Sterling Trucks 360 2006 Manual Download Page 190

Page: 190 / 213

12-16

In an emergency

adl

ht b

ulb

rep

For safety and simplicity, bulb replacement is per-

formed with the headlight removed. In order to

remove the headlight, the front and side turn signal

lens and the reflector must be removed first.

1.1

Hea

dli

ght

rem

ova

l an

d in

all

ati

Remove the headlight.

remo

the

headli

ght

firs

remo

the

screw

and

rivet

Then

move

the

headlight

bezel

from

underneath

the

headlight

toward

the centerline of the vehicle to release it from

the

mounting

tabs

CAUTION

When removing the headlight bezel, do not pull

it with excessive force. The

mounting tabs could

break.

Open

the doo

then lo

osen

the tw

o keep

screws

behind

the

front

and

side

turn

signal

lens

and

the

keeper

screw

behind

the

reflector

Continue

loosening

the

screws

until

they spin freely.

NOTE:

The keeper screws are designed to remain in the

vehicle. They are not supposed to be

removed.

Pull

each

keepe

scre

towar

you

until

fully extended.

CAUTION

Unless the keeper screw is extended, the front

and side turn signal lens and the reflector will

catch on it and you will not be able to remove

them from the vehicle without damaging them.

e t

Pull

the

front

and

side

turn

signa

lens

away

from the vehicle as shown in the illustration.

Then

remove

the

connector

CAUTION

When removing the front and side turn sig-

nal lens, do not pull it forward (toward the

front of the vehicle) or its tabs could break.

Do not open the door with the front and side

Z11264

Z11265

Z11266

https://www.besttruckmanuals.com/

Summary of Contents for 360 2006

Page 1: ...ME MAILING ADDRESS MAILING ADDRESS C CI IT TY Y S ST TA AT TE E Z ZI IP P VEHICLE IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER DA DATE OF TE OF DELIVERY WARRANTY DELIVERY WARRANTY STAR START DA...

Page 2: ...iscard materials you should attempt to reclaim Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appro...

Page 3: ...l contains important hazard messages under the following four headings that identify the This manual contains important hazard messages under the following four headings that identify the nature and i...

Page 4: ...8 Heating and air condition Heating and air conditioning ing 8 8 1 1 9 9 Interior equipment and accesso Interior equipment and accessories ries 9 9 1 1 10 10 In cold weather In cold weather 1 10 0 1 1...

Page 5: ...2 1 2 Vehicle identification number VIN Vehicle identification number VIN 1 3 1 3 Maintenance Maintenance 1 4 1 4 Fuel Fuel 1 5 1 5 Reporting safety defects Reporting safety defects 1 8 1 8 Obtaining...

Page 6: ...left hand side of the crankcase of the crankcase The The power power line line label label is is located located on on the the passen passen ger s B pillar door post It gives the vehicle model ger s...

Page 7: ...ydra draulic ulic F F 26 26 0 001 t 01 to 33 o 33 0 000 l 00 lb F b Full ull ai air r L Li in ne e A A S St te er rl li in ng g 3 36 60 0 C CO OE E 3 30 0 B B S Ste terl rlin ing 36 g 360 CO 0 COE 40...

Page 8: ...7 P 11 7 3 3 In Init itia ial ma l main inte tena nanc nce e After After you you have have traveled traveled the the first first 2500 2500 miles miles 4000 4000 km your vehicle needs a free initial ma...

Page 9: ...h responsi both responsi ble for keeping the fuel clean ble for keeping the fuel clean 2 2 Dan Danger ger of f of fire a ire and ex nd explos plosion ion resu resultin lting g from fuel mixtures from...

Page 10: ...ly If they become so dirty breather regularly If they become so dirty that the breather gets blocked the fuel tank that the breather gets blocked the fuel tank may suffer damage and the fuel injection...

Page 11: ...fuel pump do not continue pumping after fuel pump do not continue pumping after the pump automatically stops The tank is the pump automatically stops The tank is full at this point full at this point...

Page 12: ...also obtain other information about motor vehicle safety from http www safercar gov vehicle safety from http www safercar gov Canadian customers who wish to report a safety Canadian customers who wis...

Page 13: ...2 1 2 1 Locations in cab Locations in cab 2 2 2 2 Locations outside cab Locations outside cab 2 4 2 4 2 Warning labels 2 Warning labels https www besttruckmanuals com...

Page 14: ...y only to the vehicle itself For vendor vehicle itself For vendor equipment mounted on the vehicle please refer equipment mounted on the vehicle please refer to the equipment manufacturer s manual to...

Page 15: ...ssion Hydraulic brake booster Hydraulic brake booster Sterling 360 COE 50 Sterling 360 COE 50 Hydraulic brake system bleeding Hydraulic brake system bleeding Sterling 360 COE 50 Sterling 360 COE 50 Ma...

