAB AIR BAG” on
2 page 13-3.)

TPS-083
1 Detent Position 1 (full open) 3 Detent Position 3 (minimum
open)
2 Detent Position 2 (half 4 Lock Bar
open)
Figure 13-9: Lock Bar
2. Raise cab completely and allow it to settle into detent
position 1 (full open) (1) of the lock bar (4).

TICO Manufacturing Service Manual 13-7

CAB PRO-SPOTTER

Removal
See Figures 13-11 and 13-12.

NOTE
Procedure is written for the left side cab latch. Right side 6
10
cab latch procedure is similar.
1. Park and prepare tractor for service. (See “Park 7
Tractor Safely” on page 1-3.)

8
5
9

TPS-149
5 Hydraulic Line 8 Washer (8 used)
6 Hydraulic Line 9 Lock Nut (4 used)
7 Cap Screw (4 used) 10 Cab Latch
4 Figure 13-12: Cab Latch (left side shown)
3. Apply alignment marks to bracket and adjuster to aid
when installing.
4. Install identification tags and disconnect hydraulic
3 lines (5 and 6). Close all openings using caps and
plugs.
2 5. Remove cap screws (7), washers (8), lock nuts (9),
and cab latch (10).
1 6. Repair or replace components as necessary.

TPS-083
Inspection
1 Detent Position 1 (full open) 3 Detent Position 3 (minimum
open) • Clean all parts of dirt and debris.
2 Detent Position 2 (half 4 Lock Bar
open) • Inspect hydraulic lines, fittings, and connections for
Figure 13-11: Lock Bar leaks, holes, cracks, and loose connections. Replace
parts found to be unserviceable.
2. Raise cab completely and allow it to settle into detent
• Check all threaded components for damaged or
position 1 (full open) (1) of the lock bar (4).
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.

Installation
Installation is the reverse of the removal procedure.
• Check cab air shock alignment with latch. (See
“Adjustment” on page 13-7.)

13-8 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

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.)

12

TPS-148
3 5 Cab Leveling Valve 12 Lock Nut (2 used)
Figure 13-14: Adjusting Cab Leveling Valve
2
4. Loosen lock nuts (12).
1 5. Adjust cab leveling valve (5) by repositioning lower
portion of cab leveling valve as necessary.
TPS-083 6. Tighten lock nuts.
1 Detent Position 1 (full open) 3 Detent Position 3 (minimum 7. Lower cab.
open)
8. Operate tractor and allow air pressure to increase to
2 Detent Position 2 (half 4 Lock Bar
open) normal operating pressure.
Figure 13-13: Lock Bar 9. Check cab ride height for leveling.
2. Raise cab completely and allow it to settle into detent
position 1 (full open) (1) of the lock bar (4).
3. Apply alignment marks to bracket and adjuster to aid
when adjusting.

TICO Manufacturing Service Manual 13-9

CAB PRO-SPOTTER

Removal
See Figures 13-15 and 13-16. 7 8
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) 6 5

9
12
11

10
4
TPS-147
5 Cab Leveling Valve 9 Nut
6 Air Line 10 Linkage
7 Air Line 11 Washer (2 used)
3 8 Air Line 12 Lock Nut (2 used)
Figure 13-16: Cab Leveling Valve
2
4. Install identification tags and disconnect air lines (6—
8). Close all openings using caps and plugs.
1
5. Remove nut (9) and disconnect linkage (10).
TPS-083 6. Remove lock nuts (12), washers (11), and cab
1 Detent Position 1 3 Detent Position 3 leveling valve (5).
(full open) (minimum open) 7. Repair or replace components as necessary.
2 Detent Position 2 4 Lock Bar
(half open)
Figure 13-15: Lock Bar Inspection
2. Raise cab completely and allow it to settle into detent • Clean all parts of dirt and debris.
position 1 (full open) (1) of the lock bar (4). • Inspect air lines, fittings, and connections for leaks,
3. Apply alignment marks to bracket and adjuster to aid holes, cracks, and loose connections. Replace parts
when installing. 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.

Installation
Installation is the reverse of the removal procedure.
• Check cab ride height and adjust as necessary. (See
“Adjustment” on page 13-9.)

13-10 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

CAB TILT CYLINDER

7
Removal
See Figures 13-17 and 13-18. 8
1. Park and prepare tractor for service. (See “Park 6
Tractor Safely” on page 1-3.)

5
5

9
3

2 10
12
1 11
TPS-084
TPS-083 5 Cab Tilt Cylinder 9 Cab Tilt Pump-to-Cab Tilt
Cylinder Hydraulic Line
1 Detent Position 1 (full open) 4 Lock Bar
6 Roll Pin 10 Roll Pin
2 Detent Position 2 (half 5 Cab Tilt Cylinder
open) 7 Cylinder Pin 11 Spacer (as required)
3 Detent Position 3 (minimum 8 Spacer (as required) 12 Cylinder Pin
open) Figure 13-18: Cab Tilt Cylinder
Figure 13-17: Lock Bar
4. Install identification tags and disconnect cab tilt
2. Raise cab completely and allow it to settle into detent pump-to-cab tilt cylinder hydraulic line (9). Close all
position 1 (full open) (1) of the lock bar (4). openings using caps and plugs.
5. Remove roll pin (6).
 CAUTION 6. Using appropriate lifting device, support cab tilt
Avoid personal injury from high-pressure fluid. cylinder.
High-pressure release of oil from a pressurized 7. Remove cylinder pin (7) and spacers (8).
system can cause serious burns or penetrating 8. Remove roll pin (10).
injury. Relieve pressure from cab tilt hydraulic
9. Remove cylinder pin (12), spacers (11), and cab tilt
system before servicing.
cylinder.
10. Repair or replace components as necessary.
3. Press the cab lower button again to reduce cab tilt
hydraulic pressure on the cab tilt cylinder (5).

TICO Manufacturing Service Manual 13-11

CAB 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.
leaks, holes, cracks, and loose connections. Replace
9. Install cab tilt pump if necessary. (See “CAB TILT
parts found to be unserviceable.
PUMP” on page 13-13.)
• Check all threaded components for damaged or
10. Connect cab tilt pump-to-cab tilt cylinder hydraulic
stripped threads. Repair light damage with thread
line.
chasers. Replace parts found to be unserviceable.
11. Fill cab tilt hydraulic fluid. (See “Cab Tilt Hydraulic
• Inspect cab tilt cylinder for damage. Repair or replace
Fluid Filling” on page 13-12.)
as needed.

Installation Cab Tilt Hydraulic Fluid Filling

See Figure 13-20.
Installation is the reverse of the removal procedure.
1. Park and prepare tractor for service. (See “Park
• Check cab tilt system fluid level. (See “Cab Tilt
Tractor Safely” on page 1-3.)
Hydraulic Fluid Filling” on page 13-12.)
2. Lower cab to fully down position.

CAB TILT HYDRAULIC FLUID

MAINTENANCE
Cab Tilt Hydraulic Fluid Draining 3
See Figure 13-19.
1. Park and prepare tractor for service. (See “Park 1
Tractor Safely” on page 1-3.) 2
4
2. Lower cab completely and allow it to settle into full
resting position.
3. Remove cab tilt pump cover. (See “LEFT COVERS
AND GUARDS” on page 14-8.) TPS-145
1 Cab Tilt Reservoir 3 Reservoir Cap
2 Applied Level Mark 4 Actual Fluid Level
Figure 13-20: Cab Tilt Reservoir
1
3. Remove reservoir cap (3).
4. Add oil to fill reservoir.
5. Compare actual fluid level (4) to applied level mark
(2) on the cab tilt reservoir (1).
2 6. Install the reservoir cap.
7. Tilt cab to verify proper operation.

TPS-146
1 Cab Tilt Pump-to-Cab Tilt 2 Cab Tilt Pump
Cylinder Hydraulic Line
Figure 13-19: Cab Tilt Pump
4. Position a suitable container 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. Allow cab tilt hydraulic fluid to drain.

13-12 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

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” on page 1-3.)
2. Lower cab completely and allow it to settle into full 2. Lower cab completely and allow it to settle into full
resting position. resting position.
3. Remove cab tilt pump cover. (See “LEFT COVERS
AND GUARDS” on page 14-8.)

3
3
1
2
1 2 4

6
4 TPS-145
1 Cab Tilt Reservoir 3 Reservoir Cap
5
2 Applied Level Mark 4 Actual Fluid Level
Figure 13-22: Cab Tilt Reservoir
TPS-146
1 Electrical Connector 4 Cap Screw (2 used) 3. Compare actual fluid level (4) to applied level mark
2 Electrical Connector 5 Washer (2 used) (2) on the cab tilt reservoir (1).
3 Cab Tilt Pump-to-Cab Tilt 6 Cab Tilt Pump
Cylinder Hydraulic Line 4. If necessary, add oil to fill reservoir. (See “Cab Tilt
Figure 13-21: Cab Tilt Pump Hydraulic Fluid Filling” on page 13-12.)
4. Install identification tags and disconnect electrical
connectors (1 and 2).
5. Install identification tags and disconnect hydraulic
line (3). Close all openings using caps and plugs.
6. Remove cap screws (4), washers (5), and cab tilt
pump (6).
7. Repair or replace components as necessary.

Inspection
• Clean all parts of dirt and debris.
• Inspect hydraulic lines, fittings, and connections 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 with thread
chasers. Replace parts found to be unserviceable.
• Inspect electrical connectors and wiring for damage,
corrosion, or loose connections. Replace parts found
to be unserviceable.

Installation
Installation is the reverse of the removal procedure.

TICO Manufacturing Service Manual 13-13

CAB PRO-SPOTTER

TRAINER SEAT
9
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.

10

1 2 11 12 TPS-170
3 9 Trainer Seat 11 Washer (10 used)
4 10 Cap Screw (5 used) 12 Lock Nut (5 used)
7 Figure 13-24: Trainer Seat
5
5. Remove cap screws (10), washers (11), lock nuts
(12), and trainer seat.
6 6. Repair or replace components as necessary.
TPS-169
1
2
Cap Screw
Washer (2 used)
6
7
Lock Nut
Bracket
Inspection
3 Lock Nut 8 Trainer Seat Belt • Clean all parts of dirt and debris.
4 Cap Screw 9 Trainer Seat
5 Washer (2 used)
• Check all threaded components for damaged or
stripped threads. Repair light damage with thread
Figure 13-23: Trainer Seat Belt
chasers. Replace parts found to be unserviceable.
3. Remove cap screw (1), washers (2), and lock nut (3). • Inspect seat belt for damage, frayed belts, or loose
4. Remove cap screw (4), washers (5), lock nut (6), latch. Replace parts found to be unserviceable.
bracket (7), and trainer seat belt (8).
Installation
Installation is the reverse of the removal procedure.

13-14 Service Manual TICO Manufacturing

PRO-SPOTTER CAB

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.)

19

13

TPS-173
19 Cap Screw Mounting Location (6 used)
14
Figure 13-27: Cap Screw Mounting Locations
15 9 4. Remove floor mat to reveal floor cap screw mounting
TPS-171
locations (19).
9 Trainer Seat 14 Washer 5. Replace floor mat. Drill corresponding holes through
13 Cap Screw 15 Seat Belt Latch the floor mat to access cap screw mounting
Figure 13-25: Trainer Seat Latch locations.
2. Install cap screw (13), washer (14), and seat belt
latch (15) to trainer seat (9).
9

8 1 2

3
17 5 4
10 7
16
11
18 12 6
17 TPS-169
1 Cap Screw 7 Bracket
7 2 Washer (2 used) 8 Trainer Seat Belt
3 Lock Nut 9 Trainer Seat
TPS-172 4 Cap Screw 10 Cap Screw (5 used)
7 Bracket 17 Washer (2 used) 5 Washer (2 used) 11 Washer (10 used)
8 Trainer Seat Belt 18 Lock Nut 6 Lock Nut 12 Lock Nut (5 used)
16 Cap Screw Figure 13-28: Trainer Seat Belt
Figure 13-26: Trainer Seat Belt and Bracket
6. Install cap screws (10), washers (11), lock nuts (12),
3. Install cap screw (16), washers (17), lock nut (18), and trainer seat.
bracket (7), and trainer seat belt (8). 7. Install cap screw (4), washers (5), lock nut (6), and
bracket (7) to trainer seat.

TICO Manufacturing Service Manual 13-15

CAB PRO-SPOTTER

WIPER MOTOR Inspection

• Clean all parts of dirt and debris.
Removal • Inspect washer hoses, fittings, and clamps for leaks,
See Figures 13-29 and 13-30. holes, cracks, and loose connections. Replace parts
found to be unserviceable.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
2. Lower cab completely and allow it to settle into full chasers. Replace parts found to be unserviceable.
resting position.
• Inspect electrical connectors and wiring for damage,
corrosion, or loose connections. Replace parts found
to be unserviceable.
2
1 Installation
Installation is the reverse of the removal procedure.

TPS-154
1 Cap Screw (14 used) 2 Wiper Motor Cover
Figure 13-29: Wiper Motor Cover
3. Remove cap screws (1) and wiper motor cover (2).

4 5

6
7

TPS-168
3 Electrical Connector 6 Nut (2 used)
4 Clip (2 used) 7 Wiper Motor
5 Arm (2 used)
Figure 13-30: Wiper Motor
4. Install identification tags and disconnect electrical
connector (3).
5. Remove clips (4) and set arms (5) aside.
6. Remove nuts (6) and wiper motor (7).
7. Repair or replace components as necessary.

13-16 Service Manual TICO Manufacturing

 Section 14

COVERS AND GUARDS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
FRONT COVERS 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
RIGHT COVERS AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13

TICO Manufacturing Service Manual 14-1

COVERS AND GUARDS PRO-SPOTTER

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. Removing the covers and guards
allows the service and maintenance personnel to gain
access to other critical components for service or
maintenance.
Service and maintenance personnel should only remove
covers deemed necessary for the service or maintenance
procedure being performed.
For additional information, please contact TICO factory
support. (See “CONTACT TICO SUPPORT” on
page 0-15.)

14-2 Service Manual TICO Manufacturing

PRO-SPOTTER COVERS AND GUARDS

FRONT COVERS AND GUARDS

Removal
See Figures 14-1, 14-2, 14-3, and 14-4.

3 1

2
4

13

5
7 8 12
6

TPS-108
1 Screw (14 used) 4 Front Right Cover 7 Washer (24 used) 13 Radiator Guard
2 Front Left Cover 5 Bumper 8 Nut (12 used)
3 Screw (14 used) 6 Cap Screw (12 used) 12 Brush Guard
Figure 14-1: Front Covers and Guards
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.)  CAUTION
2. Remove screws (1) and front left cover (2).
Prevent possible crushing injury from heavy
3. Remove screws (3) and front right cover (4). component. Use appropriate lifting device.

4. Using an appropriate lifting device, support front

bumper (5).
5. Remove cap screws (6), washers (7), nuts (8), and
front bumper.

TICO Manufacturing Service Manual 14-3

COVERS AND GUARDS PRO-SPOTTER

10 10
11 9

17

9
18
12 11 10 TPS-053
9 Cap Screw (5 used) 11 Lock Nut (5 used)
10 Washer (10 used) 12 Brush Guard
Figure 14-2: Brush Guard
6. Remove cap screws (9), washers (10), lock nuts (11), TPS-139
and brush guard (12). 17 Engine Block Heater 18 Connector Release Button
Connector (if equipped)
Figure 14-4: Engine Block Heater Connector (if
equipped)
9. With radiator guard still supported, locate the engine
block heater connector (if equipped) (17) on back
side of radiator guard.
10. Install identification tags, press connector release
button (18), and disconnect engine block heater
connector (if equipped).
11. Remove radiator guard.
12. Repair or replace components as necessary.

13 16
15
Inspection
1. Check all threaded components for damaged or
14 TPS-138 stripped threads. Repair light damage with thread
13 Radiator Guard 15 Washer (8 used) chasers. Replace parts found to be unserviceable.
14 Cap Screw (4 used) 16 Nut (4 used)
Figure 14-3: Radiator Guard Installation
Installation is the reverse of the removal procedure.
 CAUTION
Prevent possible crushing injury from heavy
component. Use appropriate lifting device.

7. Using an appropriate lifting device, support radiator

guard (13).
8. Remove cap screws (14), washers (15), and nuts
(16).

14-4 Service Manual TICO Manufacturing

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” on page 1-3.)
2. Lower the boom and fifth wheel.

2 5
6

1
7

4
3

TPS-141
1 Handrail 3 Top Fuel Tank Grate 5 Cab Step Grate 7 Boom Grate
2 Entry Tread Plate 4 Bottom Fuel Tank Grate 6 Transmission Grate
Figure 14-5: Grates and Covers (off-road tractor shown)

TICO Manufacturing Service Manual 14-5

COVERS AND GUARDS PRO-SPOTTER

4. Raise the cab.

2
11

14

15
TPS-144
1
2 Entry Tread Plate 14 Washer (8 used)
11 Cap Screw (4 used) 15 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).

5
9
10
6

24
8 16
17 23
19 24
TPS-140
18
1 Handrail 9 Washer (8 used) 20
8 Cap Screw (4 used) 10 Lock Nut (4 used) 22 21
Figure 14-6: Handrail TPS-142
5 Cab Step Grate 20 Washer (4 used)
3. Remove cap screws (8), washers (9), lock nuts (10),
6 Transmission Grate 21 Lock Washer (4 used)
and handrail (1). 16 Cap Screw (4 used) 22 Nylon Washer (4 used)
17 Washer (8 used) 23 Middle Transmission Heat
Shield
18 Nut (4 used) 24 Outer Transmission Heat
Shield (2 used)
19 Cap Screw (4 used)
Figure 14-8: Cab Step and Transmission Grates
6. Remove cap screws (16), washers (17), nuts (18),
and cab step grate (5).
7. Remove cap screws (19), washers (20), lock
washers (21), nylon washer (22), transmission heat
shields (23 and 24), and transmission grate (6).

14-6 Service Manual TICO Manufacturing

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.
3
12
Installation
Installation is the reverse of the removal procedure.
4

13

TPS-109
3 Top Fuel Tank Grate 12 Cap Screw (10 used)
4 Bottom Fuel Tank Grate 13 Cap Screw (4 used)
Figure 14-9: Fuel Tank Grates
8. Remove cap screws (12) and top fuel tank grate (3).
9. Remove cap screws (13) and bottom fuel tank grate
(4).

7 27

26

27 24

25

TPS-143
7 Boom Grate 26 Middle Boom Heat Shield
24 Cap Screw (2 used) 27 Outer Boom Heat Shield (2
25 Washer (2 used) used)
Figure 14-10: Boom Grate
10. Remove cap screws (24), washers (25), boom heat
shields (26 and 27), and boom grate (7).
11. Repair or replace components as necessary.

TICO Manufacturing Service Manual 14-7

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. Tractor Safely” on page 1-3.)