Page 16: ...2 4 2 4 Warning labels Warning labels Locations outside cab Locations outside cab Z12496 Z12496 https www besttruckmanuals com...

Page 17: ...ure cap Radiator pressure cap A ATF TF co cool olin ing g fa fan n A Aut utom omat atic ic tr tran ansm smis issi sion on A ATF TF co cool oler er A Aut utom omat atic ic tr tran ansm smis issi sion o...

Page 18: ...reference 33 gallon 125 liter fuel tank 33 gallon 125 liter fuel tank Air conditioner Air conditioner Cab tilt safety Cab tilt safety Limited slip differential Limited slip differential Z11803 Z11803...

Page 19: ...2 7 2 7 Warning labels Warning labels 30 gallon 113 liter fuel tank 30 gallon 113 liter fuel tank Z12494 Z12494 https www besttruckmanuals com...

Page 20: ...2 3 2 Master door locks Master door locks 3 4 3 4 Entering and exiting the vehicle Entering and exiting the vehicle 3 5 3 5 Door window Door window 3 6 3 6 3 Vehicle access 3 Vehicle access https www...

Page 21: ...the door and suddenly blow it open causing a causing a personal injury personal injury Exercise caution when opening a door on Exercise caution when opening a door on a downward slope Otherwise the i...

Page 22: ...ked Only the driver s door is unlocked unlocked When you leave your vehicle be sure to When you leave your vehicle be sure to remove remove the ignition key from the ignition switch to pre the ignitio...

Page 23: ...n either automatically locked If the lock button on either door is subsequently pushed rearward only that door is subsequently pushed rearward only that door is unlocked door is unlocked When the driv...

Page 24: ...int contact with Always maintain three point contact with the vehicle while entering and exiting the the vehicle while entering and exiting the cab Three point contact means both feet cab Three point...

Page 25: ...a window switch it can cause a mal function function Door window Door window WARNING WARNING Do not allow anyone to put their hands or Do not allow anyone to put their hands or head out of a window T...

Page 26: ...on any of the window switches If water or any other liq of the window switches If water or any other liq uid gets on a window switch it can cause a mal uid gets on a window switch it can cause a mal f...

Page 27: ...1 4 1 Seats Seats 4 2 4 2 Seat belts Seat belts 4 4 4 4 Steering wheel Steering wheel 4 7 4 7 4 Seat and steering wheel adjustments 4 Seat and steering wheel adjustments https www besttruckmanuals co...

Page 28: ...nt injury do not adjust the seat while the vehicle is in motion The seat while the vehicle is in motion The seat may move more than you intend Stop the may move more than you intend Stop the vehicle a...

Page 29: ...dle seat seat Pull Pull the the backrest backrest tilt tilt lever lever to to adjust adjust the the back back rest angle While holding the rest angle While holding the lever grasp the top lever grasp...

Page 30: ...with Emergency point lap and shoulder belts with Emergency Locking Retractor ELR while the middle seat Locking Retractor ELR while the middle seat has a 2 point lap belt has a 2 point lap belt Seat be...

Page 31: ...e en ni in ng g 1 1 Pres Press s the the releas release e butto button n to to unloc unlock k the the buck buckle le 2 2 The bel The belt autom t automatica atically ret lly retract racts when s when...

Page 32: ...A pregnant woman should wear her seat belt as A pregnant woman should wear her seat belt as low as possible across the hips not across her low as possible across the hips not across her abdomen abdom...

Page 33: ...y adjustment try to move the After every adjustment try to move the steering wheel back and forth to make steering wheel back and forth to make sure that it is securely locked Unless the sure that it...

Page 34: ...er manual transm Shift lever manual transmission ission 5 14 5 14 Shift selector automatic Shift selector automatic transmission transmission 5 15 5 15 Overdrive lockout sw Overdrive lockout switch it...

Page 35: ...ght switch headlight high beam dimmer turn signal switch turn signal switch L Lo ow w o oi il l l le ev ve el l s sw wi it tc ch h P 11 18 P 11 18 M Ma as st te er r d do oo or r l lo oc ck k s sw wi...

Page 36: ...long periods since this could completely dis periods since this could completely dis charge the battery charge the battery Example Example listening to the listening to the radio with the engine shut...

Page 37: ...y and Once the engine is running release the key and the switch will automatically return to ON the switch will automatically return to ON NOTE NOTE Do not turn the key until it is fully inserted into...

Page 38: ...If the engine idle control is used to increase engine speed while the engine warm up switch is ON the speed while the engine warm up switch is ON the engine may produce black smoke Before turning eng...

Page 39: ...uthorized Sterling service facility Sterling service facility If exhaust gases come into the cab ventilate the If exhaust gases come into the cab ventilate the cab with fresh air by opening the doors...

Page 40: ...sure to crank the engine before starting it the engine before starting it If the engine pre heat If the engine pre heat indicator does not illu indicator does not illu minate in cold weather the fuse...

Page 41: ...ailroad crossing railroad crossing 2 2 St Star arti ting ng pr proc oced edur ure e 1 1 Tur Turn the ig n the ignition nition swit switch to ch to the O the ON po N position sition 2 2 Chec Check wh k...

Page 42: ...to protect the turbocharger the turbocharger 1 1 Make Make sure t sure the pa he parking rking brak brake is fu e is fully ap lly applied plied 2 2 Manu Manual al trans transmiss mission ion vehic veh...

Page 43: ...nd the exhaust pipe and check whether exhaust gases check whether exhaust gases are leaking through holes or cracks caused by cor are leaking through holes or cracks caused by cor rosion or damage If...

Page 44: ...tomatic control position the engine s idle speed is adjusted control position the engine s idle speed is adjusted automatically To make the engine warm up more automatically To make the engine warm up...

Page 45: ...ore allow some time for the engine to idle before shutting it down idle before shutting it down 4 4 T To shut d o shut down the e own the engine t ngine turn the i urn the ignitio gnition swit n switc...

Page 46: ...pedal could pre of the clutch Riding the clutch pedal could pre vent the engine brake and exhaust brake from vent the engine brake and exhaust brake from taking effect taking effect Depress the clutch...

Page 47: ...t lever Shifting with the clutch partly engaged can damage the the clutch partly engaged can damage the transmission transmission The gear pattern is inscribed on the top surface The gear pattern is i...

Page 48: ...epressed Even with the brake pedal depressed the shift Even with the brake pedal depressed the shift selector cannot be moved if the ignition selector cannot be moved if the ignition switch is switch...

Page 49: ...d weather pro gram is implemented to accelerate transmission gram is implemented to accelerate transmission warm up Note that this program will be terminated warm up Note that this program will be ter...

Page 50: ...on a downhill grade or on long uphill grades In D drive the transmission shifts auto grades In D drive the transmission shifts auto matically from 1st through 4th gears matically from 1st through 4th...

Page 51: ...nt of of sw swit itche ches s Headlight switch Headlight switch Headlight high beam dimmer Headlight high beam dimmer Turn signal switch Turn signal switch Exhaust brake switch manual Exhaust brake sw...

Page 52: ...return to the low beams When the high beams are on the high beam When the high beams are on the high beam indicator illuminates indicator illuminates 4 4 T Tur urn s n sig igna nal s l swi witc tch h...

Page 53: ...ck brake system ABS is operating The antilock brake system ABS is operating Full exhaust brake function will return as soon as Full exhaust brake function will return as soon as the original condition...

Page 54: ...of th nd of the lev e lever act er acti i vates the windshield wipers in one of the follow vates the windshield wipers in one of the follow ing three modes ing three modes IN INT T Wi Wipe pers rs op...

Page 55: ...ights brighter or hold the rocker switch to make the lights brighter or dimmer as shown in the illustration When the lights dimmer as shown in the illustration When the lights have reached the desired...

Page 56: ...This can drain the battery and make it impossible to start the engine impossible to start the engine Rear view mirrors Rear view mirrors WARNING WARNING During normal driving adjust the mirrors During...

Page 57: ...hometer Tachometer 6 2 6 2 Coolant temperature gauge Coolant temperature gauge 6 3 6 3 Fuel level gauge Fuel level gauge 6 4 6 4 Warning and indicator lights Warning and indicator lights 6 5 6 5 6 Ins...

Page 58: ...elected point to its present location is shown to the nearest point to its present location is shown to the nearest 0 1 mile 0 1 mile The tripmeter has two indications TRIP A and The tripmeter has two...

Page 59: ...un the engine at a speed slightly higher than normal the engine at a speed slightly higher than normal idle If the vehicle has air conditioning turn it off idle If the vehicle has air conditioning tur...

Page 60: ...hes the E mark refuel When the needle approaches the E mark refuel as soon as possible as soon as possible If the vehicle runs completely out of fuel air If the vehicle runs completely out of fuel air...

Page 61: ...cator lights Warning and indicator lights WARNING WARNING A red warning light if illuminated warns you A red warning light if illuminated warns you of a serious problem with the vehicle and of a serio...

Page 62: ...do ow wn n 11 4 11 4 Transm Transmission temperature ission temperature warning warning Automatic transmission vehicles Automatic transmission vehicles The automatic transmission fluid The automatic...