6
2
3 5

1
4
7
TPS-002
1 Left Front Fender 3 Top Fuel Tank Grate 5 Diesel Exhaust Fluid (DEF) 7 Mud Flap (2 used)
Cover
2 Cab Lift Pump Cover 4 Bottom Fuel Tank Grate 6 Rear Fender
Figure 14-11: Left Covers and Guards (off-road tractor shown)

NOTE
Figure 14-12 shows the cab lift pump removed for clarity.
10 2. Remove cap screws (8), washers (9), nuts (10), and
9
front fender bracket (11).
8

11

1
TPS-126
1 Left Front Fender 10 Lock Nut (2 used)
8 Cap Screw (2 used) 11 Front Fender Bracket
9 Washer (4 used)
Figure 14-12: Left Front Fender

14-8 Service Manual TICO Manufacturing

PRO-SPOTTER COVERS AND GUARDS

22 5
23

2
1

TPS-124
2 Cab Lift Pump Cover 23 Washer (2 used)
22 Cap Screw (2 used)
Figure 14-13: Cab Lift Pump 14
TPS-110
3. Remove cap screws (22), washers (23), and cab lift 15
pump cover (2).

16

3
12
5 Diesel Exhaust Fluid (DEF) 15 Washer (4 used)
Tank Cover
14 Cap Screw (2 used) 16 Lock Nut (2 used)
4 Figure 14-15: Diesel Exhaust Fluid (DEF) Tank Cover
6. Remove cap screws (14), washers (15), lock nuts
13 (16), and diesel exhaust fluid (DEF) tank cover (5).

TPS-109
3 Top Fuel Tank Grate 12 Cap Screw (10 used)
4 Bottom Fuel Tank Grate 13 Cap Screw (4 used)
Figure 14-14: Fuel Tank Grates
4. Remove cap screws (12) and top fuel tank grate (3).
5. Remove cap screws (13) and bottom fuel tank grate
(4).

TICO Manufacturing Service Manual 14-9

COVERS AND GUARDS PRO-SPOTTER

Inspection
6
• Clean all parts of dirt and debris.
21
• Check all threaded components for damaged or
17 stripped threads. Repair light damage with thread
18 chasers. Replace parts found to be unserviceable.

Installation
21
Installation is the reverse of the removal procedure.

7
7
TPS-111
6 Rear Fender 18 Nut (4 used)
7 Mud Flap (2 used) 21 Rear Fender Bracket (2
17 Cap Screw (4 used) used)
Figure 14-16: Rear Fender and Mud Flaps Assembly

NOTE
Rear fender (6), mud flaps (7), and rear fender brackets
(21) can be removed as an assembly or individually. This
procedure documents removing the assembly.
7. Remove cap screws (17) and nuts (18).
8. Remove rear fender (6), mud flaps (7), and rear
fender brackets (21) as an assembly.
9. Repair or replace components as necessary.

14-10 Service Manual TICO Manufacturing

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.)

2 4 5

1
6
1
3
TPS-003
1 Mud Flap (2 used) 3 Lower Aftertreatment 5 Upper Aftertreatment
Cover Cover
2 Rear Fender 4 Intermediate 6 Front Mud Flap
Aftertreatment Cover
Figure 14-17: Right Covers and Guards (off-road tractor shown)

7 9

TPS-125
6 Front Mud Flap 8 Washer (8 used)
7 Cap Screw (4 used) 9 Lock Nut (4 used)
Figure 14-18: Front Mud Flap
2. Remove cap screws (7), washers (8), lock nuts (9),
and front mud flap (6).

TICO Manufacturing Service Manual 14-11

COVERS AND GUARDS PRO-SPOTTER

21
22 33
20 32

23 10 31
19 4

11
29
18
5
17 12 27

28

3
30

16 25
26 24

15 34
14

13
TPS-167
3 Lower Aftertreatment 14 Washer (8 used) 21 Washer (6 used) 28 Washer (5 used)
Cover
4 Intermediate 15 Lock Nut (4 used) 22 Lock Nut (3 used) 29 Lock Nut (5 used)
Aftertreatment Cover
5 Upper Aftertreatment 16 Plate 23 Rear Heat Shield 30 Mud Guard
Cover
10 Cap Screw (6 used) 17 Cap Screw (6 used) 24 Cap Screw (2 used) 31 Cap Screw (3 used)
11 Washer (6 used) 18 Washer (6 used) 25 Washer (4 used) 32 Washer (3 used)
12 Lock Nut (6 used) 19 Lock Washer (6 used) 26 Lock Nut (2 used) 33 Lock Nut (3 used)
13 Cap Screw (4 used) 20 Cap Screw (3 used) 27 Cap Screw (5 used) 34 Front Heat Shield
Figure 14-19: Off-Road Aftertreatment Covers
5. Remove cap screws (17), washers (18), lock
 CAUTION washers (19), and lower aftertreatment cover (3).
6. Remove cap screws (20), washers (21), lock nuts
Avoid injury and serious burns from hot
(22), and rear heat shield (23).
components. Allow aftertreatment covers and
heat shields to cool before removing. 7. Remove cap screws (24), washers (25), lock nuts
(26), and upper aftertreatment cover (5).
8. Remove cap screws (27), washers (28), lock nuts
3. Remove cap screws (10), washers (11), lock nuts
(29), and mud guard (30).
(12), and intermediate aftertreatment cover (4).
9. Remove cap screws (31), washers (32), lock nuts
4. Remove cap screws (13), washers (14), lock nuts
(33), and front heat shield (34).
(15), and plate (16).

14-12 Service Manual TICO Manufacturing

PRO-SPOTTER COVERS AND GUARDS

Inspection
2 1. Check all threaded components for damaged or
stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
36
Installation
35 Installation is the reverse of the removal procedure.

37

1
TPS-127
1 Mud Flap (2 used) 36 Nut (4 used)
2 Rear Fender 37 Rear Fender Bracket (2
35 Cap Screw (4 used) used)
Figure 14-20: Rear Fender and Mud Flaps Assembly

NOTE
Rear fender (2), mud flaps (1), and rear fender brackets
(37) can be removed as an assembly or individually. This
procedure documents removing the assembly.
10. Remove cap 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.

TICO Manufacturing Service Manual 14-13

 PRO-SPOTTER

15-0 Service Manual TICO Manufacturing

 Section 15

HEATING AND AIR CONDITIONING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
CAUTIONS AND PROPER HANDLING OF R134a REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . 15-3
R134a REFRIGERANT HOSES AND TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
R134a REFRIGERANT OIL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
R134a REFRIGERANT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
R134a REFRIGERANT RECOVERY, RECYCLING, AND RECHARGING STATION . . . . . . . . . 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 Compressor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Condenser Flush and Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Evaporator Flush and Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Procedure Wrap-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

TICO Manufacturing Service Manual 15-1

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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19

15-2 Service Manual TICO Manufacturing

PRO-SPOTTER HEATING AND AIR CONDITIONING

INTRODUCTION CAUTIONS AND PROPER

The purpose of the HEATING AND AIR CONDITIONING HANDLING OF R134a
section is to provide service and maintenance personnel REFRIGERANT
with guidance on the proper procedures for servicing
heating and air conditioning systems on the TICO
Pro-Spotter terminal trucks.  CAUTION
The TICO Pro-Spotter terminal trucks have been Prevent refrigerant from contacting eyes or skin.
engineered for quick and efficient servicing while Refrigerant will freeze eyes or skin on contact.
minimizing downtime. Wear goggles, gloves, and protective clothing.
Service and maintenance personnel should only open If refrigerant contacts eyes or skin, do not touch
the heating and air conditioning systems if absolutely or rub the area. Splash large amounts of cool
necessary. water on affected area. Seek out medical
For additional information, please contact TICO factory treatment immediately.
support. (See “CONTACT TICO SUPPORT” on
page 0-15.)
 CAUTION
Do not allow refrigerant to contact open flames or
hot surfaces such as electric welding arc, electric
heating element, and lighted smoking materials.
Do not heat refrigerant over 52°C (125°F) in a
closed container. Internal pressure increases
when the refrigerant container is heated. The
increased pressure can make the container burst.
Keep refrigerant containers away from heat
sources. Store refrigerant in a cool place.

 CAUTION
Do not handle damp refrigerant container with
bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour cool water over
container to free the skin. Seek out medical
treatment immediately.

IMPORTANT
R134a refrigerant is used in the air conditioning
system in order to meet government standards
relating to the use of refrigerants. Because it does
not contain chlorine, R134a is not detrimental 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 station.

TICO Manufacturing Service Manual 15-3

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.
refrigerant gas.
Wear goggles, gloves, and protective clothing.
Do not use hydraulic hoses as replacement hoses in
the air conditioning system.
Whenever a component is disconnected from the air 1. Handle refrigerant safely. (See “R134a
conditioning system, a thorough inspection of hoses and REFRIGERANT HOSES AND TUBING” on
tubing for moisture, grease, dirt, rust, or other foreign page 15-4.)
material must be completed. If such contamination is 2. Park and prepare tractor for service. (See “Park
present in any hoses, tubing, or fittings and cannot be Tractor Safely” on page 1-3.)
removed by cleaning, then replace parts.