Page 63: ...oes s of off w f whe hen t n the he en engi gine ne is is s st ta art rted ed Amber Check engine indicator Amber Check engine indicator Goes off when the engine is Goes off when the engine is started...

Page 64: ...when the parking brake is set With the ignition when the parking brake is set With the ignition switch ON and the engine not running the brake switch ON and the engine not running the brake warning st...

Page 65: ...probably in the vehicle charging system Bring the vehicle to an authorized Ster system Bring the vehicle to an authorized Ster ling service facility for ling service facility for repairs repairs 4 4 L...

Page 66: ...r arni ning ng If the water in fuel warning is illuminated there is If the water in fuel warning is illuminated there is an an excessive amount of water in the fuel filter Pull off excessive amount of...

Page 67: ...oblem If the light illuminates again shut down the illuminates again shut down the engine and contact engine and contact an authorized an authorized Sterling service facility Sterling service facility...

Page 68: ...e engine overheated the engine overheats With the engine overheated the needle in the coolant temperature gauge is in the needle in the coolant temperature gauge is in the red zone red zone Stop the v...

Page 69: ...ntilock braking system ABS stem ABS 7 7 7 7 On uphill and downhill grades On uphill and downhill grades 7 9 7 9 On rough roads and in bad weather On rough roads and in bad weather 7 11 7 11 Parking Pa...

Page 70: ...e and suddenly engage the clutch Do not engine and suddenly engage the clutch Do not ride the clutch for extended periods This can ride the clutch for extended periods This can cause clutch damage cau...

Page 71: ...ns and and hard hard braking braking except except in in emergencies emergencies When driving on narrow streets or when When driving on narrow streets or when making making a turn keep in mind that th...

Page 72: ...ns that the tires ride on a film of water and lose contact with the road surface water and lose contact with the road surface This is known as hydroplaning If this should This is known as hydroplaning...

Page 73: ...s road conditions p pe er rm mi it t P 5 17 P 5 17 It is possible to shift up using the shift selector It is possible to shift up using the shift selector the same as with the same as with a manual ge...

Page 74: ...This will overdrive as road conditions permit This will increase fuel economy increase fuel economy Try to drive at moderate and constant speeds Try to drive at moderate and constant speeds Unnecessa...

Page 75: ...d for driver intervention intervention Braking Braking WARNING WARNING If any of the brake warning lights illumi If any of the brake warning lights illumi nate there is a possibility of brake failure...

Page 76: ...n the brake pedal The sound of the solenoid in in the brake pedal The sound of the solenoid in operation may be heard These sounds indicate operation may be heard These sounds indicate ABS is ABS is o...

Page 77: ...long or steep downhill Before driving down a long or steep downhill grade test the service brakes and exhaust grade test the service brakes and exhaust brake to make sure that they are OK brake to mak...

Page 78: ...significantly and results in poor braking results in poor braking Reduce engine speed before Reduce engine speed before downshifting downshifting Do not downshift more than two gears at a time Do not...

Page 79: ...rake by itself can cause a brake by itself can cause a skid Drive at a com skid Drive at a com fortable speed and stay in control of the fortable speed and stay in control of the vehicle vehicle If th...

Page 80: ...al depressed Then move the with the brake pedal depressed Then move the shift selector to P shift selector to P park park Parking Parking WARNING WARNING Park the vehicle on a level Park the vehicle o...

Page 81: ...ure to turn off all lights after parking to Be sure to turn off all lights after parking to prevent discharging the prevent discharging the battery battery 5 5 If pa If parking rking on a sl on a slop...

Page 82: ...t all skids Follow safe driving practices to prevent all skids Follow safe driving practices to minimize opportunities for skidding minimize opportunities for skidding On slippery road surfaces do not...

Page 83: ...GAWR look on the vehicle identification rear GAWR look on the vehicle identification plate located inside the driver s door as shown plate located inside the driver s door as shown NOTE NOTE If the v...

Page 84: ...it down securely and cover it with a tarpaulin Secure securely and cover it with a tarpaulin Secure the tarpaulin ends neatly so they do not the tarpaulin ends neatly so they do not flap flap WARNING...

Page 85: ...ront air outlets 8 2 8 2 Heater Heater 8 3 8 3 Air conditioner Air conditioner 8 7 8 7 Outside air inlets Outside air inlets 8 11 8 11 8 Heating and air conditioning 8 Heating and air conditioning htt...

Page 86: ...et outlet as as desired desired by by moving moving the the knob knob to to the the left or right left or right Adjust Adjust the the up down up down airflow airflow direction direction from from each...

Page 87: ...it tc ch h The fan switch allows you to adjust the fan speed The fan switch allows you to adjust the fan speed To increase fan speed turn the dial clockwise in To increase fan speed turn the dial cloc...