IMPORTANT
 CAUTION
Chlorinated solvents (such as trichloroethylene) are Avoid possible injury. New compressors are
contaminants, and must not be used for cleaning. charged with a mixture of nitrogen, R134a
Chlorinated solvents will cause hose deterioration. refrigerant, and R134a refrigerant oil. Wear safety
goggles and discharge compressor slowly.
Fittings that have grease or dirt on them should be wiped
clean with a cloth dampened with alcohol.
Apply a small amount of clean, correct viscosity 3. Remove and repair or replace air conditioner
refrigerant oil on all hose and tube connections to help compressor. (See “AIR CONDITIONER
prevent leaking at joints and connections. Dip O-rings in COMPRESSOR” on page 15-10.)
correct viscosity refrigerant oil before assembling. 4. If a new compressor is required, drain existing oil into
graduated container while rotating compressor shaft.
5. Record measured oil volume and discard oil properly.
6. If oil drained from a compressor that was removed
from operation is very black or amount of oil is less
than specification, perform the following:

Specification
Compressor Oil—Volume 200 mL
6.8 fl oz

a. Inspect for R134a leakage. (See “R134a

REFRIGERANT LEAK TEST” on page 15-5.)
b. Remove and discard receiver/dryer. (See
“RECEIVER/DRYER” on page 15-19.)
c. Determine if a complete system flush is required
and flush if necessary. (See “FLUSH AND
PURGE AIR CONDITIONING SYSTEM” on
page 15-9.)
d. If compressor is serviceable, pour flushing
solvent in manifold ports and internally wash out
any remaining old oil.
e. Install a new receiver/dryer. (See
“RECEIVER/DRYER” on page 15-19.)

15-4 Service Manual TICO Manufacturing

PRO-SPOTTER HEATING AND AIR CONDITIONING

Inspection R134a REFRIGERANT LEAK

1. Check all threaded components for damaged or TEST
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. (See “R134a REFRIGERANT HOSES AND
TUBING” on page 15-4.)  CAUTION
3. Check components, lines, and fittings for signs of Prevent refrigerant from contacting eyes or skin.
leakage. (See “R134a REFRIGERANT LEAK TEST” Refrigerant will freeze eyes or skin on contact.
on page 15-5.) Wear goggles, gloves, and protective clothing.

Installation 1. Handle refrigerant safely. (See “R134a

1. Install the compressor. (See “AIR CONDITIONER REFRIGERANT HOSES AND TUBING” on
COMPRESSOR” on page 15-10.) page 15-4.)
2. Park and prepare tractor for service. (See “Park
IMPORTANT Tractor Safely” on page 1-3.)
• Prevent possible air conditioning system
damage. Do not add any more oil than required  CAUTION
or maximum cooling will be reduced.
R134a refrigerant is under high pressure. Only
• Prevent possible air conditioning system
qualified personnel should attempt to service the
contamination. Do not leave system or R134a
system. Failure to follow proper service practices
compressor oil containers open. Refrigerant oil
may result in injury.
absorbs moisture quickly.
Should an accidental system discharge occur,
• Prevent possible damage to acrylic or ABS
perform the following:
plastic materials. Spilling R134a refrigerant oil on
these will cause rapid material deterioration. • Avoid breathing in the air conditioner
refrigerant and lubricant vapor or mist.
• Prevent possible air conditioning system
Exposure may irritate the eyes, nose, and
damage. Identify R134a oil containers and
throat.
measures to eliminate accidental mixing of
different oils. • Ventilate the work area before continuing
work.
2. Add required amount of R134a compressor oil. If any
section of hose is removed and flushed or replaced, • See additional health and safety information
measure length of hose and use formula 3 mL per 30 available from the refrigerant and lubricant
cm (0.1 fl oz per ft) to determine correct amount of oil manufacturers.
to be added.

Specifications NOTES
• Small amounts of refrigerant oil escape with leaking
Compressor Oil—Volume 200 mL
refrigerant.
6.8 fl oz
• Some refrigerant manufacturers add dye to
System Oil—Volume 200 mL
refrigerant to aid in leak detection.
6.8 fl oz
1. Inspect all lines, fittings, and components for oily or
dusty conditions or for traces of refrigerant dye.
3. Connect all components. 2. Spray a solution of soap and water on system
4. Evacuate air conditioning system. (See “Evacuate components, lines, and connections. Look for
R134a System” on page 15-7.) bubbles to form as a sign of leakage.
5. Recharge R134a air conditioning system. (See 3. If available, use a R134a refrigerant leak detector to
“Recharge R134a System” on page 15-8.) slowly go over and around lines and fittings.

TICO Manufacturing Service Manual 15-5

HEATING AND AIR CONDITIONING PRO-SPOTTER

R134a REFRIGERANT
RECOVERY, RECYCLING, AND  CAUTION
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.
Use correct refrigerant recovery, recycling, and
1 recharging stations. Do not mix refrigerant, hoses,
fittings, components, or refrigerant oils.
3. Close both high and low-pressure valves on
refrigerant recovery, recycling, and recharging station
(1).
4 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 to
low-pressure test port.
2
5 6. Connect red high-pressure hose (5) to high-pressure
test port.
7. Follow manufacturer’s instructions when using
3 refrigerant recovery, recycling, and recharging
station.

TPS-085
1 Refrigerant Recovery, 4 Low-Pressure Hose (blue)
Recycling, and Recharging
Station
2 Low-Pressure Test Port 5 High-Pressure Hose (red)
3 High-Pressure Test Port
Figure 15-1: Refrigerant Recovery, Recycling, and
Recharging Station

 CAUTION
Prevent refrigerant from contacting eyes or skin.
Refrigerant will freeze eyes or skin on contact.
Wear goggles, gloves, and protective clothing.

1. Handle refrigerant safely. (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.)

15-6 Service Manual TICO Manufacturing

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.
Wear goggles, gloves, and protective clothing. Wear goggles, gloves, and protective clothing.

1. Handle refrigerant safely. (See “R134a 1. Handle refrigerant safely. (See “R134a
REFRIGERANT HOSES AND TUBING” on REFRIGERANT HOSES AND TUBING” on
page 15-4.) page 15-4.)
2. Park and prepare tractor for service. (See “Park 2. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) Tractor Safely” on page 1-3.)

 CAUTION  CAUTION
Avoid possible injury from air conditioning Avoid possible injury from air conditioning
system refrigerant. Do not remove high-pressure system refrigerant. Do not remove high-pressure
relief valve. Air conditioning system will relief valve. Air conditioning system will
discharge rapidly. discharge rapidly.

IMPORTANT IMPORTANT
Prevent possible air conditioning system damage. Prevent possible air conditioning system damage.
Use correct refrigerant recovery, recycling, and Use correct refrigerant recovery, recycling, and
recharging stations. Do not mix refrigerant, hoses, recharging stations. Do not mix refrigerant, hoses,
fittings, components, or refrigerant oils. fittings, components, or refrigerant oils.
3. Run air conditioning system for 3 minutes to help in 3. Connect refrigerant recovery, recycling, and charging
recovery process. station. (See “R134a REFRIGERANT RECOVERY,
4. Turn air conditioning system off before proceeding RECYCLING, AND RECHARGING STATION” on
with recovery steps. page 15-6.)
5. With engine OFF, connect refrigerant recovery, 4. Open low and high-pressure valves on refrigerant
recycling, and charging station. (See “R134a recovery, recycling, and recharging station.
REFRIGERANT RECOVERY, RECYCLING, AND 5. Follow manufacturer’s instructions and evacuate
RECHARGING STATION” on page 15-6.) system.
6. Follow manufacturer’s instructions when using
refrigerant recovery, recycling, and recharging NOTE
station. Vacuum specifications listed are for sea level conditions.
Subtract 3.4 kPa (34 mbar) (1 in Hg) from 98 kPa (980
mbar) (29 in Hg) for each 300 m (1000 ft) elevation above
sea level.
6. Evacuate system until low-pressure gauge registers
specified vacuum.
If specified vacuum cannot be obtained in 15
minutes, a leak may be present. Locate and repair
leak. (See “R134a REFRIGERANT LEAK TEST” on
page 15-5.)

TICO Manufacturing Service Manual 15-7

HEATING AND AIR CONDITIONING PRO-SPOTTER

Specifications
Recharge R134a System
Vacuum—Pressure at Sea Level 98 kPa
980 mbar
 CAUTION
29 in Hg Prevent refrigerant from contacting eyes or skin.
Pressure Above Sea Level Subtract 3.4 Refrigerant will freeze eyes or skin on contact.
kPa from 98 Wear goggles, gloves, and protective clothing.
kPa for each
300 m 1. Handle refrigerant safely. (See “R134a
elevation. REFRIGERANT HOSES AND TUBING” on
Subtract 34 page 15-4.)
mbar from
2. Park and prepare tractor for service. (See “Park
980 mbar for
Tractor Safely” on page 1-3.)
each 300 m
elevation.
Subtract 1 in  CAUTION
Hg from 29 Avoid possible injury from air conditioning
in Hg for system refrigerant. Do not remove high-pressure
each 1000 ft relief valve. Air conditioning system will
elevation. discharge rapidly.