Page 88: ...ntering the cab to prevent dust from entering the cab CAUTION CAUTION Do not use the recirculated air setting for a long Do not use the recirculated air setting for a long period of time 20 minutes or...

Page 89: ...5 position position m most ost of the of the air is air is directed directed toward toward the the feet and the rest of feet and the rest of the air is directed toward the the air is directed toward...

Page 90: ...he dial on the fan switch clockwise to maximum fan dial on the fan switch clockwise to maximum fan speed speed T To defrost the o defrost the windshield faster also turn the dial windshield faster als...

Page 91: ...e air conditioner is operating operating A A fast fast idling idling device device can can be be installed installed by by any any authorized Sterling authorized Sterling service facility service faci...

Page 92: ...rrow T T o o make the cab make the cab cooler cooler turn turn the dial the dial counterclockw counterclockwise ise in in the the direction direction of of arrow arrow 1 1 3 3 Re Reci circ rcul ulat a...

Page 93: ...he air selection switch in the face Place the air selection switch in the face position position For cool airflow toward the upper body and For cool airflow toward the upper body and toward the feet t...

Page 94: ...f the level of the refrigerant is too low the A C will not work as well Check the refrigerant level when not work as well Check the refrigerant level when ever a problem appears Set the air conditione...

Page 95: ...res a method different from the conventional requires a method different from the conventional method be sure to contact an authorized Sterling method be sure to contact an authorized Sterling service...

Page 96: ...s Coat hooks 9 4 9 4 Sun visors Sun visors 9 4 9 4 Dome light Dome light 9 4 9 4 Storage compartments Storage compartments 9 5 9 5 Radio Radio 9 7 9 7 Accessories Accessories 9 8 9 8 9 Interior equipm...

Page 97: ...et Your vehicle s cigarette into your vehicle s socket Your vehicle s cigarette lighter is designed for a 12 V power supply Do not lighter is designed for a 12 V power supply Do not use a 24 V use a 2...

Page 98: ...could break Replace a could break Replace a broken ashtray with a new one broken ashtray with a new one Ashtrays Ashtrays WARNING WARNING To prevent fires close the lids on the ash To prevent fires cl...

Page 99: ...can be used with the ignition switch in any position in any position CAUTION CAUTION Always turn off the lights before you leave the Always turn off the lights before you leave the vehicle Do not lea...

Page 100: ...cab interior age the cab interior Storage compartments Storage compartments WARNING WARNING Always close the storage compartments Always close the storage compartments before operating the vehicle bef...

Page 101: ...e dash retracted inside the dash A fuse A fuse box is box is located below located below the the cup holder cup holder Be Be careful not to splash liquids on the fuse box careful not to splash liquids...

Page 102: ...ignition switch in the ON position or ACC position ON position or ACC position CAUTION CAUTION Using the radio for an extended period of time Using the radio for an extended period of time without th...

Page 103: ...should from electromagnetic emissions you should consult an authorized Sterling dealer before consult an authorized Sterling dealer before adding equipment that emits electronic signals adding equipm...

Page 104: ...Engine oil Engine oil 10 2 10 2 Fuels Fuels 10 2 10 2 Cold weather operation Cold weather operation 10 3 10 3 Installing tire chains Installing tire chains 10 4 10 4 10 In cold weather 10 In cold wea...

Page 105: ...eratures temperatures the the viscosity viscosity of of engine engine oil oil increases This can make it hard to increases This can make it hard to start the engine start the engine especially early i...

Page 106: ...or while parked in cold weather covered roads or while parked in cold weather braking performance can be reduced Drive braking performance can be reduced Drive carefully and be alert to carefully and...

Page 107: ...chains as soon as possi ble after you come back on dry road ble after you come back on dry road Make sure that the chains and their spring Make sure that the chains and their spring bands are not exc...

Page 108: ...twisted 7 7 Fast Fasten extr en extra chain li a chain links wi nks with a met th a metal wire t al wire to pre o pre vent them from hitting against other vehicle vent them from hitting against other...

Page 109: ...checking Steering wheel checking 11 41 11 41 Service brake check Service brake checking ing 11 42 11 42 Parking brake chec Parking brake checking and adjusting king and adjusting 11 44 11 44 Clutch c...

Page 110: ...h the engine running Chock all the the engine running Chock all the tires fore tires fore and aft set the parking brake and place and aft set the parking brake and place the transmission in park If th...

Page 111: ...ghtly Water emitted by the exhaust pipe is slightly acidic and could cause your hands to be acidic and could cause your hands to be chapped If you touch this water rinse it off chapped If you touch th...

Page 112: ...e sure there is ade Before tilting the cab make sure there is ade quate clearance in front of the cab and above it quate clearance in front of the cab and above it see table and that the area is free...