7. When vacuum reaches specified level, close low side

and high side valves. Turn vacuum pump off. IMPORTANT
8. If vacuum decreases more than specified amount in Prevent possible air conditioning system damage.
5 minutes, there is a leak in the system. Use correct refrigerant recovery, recycling, and
recharging stations. Do not mix refrigerant, hoses,
Specification fittings, components, or refrigerant oils.
3. Connect refrigerant recovery, recycling, and
Leak Present—Decrease in Vacuum 3.4 kPa
recharging station. (See “R134a REFRIGERANT
34 mbar
RECOVERY, RECYCLING, AND RECHARGING
1 in Hg
STATION” on page 15-6.)
4. Evacuate system. (See “Evacuate R134a System” on
9. Locate and repair leak. (See “R134a REFRIGERANT page 15-7.)
LEAK TEST” on page 15-5.)
10. Start evacuation. Open low side and high side IMPORTANT
valves. Before beginning to charge air conditioning system,
11. Evacuate system for 30 minutes after initial specified the following conditions must exist:
vacuum is reached. • Engine must be stopped.
12. Stop evacuation. Close low side and high side • Pump must be capable of pulling at least 28.6 in
valves. Hg vacuum (sea level).
13. Charge system. (See “Recharge R134a System” on • Adjust targeted vacuum if elevation is 300 m
page 15-8.) (1000 ft) or more above sea level, if applicable.
Subtract 3.4 kPa (34 mbar) (1 in Hg) from 98 kPa
(980 mbar) (29 in Hg) for each 300 m (1000 ft)
elevation above sea level.
5. Follow manufacturer’s instructions and charge
system.
6. Add refrigerant until system is charged to
specification.

15-8 Service Manual TICO Manufacturing

PRO-SPOTTER HEATING AND AIR CONDITIONING

Specification NOTE
Air Conditioning System 1.12—1.37 kg A new receiver/dryer must be installed anytime the air
Refrigerant Charge Weight 2.48—3.03 lb conditioning system is discharged.
5. Remove and discard receiver/dryer. (See
“RECEIVER/DRYER” on page 15-19.)
7. Disconnect refrigerant recovery, recycling, and
recharging station.
8. Turn on air conditioning system and verify proper Air Conditioner Compressor Cleaning
operation. 1. Pour cooling system flushing solvent into the suction
and discharge ports. Plug both ports in compressor
FLUSH AND PURGE AIR manifold.
2. Turn compressor end-for-end and roll compressor
CONDITIONING SYSTEM side-to-side.
3. Remove both plugs from manifold ports and drain
Procedure Set-Up flushing solvent from air conditioner compressor.
4. Connect battery power and ground to engage air
 CAUTION compressor clutch solenoid. Rotate pulley at least 5
revolutions to move cooling system flushing solvent
Prevent refrigerant from contacting eyes or skin. out of cylinders.
Refrigerant will freeze eyes or skin on contact. 5. Invert air conditioner compressor. Roll end-for-end
Wear goggles, gloves, and protective clothing. and side-to-side. Drain thoroughly.
6. Repeat previous two steps at least 3 times.
1. Handle refrigerant safely. (See “R134a 7. Dispose of cooling system flushing solvent properly.
REFRIGERANT HOSES AND TUBING” on
page 15-4.)
2. Park and prepare tractor for service. (See “Park
Condenser Flush and Purge
Tractor Safely” on page 1-3.) 1. Determine if condenser is a continuous loop or
parallel flow style.
 CAUTION 2. Add cooling system flushing solvent to inlet end of
compressor discharge line.
Avoid possible injury from air conditioning
system refrigerant. Do not remove high-pressure 3. Attach a return hose to end of receiver/dryer inlet
relief valve. Air conditioning system will hose. Place hose into a suitable container to collect
cooling system flushing solvent.
discharge rapidly.
4. Using compressed air, force cooling system flushing
solvent through condenser circuit. Air pressure must
be at least to specification for flushing and purging.
IMPORTANT
Prevent possible air conditioning system damage.
Use correct refrigerant recovery, recycling, and
Specification
recharging stations. Do not mix refrigerant, hoses, Air Pressure Minimum Pressure (for 620 kPa
fittings, components, or refrigerant oils. flushing and purging) 6.2 bar
3. Connect refrigerant recovery, recycling, and 90 psi
recharging station. (See “R134a REFRIGERANT
RECOVERY, RECYCLING, AND RECHARGING
STATION” on page 15-6.) NOTES
• Purging condenser circuit takes 10—12 minutes to
IMPORTANT thoroughly remove solvent.
Air conditioner compressor is serviceable. Do not • Additional flushing cycles are required if system is
attempt to flush through receiver/dryer. Flushing heavily contaminated with burned oil or metal
solution may not be completely removed from particles.
component and could cause system malfunction.
4. Recover refrigerant from system. (See “Recover
R134a Refrigerant” on page 15-7.)

TICO Manufacturing Service Manual 15-9

HEATING AND AIR CONDITIONING PRO-SPOTTER

5. Test for cooling system flushing solvent. Hold hose

close to a piece of cardboard; continue purging until
AIR CONDITIONER
cardboard is dry. COMPRESSOR
6. Dispose of cooling system flushing solvent properly.
Removal
Evaporator Flush and Purge See Figures 15-2 and 15-3.
1. Add cooling system flushing solvent to inlet end of 1. Park and prepare tractor for service. (See “Park
evaporator inlet line. Tractor Safely” on page 1-3.)
2. Attach a return hose to air conditioner compressor 2. Raise the cab.
inlet hose. Place hose into a suitable container to 3. Recover existing R134a refrigerant from the system.
collect cooling system flushing solvent. (See “Recover R134a Refrigerant” on page 15-7.)
3. Using compressed air, force cooling system flushing
solvent through evaporator circuit. Air pressure must
be at least to specification for flushing and purging. 3

Specification
Air Pressure Minimum Pressure (for 620 kPa
flushing and purging) 6.2 bar
90 psi

NOTES 2
1
• Purging evaporator circuit takes 10—12 minutes to
thoroughly remove solvent.
• Additional flushing cycles are required if system is TPS-080
heavily contaminated with burned oil or metal 1 Low-Pressure Refrigerant 3 Air Conditioner
Line Compressor
particles. 2 High-Pressure Refrigerant
4. Test for cooling system flushing solvent. Hold hose Line
close to a piece of cardboard; continue purging until Figure 15-2: Air Conditioner Compressor Lines
cardboard is dry. 4. Install identification tags and disconnect
5. Dispose of cooling system flushing solvent properly. low-pressure refrigerant line (1) and high-pressure
refrigerant line (2). Close all openings using caps and
Procedure Wrap-Up plugs.

1. Install a new receiver/dryer. (See

“RECEIVER/DRYER” on page 15-19.)
2. Add required oil. (See “R134a REFRIGERANT OIL
INFORMATION” on page 15-4.)
3. Install air conditioner compressor. (See “AIR
CONDITIONER COMPRESSOR” on page 15-10.)
4. Evacuate the system. (See “Evacuate R134a
System” on page 15-7.)
5. Recharge the system. (See “Recharge R134a
System” on page 15-8.)

15-10 Service Manual TICO Manufacturing

PRO-SPOTTER HEATING AND AIR CONDITIONING

Inspection
9 1. Check all threaded components for damaged or
10 stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
2. Check condition of air conditioning system lines and
8 tubing. (See “R134a REFRIGERANT HOSES AND
TUBING” on page 15-4.)
3. Check components, lines, and fittings for signs of
3 7 leakage. (See “R134a REFRIGERANT LEAK TEST”
on page 15-5.)

Installation
Installation is the reverse of the removal procedure.
• If replacing with a new air conditioner compressor,
4 flush and purge each component in the air
conditioning system individually. (See “FLUSH AND
5
6 PURGE AIR CONDITIONING SYSTEM” on
page 15-9.)
• Evacuate the system. (See “Evacuate R134a
TPS-081 System” on page 15-7.)
3 Air Conditioner 7 Nut (2 used)
Compressor • Recharge the system. (See “Recharge R134a
4 Electrical Connector 8 Cap Screw (2 used) System” on page 15-8.)
5 Electrical Connector 9 Belt
6 Cap Screw (4 used) 10 Belt Tensioner
Figure 15-3: Air Conditioner Compressor
5. Install identification tags and disconnect electrical
connectors (4 and 5).
6. Loosen cap screws (8) and nuts (7).
7. Loosen belt (9).
8. Remove cap screws (6) and air conditioner
compressor (3).
9. Repair or replace components as necessary.

TICO Manufacturing Service Manual 15-11

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 16
Tractor Safely” on page 1-3.)
17
9
2. Remove front right cover. (See “FRONT COVERS
15
AND GUARDS” on page 14-3.)

12
10
1 13
11 14 18

19
2 TPS-131
9 Electrical Connector 15 Hose
10 Electrical Connector 16 Hose
11 Electrical Connector 17 Hose
12 Electrical Connector 18 Cap Screw (10 used)
3 TPS-129 13 Hose 19 Upper Cover
1 Nut (2 used) 3 Fresh Air Filter 14 Hose
2 Plate Figure 15-6: Blower Motor Cover
Figure 15-4: Fresh Air Filter
5. Install identification tags and disconnect electrical
3. Loosen nuts (1). Remove plate (2) and fresh air filter connectors (9—12).
(3). 6. Install identification tags and disconnect hoses (13—
17).
NOTE 7. Remove cap screws (18) and upper cover (19).
Cap screws (6) do not need to be removed in order to
remove interior covers (7 and 8).

6 20

21
4

22
23
5
7 TPS-132
20 Cap Screw (2 used) 22 Cap Screw (6 used)
8 21 Valve 23 Blower Motor Cover
Figure 15-7: Blower Motor Cover (front)
TPS-130 8. Remove cap screws (20) and set valve (21) aside.
4 Cap Screw (7 used) 7 Interior Cover 9. Remove cap screws (22). Roll blower motor cover
5 Cap Screw (5 used) 8 Interior Cover
(23) assembly to interior.
6 Cap Screw (3 used)
Figure 15-5: Interior Covers

15-12 Service Manual TICO Manufacturing

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
24 chasers. Replace parts found to be unserviceable.
25

26 Installation
Installation is the reverse of the removal procedure.
23

TPS-133
23 Blower Motor Cover 25 Electrical Connector
24 Electrical Connector 26 Blower Motor
Figure 15-8: Blower Motor
10. Install identification tags and disconnect electrical
connectors (24 and 25).
11. Move blower motor (26) and blower motor cover (23)
to interior of cab.

26 32

27

28 31

29 30

TPS-135
26 Blower Motor 30 Electrical Connector
27 Electrical Connector 31 Electrical Connector
28 Electrical Connector 32 Cap Screw (4 used)
29 Electrical Connector
Figure 15-9: Blower Motor
12. Install identification tags and disconnect electrical
connectors (27—31).
13. Remove cap screws (32) and blower motor.
14. Repair or replace components as necessary.

TICO Manufacturing Service Manual 15-13

HEATING AND AIR CONDITIONING PRO-SPOTTER

CONDENSER Inspection
• Clean all parts of dirt and debris.
Removal • Check all threaded components for damaged or
See Figure 15-10. stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) • Check condition of air conditioning system lines and
tubing. (See “R134a REFRIGERANT HOSES AND
2. Recover existing R134a refrigerant from the system. TUBING” on page 15-4.)
(See “Recover R134a Refrigerant” on page 15-7.)
• Check components, lines, and fittings for signs of
3. Remove brush guard. (See “FRONT COVERS AND leakage. (See “R134a REFRIGERANT LEAK TEST”
GUARDS” on page 14-3.) on page 15-5.)

Installation
Installation is the reverse of the removal procedure.
5 • Evacuate the system. (See “Evacuate R134a
4 System” on page 15-7.)
• Recharge the system. (See “Recharge R134a
1 3
System” on page 15-8.)

2 6

TPS-136
1 Refrigerant Line 4 Washer (4 used)
2 Refrigerant Line 5 Nut (4 used)
3 Cap Screw (4 used) 6 Condenser
Figure 15-10: Condenser
4. Install identification tags and disconnect refrigerant
lines (1 and 2). Close all openings using caps and
plugs.
5. Remove cap screws (3), washers (4), nuts (5), and
condenser (6).
6. Repair or replace components as necessary.

15-14 Service Manual TICO Manufacturing

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.
17 16
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) 9
15
2. Remove front right cover. (See “FRONT COVERS
AND GUARDS” on page 14-3.)
3. Recover existing R134a refrigerant from the system. 12
(See “Recover R134a Refrigerant” on page 15-7.) 10
13
11 14 18
1
19
TPS-131
9 Electrical Connector 15 Hose
2 10 Electrical Connector 16 Hose
11 Electrical Connector 17 Hose
12 Electrical Connector 18 Cap Screw (10 used)
13 Hose 19 Upper Cover
14 Hose
3 TPS-129
Figure 15-13: Blower Motor Cover
1 Nut (2 used) 3 Fresh Air Filter 6. Install identification tags and disconnect electrical
2 Plate connectors (9—12).
Figure 15-11: Fresh Air Filter 7. Install identification tags and disconnect hoses (13—
4. Loosen nuts (1). Remove plate (2) and fresh air filter 17).
(3). 8. Remove cap screws (18) and upper cover (19).

NOTE
Cap screws (6) do not need to be removed in order to
remove interior covers (7 and 8).
20

6 21
4 5

22
23

TPS-132
20 Cap Screw (2 used) 22 Cap Screw (6 used)
7 21 Valve 23 Blower Motor Cover
Figure 15-14: Blower Motor Cover (front)
8 9. Remove cap screws (20) and set valve (21) aside.
TPS-130 10. Remove cap screws (22). Roll blower motor cover
4 Cap Screw (7 used) 7 Interior Cover (23) assembly to interior.
5 Cap Screw (5 used) 8 Interior Cover
6 Cap Screw (3 used)
Figure 15-12: Interior Covers

TICO Manufacturing Service Manual 15-15

HEATING AND AIR CONDITIONING PRO-SPOTTER

24 33
25
29
26

34
23
35

32
TPS-133 TPS-134

23 Blower Motor Cover 25 Electrical Connector 29 Evaporator 34 Refrigerant Line

24 Electrical Connector 26 Blower Motor 32 Cap Screw (2 used) 35 Refrigerant Line
33 Plate
Figure 15-15: Blower Motor
Figure 15-17: Evaporator
11. Install identification tags and disconnect electrical
connectors (24 and 25). 15. Remove cap screws (32) and plate (33).
12. Move blower motor (26) and blower motor cover (23) 16. Install identification tags and disconnect refrigerant
to interior of cab. lines (34 and 35). Close all openings using caps and
plugs.
17. Remove evaporator.
18. Repair or replace components as necessary.

27 Inspection
28
• Clean all parts of dirt and debris.
30 • Check all threaded components for damaged or
stripped threads. Repair light damage with thread
29 chasers. Replace parts found to be unserviceable.
• Check condition of air conditioning system lines and
31 tubing. (See “R134a REFRIGERANT HOSES AND
TUBING” on page 15-4.)
• Check components, lines, and fittings for signs of
leakage. (See “R134a REFRIGERANT LEAK TEST”
on page 15-5.)
TPS-137
27 Clamp 30 Cap Screw (4 used)
28 Freeze Probe 31 Cover Plate Installation
29 Evaporator
Installation is the reverse of the removal procedure.
Figure 15-16: Freeze Probe
• Evacuate the system. (See “Evacuate R134a
13. Remove clamp (27) and freeze probe (28) from System” on page 15-7.)
within evaporator (29). • Recharge the system. (See “Recharge R134a
14. Remove cap screws (30) and cover plate (31). System” on page 15-8.)

15-16 Service Manual TICO Manufacturing

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.
17 16
1. Park and prepare tractor for service. (See “Park
Tractor Safely” on page 1-3.) 9
15
2. Remove front right cover. (See “FRONT COVERS
AND GUARDS” on page 14-3.)
3. Recover existing R134a refrigerant from the system. 12
(See “Recover R134a Refrigerant” on page 15-7.) 10
13
11 14 18
1

19
TPS-131
9 Electrical Connector 15 Hose
2 10 Electrical Connector 16 Hose
11 Electrical Connector 17 Hose
12 Electrical Connector 18 Cap Screw (10 used)
13 Hose 19 Upper Cover
14 Hose
3 TPS-129 Figure 15-20: Blower Motor Cover
1 Nut (2 used) 3 Fresh Air Filter
6. Install identification tags and disconnect electrical
2 Plate
connectors (9—12).
Figure 15-18: Fresh Air Filter
7. Install identification tags and disconnect hoses (13—
4. Loosen nuts (1). Remove plate (2) and fresh air filter 17).
(3).
8. Remove cap screws (18) and upper cover (19).
NOTE
Cap screws (6) do not need to be removed in order to
remove interior covers (7 and 8).
20

21
6 5
4

22
23

TPS-132
20 Cap Screw (2 used) 22 Cap Screw (6 used)
21 Valve 23 Blower Motor Cover
7
Figure 15-21: Blower Motor Cover (front)
9. Remove cap screws (20) and set valve (21) aside.
8
10. Remove cap screws (22). Roll blower motor cover
(23) assembly to interior.
TPS-130
4 Cap Screw (7 used) 7 Interior Cover
5 Cap Screw (5 used) 8 Interior Cover
6 Cap Screw (3 used)
Figure 15-19: Interior Covers

TICO Manufacturing Service Manual 15-17

HEATING AND AIR CONDITIONING PRO-SPOTTER

36

24 33
25 34
26
35

23

32
TPS-133 TPS-134

23 Blower Motor Cover 25 Electrical Connector 32 Cap Screw (2 used) 35 Coolant Line
24 Electrical Connector 26 Blower Motor 33 Plate 36 Heater Core
34 Coolant Line
Figure 15-22: Blower Motor
Figure 15-24: Heater Core
11. Install identification tags and disconnect electrical
15. Remove cap screws (32) and plate (33).
connectors (24 and 25).
16. Install identification tags and disconnect coolant lines
12. Move blower motor (26) and blower motor cover (23)
(34 and 35). Close all openings using caps and
to interior of cab.
plugs.
17. Remove heater core (36).
18. Repair or replace components as necessary.

28 27
Inspection
30 • Clean all parts of dirt and debris.
• Check all threaded components for damaged or
29 stripped threads. Repair light damage with thread
chasers. Replace parts found to be unserviceable.
31 • Check condition of cooling system lines and tubing.

Installation
Installation is the reverse of the removal procedure.
TPS-137
• Fill cooling system. (See “Cooling System Filling” on
27 Clamp 30 Cap Screw (4 used)
page 4-15.)
28 Freeze Probe 31 Cover Plate
29 Evaporator
Figure 15-23: Freeze Probe
13. Remove clamp (27) and freeze probe (28) from
within evaporator (29).
14. Remove cap screws (30) and cover plate (31).

15-18 Service Manual TICO Manufacturing

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. (See “R134a REFRIGERANT HOSES AND
TUBING” on page 15-4.)
A new receiver/dryer must be installed anytime the air
conditioning system is discharged. 3. Check components, lines, and fittings for signs of
leakage. (See “R134a REFRIGERANT LEAK TEST”
1. Park and prepare tractor for service. (See “Park
on page 15-5.)
Tractor Safely” on page 1-3.)
2. Tilt the cab.
3. Remove brush guard. (See “FRONT COVERS AND
Installation
GUARDS” on page 14-3.) Installation is the reverse of the removal procedure.
4. Recover existing R134a refrigerant from the system.
NOTE
(See “Recover R134a Refrigerant” on page 15-7.)
A new receiver/dryer must be installed anytime the air
conditioning system is discharged.
• Install a new receiver/dryer.
2 • Evacuate the system. (See “Evacuate R134a
System” on page 15-7.)
1 3 • Recharge the system. (See “Recharge R134a
System” on page 15-8.)