Page 113: ...e th Use the tilt gr e tilt grip to rai ip to raise the c se the cab Af ab After co ter confirm nfirming ing that that the the lock lock lever lever is is hooked hooked onto onto the the cab cab stay...

Page 114: ...ab cab mount mount WARNING WARNING Before lowering the cab make sure that Before lowering the cab make sure that you have not you have not left flammable objects inside left flammable objects inside t...

Page 115: ...edure from the beginning and lock it again gain NOTE NOTE Sometimes the switch that activates the cab tilt Sometimes the switch that activates the cab tilt warning does not pop out when lever B is loc...

Page 116: ...er deflection when Check the belt for proper deflection when a a force of 22 lb 98 N i force of 22 lb 98 N is applied to the point mid s applied to the point mid way between the pulleys Tighten it if...

Page 117: ...ning running Parking brake lever stroke Parking brake lever stroke Check that the parking brake lever stroke is Check that the parking brake lever stroke is between 7 and 9 between 7 and 9 notches not...

Page 118: ...ently turn the steering wheel from side to Gently turn the steering wheel from side to side Make sure that it has free side Make sure that it has free play of more play of more than 0 2 in 5 mm and le...

Page 119: ...telltale warning and indicator lights are indicator lights are working properly working properly P 6 2 P 6 2 Rear view mirrors Rear view mirrors Seated in the driver Seated in the driver s seat adjust...

Page 120: ...wheels for cracks and other damage Check the tire inflation pressure and damage Check the tire inflation pressure and tread groove depth Check the tires for foreign tread groove depth Check the tires...

Page 121: ...ion damage and dirt Steering wheel operation Steering wheel operation While driving slowly check that the steering While driving slowly check that the steering wheel does not vibrate or pull to one si...

Page 122: ...the vehicle is operated at temperatures below 10 F 23 C For details consult an below 10 F 23 C For details consult an authorized Sterling service facility authorized Sterling service facility CAUTION...

Page 123: ...ar spring pin aft 4 points total 2 on each Rear spring pin aft 4 points total 2 on each side side Z12034 Z12034 FE FE 1 Rear spring pin forward 1 Rear spring pin forward 2 Rear spring pin aft 2 Rear s...

Page 124: ...ings on the propeller shaft differs from model to model differs from model to model 2 2 Doo Door hi r hinge nge 8 p 8 plac laces t es tot otal 4 al 4 on e on each ach side side Recommended lubricant R...

Page 125: ...th a classification of CD or higher CD or higher Quantity required approximate Quantity required approximate The engine oil level can be checked by using either The engine oil level can be checked by...

Page 126: ...oil lev il level that el that appear appears on t s on the dip he dipstic stick k should be in between the two notches as should be in between the two notches as shown in the illustration shown in th...

Page 127: ...sh engine o ngine oil thr il through t ough the oil he oil filler hole filler hole 6 6 Wai Wait for m t for more tha ore than 5 min n 5 minutes a utes and chec nd check the o k the oil il level using...

Page 128: ...ion oil for the first time at the initial maintenance period of 2500 initial maintenance period of 2500 miles 4000 km miles 4000 km Recommended oil Recommended oil Gear oil Gear oil API classification...

Page 129: ...out about 30 minutes before draining the oil 30 minutes before draining the oil The oil will drain The oil will drain more quickly while it is still more quickly while it is still warm warm 2 2 Clean...

Page 130: ...stick and and wipe wipe it it clean clean with with a a shop towel shop towel NOTE NOTE The ATF dipstick is located behind the cab If it is The ATF dipstick is located behind the cab If it is difficul...

Page 131: ...mple Example when driving when driving long uphill grades This oil is to be used only long uphill grades This oil is to be used only when the temperature is higher than 50 when the temperature is high...

Page 132: ...operly NOTE NOTE After operation After operation let let the the transmission cool transmission cool for for about about 30 minutes before draining the oil 30 minutes before draining the oil The oil w...

Page 133: ...Replacement intervals intervals Every 30 000 miles 50 000 km Every 30 000 miles 50 000 km or every two years or every two years WARNING WARNING Hydraulic brake fluid is hazardous and Hydraulic brake f...

Page 134: ...e the reservoir reservoir cover cover and and clean clean the the sur sur faces around the reservoir cap Remove the cap faces around the reservoir cap Remove the cap and add recommended brake fluid up...

Page 135: ...s If the fluid level is below the and MIN lines If the fluid level is below the MIN line clean the area around the power MIN line clean the area around the power steering steering reservoir reservoir...

Page 136: ...clean clean it it 6 6 Repla Replace the f ce the filter ilter elem element ass ent assembl embly with y with a new a new one Use only genuine one Use only genuine replacement parts replacement parts...