6
5

TPS-082
1 Electrical Connector 4 Clamp (2 used)
2 Receiver/Dryer 5 Electrical Connector
3 Refrigerant Line 6 Refrigerant Line
Figure 15-25: Receiver/Dryer
5. Install identification tags and disconnect electrical
connectors (1 and 5).
6. Disconnect refrigerant lines (3 and 6). Close all
openings using caps and plugs.
7. Loosen clamps (4).
8. Remove and discard receiver/dryer (2).
9. Repair or replace components as necessary.

TICO Manufacturing Service Manual 15-19

 PRO-SPOTTER

IDX-0 Service Manual TICO Manufacturing

PRO-SPOTTER INDEX

Numerics Air Brake System Tests

Air System Leak Down Test . . . . . . . . . . . . . 8-2
3—Electrical System Air System Maximum Pressure Test . . . . . . 8-2
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-5 Low Air Buzzer and Light Test . . . . . . . . . . . 8-2
Pressure Buildup, Low-Pressure Warning Cutoff,
4—Engine and Governor Cutout Test . . . . . . . . . . . . 8-2
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-5
Air Conditioner Compressor
5—Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
6—Front Axle and Steering Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-7 Air Conditioner Compressor Cleaning
7—Rear Axle Flush and Purge Air Conditioning System . 15-9
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-8 Air Dryer
8—Air System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9—ABS/ATC System
2018 Flat Rate Guideline . . . . . . . . . . . . . . . . 0-9 Air Filter
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
11—Hydraulic System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
2018 Flat Rate Guideline . . . . . . . . . . . . . . . 0-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
12—Boom and Fifth Wheel Air Intake System
2018 Flat Rate Guideline . . . . . . . . . . . . . . . 0-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
13—Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2018 Flat Rate Guideline . . . . . . . . . . . . . . . 0-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

14—Covers and Guards Air System

2018 Flat Rate Guideline . . . . . . . . . . . . . . . 0-12 Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-9

15—Heating and Air Conditioning Air System Leak Down Test

2018 Flat Rate Guideline . . . . . . . . . . . . . . . 0-13 Air Brake System Tests . . . . . . . . . . . . . . . . 8-2

2018 Flat Rate Guideline Air System Maximum Pressure Test

3—Electrical System . . . . . . . . . . . . . . . . . . . 0-5 Air Brake System Tests . . . . . . . . . . . . . . . . 8-2
4—Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 Air System Schematic . . . . . . . . . . . . . . . . . . . . 8-4
5—Transmission . . . . . . . . . . . . . . . . . . . . . . 0-7
6—Front Axle and Steering . . . . . . . . . . . . . . 0-7 Air Tank
7—Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8—Air System . . . . . . . . . . . . . . . . . . . . . . . . 0-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
9—ABS/ATC System . . . . . . . . . . . . . . . . . . . 0-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
11—Hydraulic System . . . . . . . . . . . . . . . . . 0-10 Air Tools
12—Boom and Fifth Wheel . . . . . . . . . . . . . 0-10 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
13—Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
14—Covers and Guards . . . . . . . . . . . . . . . 0-12 Alternator
15—Heating and Air Conditioning . . . . . . . . 0-13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

A Antilock Brake System (ABS) Controller

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ABS/ATC System
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-9
Adjustment
Fifth Wheel Maintenance . . . . . . . . . . . . . . . 12-5
Front Wheel Bearings . . . . . . . . . . . . . . . . . . 6-8

TICO Manufacturing Service Manual IDX-1

INDEX PRO-SPOTTER

Automatic Lubrication System Checking and Correcting Toe

Filling the Reservoir . . . . . . . . . . . . . . . . . . . 10-2 Front End Alignment . . . . . . . . . . . . . . . . . . . 6-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Checking Wheels and Tires
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Front End Alignment . . . . . . . . . . . . . . . . . . . 6-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Chemical Products
Safe Handling . . . . . . . . . . . . . . . . . . . . . . . . 1-5
B Compressed Air
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Blower Motor Condenser
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Bobtail Proportioning Valve Condenser Flush and Purge
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Flush and Purge Air Conditioning System . . 15-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Contact TICO Support . . . . . . . . . . . . . . . . . . . 0-15

Boom Coolant
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Check Fluid Level . . . . . . . . . . . . . . . . . . . . . 4-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Cooling Fan
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Boom and Fifth Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Boom Cylinders Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Service System Safely . . . . . . . . . . . . . . . . . 1-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Covers and Guards
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Flat Rate Guideline . . . . . . . . . . . . . . . . . . . 0-12
Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . 8-5

D
C
Daily Pre-Operation Checklist . . . . . . . . . . . . . 2-2
Cab Diesel Exhaust Fluid (DEF) Tank
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Charge Air Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Diesel Exhaust Fuild (DEF) . . . . . . . . . . . . . . . . 2-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7, 2-8
Check Fluid Level
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Directional Control Valve . . . . . . . . . . . . . . . . 11-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Front Axle Fluid . . . . . . . . . . . . . . . . . . . . . . . 6-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 11-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rear Drive Axle Fluid . . . . . . . . . . . . . . . . . . . 7-2 Drag Link
Transmission Fluid . . . . . . . . . . . . . . . . . . . . . 5-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Check fluid level Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Front wheel bearings . . . . . . . . . . . . . . . . . . 6-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Checking and Correcting Camber

Front End Alignment . . . . . . . . . . . . . . . . . . . . 6-6

IDX-2 Service Manual TICO Manufacturing

PRO-SPOTTER INDEX

E Flush and Purge Air Conditioning System

Air Conditioner Compressor Cleaning . . . . 15-9
Electrical Components Condenser Flush and Purge . . . . . . . . . . . . 15-9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Evaporator Flush and Purge . . . . . . . . . . . . 15-9
Procedure Set-Up . . . . . . . . . . . . . . . . . . . . 15-9
Electrical System Procedure Wrap-Up . . . . . . . . . . . . . . . . . . 15-9
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-5
Front Axle
Engine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Oil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Check Fluid Level . . . . . . . . . . . . . . . . . . . . . 4-3 Front Axle & Steering
Evacuate R134a System Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-7
R134a Refrigerant Recovery, Recycling, and Front Axle Fluid
Recharging Station . . . . . . . . . . . . . . . . . 15-7 Check Fluid Level . . . . . . . . . . . . . . . . . . . . . 6-2
Evaporator Front End Alignment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Checking and Correcting Camber . . . . . . . . 6-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Checking and Correcting Toe . . . . . . . . . . . . 6-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Checking Wheels and Tires . . . . . . . . . . . . . 6-5
Evaporator Flush and Purge Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Flush and Purge Air Conditioning System . 15-10 Front Modulator Valve (if equipped)
Every 1000 Hours of Operation . . . . . . . . . . . . . 2-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Every 2000 Hours of Operation . . . . . . . . . . . . . 2-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Every 500 Hours of Operation . . . . . . . . . . . . . . 2-3 Front Quick Release Brake Valve
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

F Front Wheel Bearings

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fasteners Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fastener Sizes . . . . . . . . . . . . . . . . . . . . . . . 1-10
Front wheel bearings
General Information . . . . . . . . . . . . . . . . . . . 1-10
Check fluid level . . . . . . . . . . . . . . . . . . . . . 6-10
Tightening Sequences and Procedures . . . . 1-12
Tightnening Sequences . . . . . . . . . . . . . . . . 1-12 Fuel
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Festeners
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Fuel Filter
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fifth Wheel Maintenance
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Fuel Tank
Fifth Wheel Top Plate
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Fuel-Water Separator
Filling the Reservoir
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Automatic Lubrication System . . . . . . . . . . . 10-2

TICO Manufacturing Service Manual IDX-3

INDEX PRO-SPOTTER

G I
General Information Inspection
Nomentclature . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Air Conditioner Compressor . . . . . . . . . . . 15-11
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
General Inormation
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Air Intake System . . . . . . . . . . . . . . . . . . . . . 4-4
Air Tank
8-5
H Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Antilock Brake System (ABS) Controller . . . . 9-2
Hazardous Materials Storage . . . . . . . . . . . . . . . 1-5 Automatic Lubrication System . . . . . . . . . . . 10-3
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 15-13
Heater Core
Bobtail Proportioning Valve . . . . . . . . . . . . . . 9-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . 12-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . 4-7
Heating and Air Conditioning Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-13 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . 4-9
Hydraulic Filter Assembly
Directional Control Valve . . . . . . . . . . . . . . . 11-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Drag Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Fifth Wheel Top Plate . . . . . . . . . . . . . . . . . 12-8
Hydraulic Fluid Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Check Fluid Level . . . . . . . . . . . . . . . . . . . . . 11-2 Front Modulator Valve (if equipped) . . . . . . . 9-4
Front Quick Release Brake Valve . . . . . . . . . 9-5
Hydraulic Fluid Draining
Front Wheel Bearings . . . . . . . . . . . . . . . . . 6-11
Hydraulic Fluid Maintenance . . . . . . . . . . . . 11-5
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Hydraulic Fluid Filling Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Hydraulic Fluid Maintenance . . . . . . . . . . . . 11-5 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Hydraulic Filter Assembly . . . . . . . . . . . . . . 11-4
Hydraulic Fluid Maintenance
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 11-6
Hydraulic Fluid Draining . . . . . . . . . . . . . . . . 11-5
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . 11-9
Hydraulic Fluid Filling . . . . . . . . . . . . . . . . . . 11-5
Leaf Spring . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Hydraulic Pump R134a Refrigerant Hoses and Tubing . . . . . 15-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 R134a Refrigerant Leak Test . . . . . . . . . . . 15-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 R134a Refrigerant Oil Information . . . . . . . . 15-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . 7-4
Hydraulic System
Rear Modulator Valve (if equipped) . . . . . . . . 9-6
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-10
Rear Quick Release Brake Valve . . . . . . . . . 9-7
Service System Safely . . . . . . . . . . . . . . . . . . 1-6
Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . 15-19
Hydraulic System Troubleshooting . . . . . . . . 11-7 Steering Gear Box . . . . . . . . . . . . . . . . . . . . 6-14
Steering Knuckle . . . . . . . . . . . . . . . . . . . . . 6-15
Hydraulic Tank
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Tie Rod Bar . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Transmission Cooler . . . . . . . . . . . . . . . . . . . 5-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
Transmission Filter . . . . . . . . . . . . . . . . . . . . 5-5
Wet Air Tank . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

IDX-4 Service Manual TICO Manufacturing

PRO-SPOTTER INDEX

Installation Lifting Equipment

Air Conditioner Compressor . . . . . . . . . . . . 15-11 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Lifting Equipment, Safety . . . . . . . . . . . . . . . . . 1-4
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Air Intake System . . . . . . . . . . . . . . . . . . . . . . 4-4 Low Air Buzzer and Light Test
Air Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Air Brake System Tests . . . . . . . . . . . . . . . . 8-2
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lubrication
Antilock Brake System (ABS) Controller . . . . 9-2
Fifth Wheel Maintenance . . . . . . . . . . . . . . 12-6
Automatic Lubrication System . . . . . . . . . . . 10-3
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 15-13 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . 2-9
Bobtail Proportioning Valve . . . . . . . . . . . . . . 9-3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . 12-4
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . 4-7
N
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Nomentclature
Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . . 4-9 General Information . . . . . . . . . . . . . . . . . . . 1-7
Directional Control Valve . . . . . . . . . . . . . . . 11-3
Drag Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 15-16 P
Fifth Wheel Top Plate . . . . . . . . . . . . . . . . . 12-9
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Parking Mower
Front Modulator Valve (if equipped) . . . . . . . . 9-4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Front Quick Release Brake Valve . . . . . . . . . 9-5
Front Wheel Bearings . . . . . . . . . . . . . . . . . 6-11 Preparation
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Front End Alignment . . . . . . . . . . . . . . . . . . . 6-5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Prepare for the Job
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . 15-18 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Filter Assembly . . . . . . . . . . . . . . 11-4
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 11-6 Pressure Buildup, Low-Pressure Warning Cutoff,
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . 11-9 and Governor Cutout Test
Leaf Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Air Brake System Tests . . . . . . . . . . . . . . . . 8-3
R134a Refrigerant Oil Information . . . . . . . . 15-5 Procedure Set-Up
R134a Refrigerant Recovery, Recycling, and Flush and Purge Air Conditioning System . 15-9
Recharging Station . . . . . . . . . . . . . . . . . 15-6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Procedure Wrap-Up
Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . 7-4 Flush and Purge Air Conditioning System 15-10
Rear Modulator Valve (if equipped) . . . . . . . . 9-6
Rear Quick Release Brake Valve . . . . . . . . . 9-7
Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . . 15-19 R
Steering Gear Box . . . . . . . . . . . . . . . . . . . . 6-14
Steering Knuckle . . . . . . . . . . . . . . . . . . . . . 6-15
R134a Refrigerant Hoses and Tubing
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Tie Rod Bar . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Transmission Cooler . . . . . . . . . . . . . . . . . . . 5-4 R134a Refrigerant Leak Test
Transmission Filter . . . . . . . . . . . . . . . . . . . . . 5-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Wet Air Tank . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
R134a Refrigerant Oil Information
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
L Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Leaf Spring
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

TICO Manufacturing Service Manual IDX-5

INDEX PRO-SPOTTER

R134a Refrigerant Recovery, Recycling, and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Recharging Station Air Conditioner Compressor . . . . . . . . . . . 15-10
Evacuate R134a System . . . . . . . . . . . . . . . 15-6 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Recharge R134a System . . . . . . . . . . . . . . . 15-6 Air Intake System . . . . . . . . . . . . . . . . . . . . . 4-4
Recover R134a Refrigerant . . . . . . . . . . . . . 15-6 Air Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Radiator
Antilock Brake System (ABS) Controller . . . . 9-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Automatic Lubrication System . . . . . . . . . . . 10-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 15-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Bobtail Proportioning Valve . . . . . . . . . . . . . . 9-3
Rear Axle Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . . 0-8 Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . 12-4
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . 4-6
Rear Drive Axle
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 15-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Diesel Exhaust Fluid (DEF) Tank . . . . . . . . . 4-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Drag Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Rear Drive Axle Fluid Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Check Fluid Level . . . . . . . . . . . . . . . . . . . . . . 7-2 Fifth Wheel Top Plate . . . . . . . . . . . . . . . . . 12-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Rear Drive Axle Fluid Draining
Front Modulator Valve (if equipped) . . . . . . . 9-4
Rear Drive Axle Fluid Maintenance . . . . . . . . 7-5
Front Quick Release Brake Valve . . . . . . . . . 9-5
Rear Drive Axle Fluid Filling Front Wheel Bearings . . . . . . . . . . . . . . . . . 6-10
Rear Drive Axle Fluid Maintenance . . . . . . . . 7-5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Rear Drive Axle Fluid Maintenance
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Rear Drive Axle Fluid Draining . . . . . . . . . . . . 7-5
Hydraulic Filter Assembly . . . . . . . . . . . . . . 11-4
Rear Drive Axle Fluid Filling . . . . . . . . . . . . . . 7-5
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . 11-6
Rear Modulator Valve (if equipped) Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . 11-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Leaf Spring . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 R134a Refrigerant Hoses and Tubing . . . . . 15-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Rear Drive Axle . . . . . . . . . . . . . . . . . . . . . . . 7-2
Rear Quick Release Brake Valve
Rear Modulator Valve (if equipped) . . . . . . . . 9-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Rear Quick Release Brake Valve . . . . . . . . . 9-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . 15-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Steering Gear Box . . . . . . . . . . . . . . . . . . . . 6-13
Receiver/Dryer Steering Knuckle . . . . . . . . . . . . . . . . . . . . . 6-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19 Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 15-19 Tie Rod Bar . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19 Transmission Cooler . . . . . . . . . . . . . . . . . . . 5-4
Transmission Filter . . . . . . . . . . . . . . . . . . . . 5-5
Recharge R134a System
Wet Air Tank . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
R134a Refrigerant Recovery, Recycling, and
Recharging Station . . . . . . . . . . . . . . . . . 15-8
Recommended Lubricants and Capacities . . . 2-6
Recover R134a Refrigerant
R134a Refrigerant Recovery, Recycling, and
Recharging Station . . . . . . . . . . . . . . . . . 15-7
Relieving Air System Pressure . . . . . . . . . . . . . 8-6

IDX-6 Service Manual TICO Manufacturing

PRO-SPOTTER INDEX

S Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Tires
Safety Service Safety . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chemical Products Handling . . . . . . . . . . . . . 1-5
Compressed Air and Air Tools . . . . . . . . . . . . 1-4 Transmission
Cooling System Safety . . . . . . . . . . . . . . . . . . 1-5 Flat Rate Guideline . . . . . . . . . . . . . . . . . . . . 0-7
Electrical Components . . . . . . . . . . . . . . . . . . 1-4 Transmission Cooler
Eye and Face Protection . . . . . . . . . . . . . . . . 1-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic System Service . . . . . . . . . . . . . . . 1-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Keep Work Area Clean . . . . . . . . . . . . . . . . . 1-3 Transmission Filter
Keep Work Area Well Ventilated . . . . . . . . . . 1-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . 1-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Machine Support . . . . . . . . . . . . . . . . . . . . . . 1-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Park Mower Safely . . . . . . . . . . . . . . . . . . . . . 1-3 Transmission Fluid
Parking Mower . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Check Fluid Level . . . . . . . . . . . . . . . . . . . . . 5-2
Prepare for the Job . . . . . . . . . . . . . . . . . . . . 1-2
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Transmission Fluid Draining
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Transmission Fluid Maintenance . . . . . . . . . 5-6
Support Tractor Securely . . . . . . . . . . . . . . . . 1-3 Transmission Fluid Filling
Tire Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Transmission Fluid Maintenance . . . . . . . . . 5-7
Use Compressed Air and Air Tools Safely . . . 1-4
Use Lifting Equipment Safely . . . . . . . . . . . . . 1-4 Transmission Fluid Maintenance
Use Proper Eye and Face Protection . . . . . . 1-3 Transmission Fluid Draining . . . . . . . . . . . . . 5-6
Volatile and Hazardous Materials Storage . . . 1-5 Transmission Fluid Filling . . . . . . . . . . . . . . . 5-6
Waste Material Disposal . . . . . . . . . . . . . . . . 1-6
Work Area Cleanliness . . . . . . . . . . . . . . . . . 1-3
Work Area Ventilation . . . . . . . . . . . . . . . . . . 1-3 V
Safety Labels
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Volatile Materials Storage . . . . . . . . . . . . . . . . . 1-5

Safety Notices
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
W
Steering Gear Box
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Waste Materials
Safe Disposal . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Steering Knuckle
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Wet Air Tank
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Surge Tank
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Work Area
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

T
Tie Rod Bar
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

TICO Manufacturing Service Manual IDX-7