Page 137: ...become damaged If you do not have the special tool please contact an authorized the special tool please contact an authorized Sterling service Sterling service facility facility Be careful not to dama...

Page 138: ...coat of eng of engine oil ine oil to to each each of of the the new new O rings O rings and and install install one one O ring O ring on on the the filter filter case case and and one one O ring O ri...

Page 139: ...dam m age and leaks Check all age and leaks Check all clamps and make sure clamps and make sure they are tight they are tight 2 2 Undo Undo the the three three clam clamps ps and and remo remove ve th...

Page 140: ...engine a ngine and chec nd check for fu k for fuel leak el leaks Che s Check ck the fuel tank cap and lines for leakage Correct the fuel tank cap and lines for leakage Correct any leaks found any leak...

Page 141: ...d water from wells and rivers as it is liable to form scale and cause corro rivers as it is liable to form scale and cause corro sion sion 3 3 Us Usin ing g co coola olant nt add addit itiv ive e To p...

Page 142: ...CLEAN CLEAN WATER AND SOAP IF YOU FEEL UNWELL WATER AND SOAP IF YOU FEEL UNWELL OR PAIN ON YOUR SKIN IMMEDIATELY OR PAIN ON YOUR SKIN IMMEDIATELY SEEK MEDICAL ATTENTION SEEK MEDICAL ATTENTION IN THE...

Page 143: ...ually is actually is Deposition may occur in the surge tank This will Deposition may occur in the surge tank This will not cause any problem not cause any problem Check that the coolant level is betwe...

Page 144: ...t at a speed eed slightly higher than normal idle slightly higher than normal idle P 5 5 P 5 5 2 2 When When the n the needle eedle in the in the cool coolant te ant temper mperature ature gauge has c...

Page 145: ...coolant without splashing connect a hose To drain coolant without splashing connect a hose to to the the nozzle nozzle below below the the engine engine drain drain plug plug 6 6 Afte After the c r th...

Page 146: ...el 12 12 Lower t Lower the cab he cab 13 13 Fill the surge tank with c Fill the surge tank with coolant in the correct oolant in the correct mixing ratio to the FULL mark Install the mixing ratio to t...

Page 147: ...e Replace t lace the belt i he belt if f damage is found damage is found Drive belt checking and adjusting Drive belt checking and adjusting Inspection Inspection intervals intervals Daily pretrip in...

Page 148: ...engine shut down 1 1 Set th Set the par e parking br king brake M ake Make s ake sure it i ure it is fully s fully applied applied 2 2 Tur Turn ON t n ON the ignit he ignition sw ion switch b itch bu...

Page 149: ...nt of steeri teering whe ng wheel mo el move ve ment between these two points This is the ment between these two points This is the steering wheel free play If the free play is not steering wheel free...

Page 150: ...r of ter of the the pedal pad to the point pedal pad to the point where resistance is felt where resistance is felt 6 6 Meas Measure th ure the amou e amount of br nt of brake pe ake pedal mo dal move...

Page 151: ...kes work effec low speed to make sure that the brakes work effec tively and evenly on all four wheels If there is any tively and evenly on all four wheels If there is any problem do not continue to op...

Page 152: ...k that the pa the parking rking brake can hold the vehicle If an appropriate brake can hold the vehicle If an appropriate downgrade is not available drive the vehicle at downgrade is not available dr...

Page 153: ...c The clutch lutch should engage smoothly without slipping should engage smoothly without slipping 5 5 If the c If the clutch s lutch shows hows signs signs of wear of wear repla replace it at a ce it...

Page 154: ...xpand sure in new tires New tires tend to expand slightly with a corresponding decrease in air slightly with a corresponding decrease in air pressure pressure On dual wheels inflate both inner and out...

Page 155: ...using the slide over a film of water causing the driver to lose control of both driver to lose control of both steering and braking steering and braking 3 3 Ch Chec ecki king fo ng for cra r crack cks...

Page 156: ...tire di ire diagonal agonally opp ly opposite osite to the to the tire t tire to o be replaced Set chocks fore and aft be replaced Set chocks fore and aft Example Example If the right rear tire is to...

Page 157: ...ted at the jacking that the jack is firmly seated at the jacking point and will not move when the vehicle point and will not move when the vehicle is raised is raised If the jack were to slip out of p...

Page 158: ...eel and el and tire assembly tire assembly NOTE NOTE To remove the tires on a dual rear wheel first To remove the tires on a dual rear wheel first loosen loosen the the outer outer wheel wheel nuts nu...

Page 159: ...for easy easy identification an R mark for right hand threads identification an R mark for right hand threads and an L mark for and an L mark for left hand threads left hand threads 3 3 Lowe Lower the...

Page 160: ...to the required torque before mounting the outer wheel required torque before mounting the outer wheel WARNING WARNING Make sure the socket is firmly seated on Make sure the socket is firmly seated on...

Page 161: ...rk for and an L mark for left hand threads left hand threads Wheel nut tightening Wheel nut tightening Inspection interval Inspection interval Every 6000 miles Every 6000 miles 10 000 km 10 000 km WAR...

Page 162: ...read for the front wheels select tires with a ribbed tread for the front wheels and tires with a traction type tread for the wheels and tires with a traction type tread for the rear wheels rear wheels...

Page 163: ...ithout wiper blades This could scratch the windshield could scratch the windshield 2 2 Re Repl placi acing t ng the r he rubb ubber e er ele leme ment nt 1 1 Rais Raise the e the wiper wiper arm a arm...

Page 164: ...w 3 3 Clos Close the e the cap cap tightl tightly af y after r ter refilli efilling ng CAUTION CAUTION Do not substitute soapy water for washer Do not substitute soapy water for washer fluid This coul...

Page 165: ...ROTECT SKIN AND EYES FROM BATTERY ELECTROLYTE ELECTROLYTE IS CORRO ELECTROLYTE ELECTROLYTE IS CORRO SIVE AND COULD RESULT IN SERIOUS PER SIVE AND COULD RESULT IN SERIOUS PER SONAL INJURY SONAL INJURY...

Page 166: ...When the indicator is blue the battery is fully When the indicator is blue the battery is fully charged If the indicator is white the battery is charged If the indicator is white the battery is not fu...

Page 167: ...pid gassing or spewing of electrolyte occurs lower the charging rate or stop lower the charging rate or stop charging the bat charging the bat tery and allow it to cool tery and allow it to cool 5 5 A...

Page 168: ...the road could damage the battery case and road could damage the battery case and battery battery plates shortening battery life plates shortening battery life T To reduce dust and o reduce dust and...

Page 169: ...n Installation 1 1 Inse Insert the sc rt the screen fil reen filter in it ter in its holde s holder with it r with its fron s front t facing you Press the screen filter securely into facing you Press...

Page 170: ...amps Once a seal clamp is loosened or clamps Once a seal clamp is loosened or removed it must be replaced removed it must be replaced 1 1 Ex Exte teri rior or cl clea eani ning ng 1 1 1 1 Cl Clea eani...

Page 171: ...n the door After washing remove moisture on and around the doors Apply silicone with on and around the doors Apply silicone with antifreeze capabilities to prevent freezing antifreeze capabilities to...

Page 172: ...vehicle finish If you find them hard to remove use a synthetic If you find them hard to remove use a synthetic cleaner that does not scratch or otherwise damage cleaner that does not scratch or other...

Page 173: ...cream vegetable oil cream chewing gum beauty cream vegetable oil wax crayon tar and asphalt wax crayon tar and asphalt Wipe off the staining agent and apply a fabric Wipe off the staining agent and ap...

Page 174: ...ard pulling it forward After After cleaning cleaning the the floor floor mat mat dry dry the the felt felt backing backing before putting the mat back on the floor When fit before putting the mat back...

Page 175: ...2 14 Difficult braking Difficult braking 12 21 12 21 Stalled engine vehicle in motion Stalled engine vehicle in motion 12 21 12 21 Flat tire vehicle in motion Flat tire vehicle in motion 12 21 12 21 E...

Page 176: ...os si it ty y i is s t to oo o h hi ig gh h R Re ep pl la ac ce e t th he e o oi il l U Us se e o oi il l o of f t th he e c co or rr re ec ct t v vi is sc co os s ity ity 11 18 11 18 P Po os ss si ib...

Page 177: ...n nt ta am mi in na at te ed d F Fl lu us sh h t th he e c co oo ol li in ng g s sy ys st te em m a an nd d c ch ha an ng ge e t th he e coolant coolant 11 33 11 33 P Po os ss si ib bl le e c ca au us...

Page 178: ...t to oo o l lo ow w A Ad dd d b br ra ak ke e f fl lu ui id d 11 25 11 25 T Th he er re e i is s a a v va ac cu uu um m l le ea ak k C Ch he ec ck k t th he e v va ac cu uu um m c ci ir rc cu ui it t...

Page 179: ...re improp The steering system components are improp erly lubricated erly lubricated Bring the vehicle to an authorized Bring the vehicle to an authorized Sterling Sterling service facility service fac...

Page 180: ...t Check the cause of the breakdown If you judge it readily repairable fix it while remaining alert to traf readily repairable fix it while remaining alert to traf fic If you are unable to repair it ca...

Page 181: ...t leak ot leaking fro ing from radi m radiator ator hoses or other parts of the cooling system hoses or other parts of the cooling system 2 2 Chec Check that t k that the fan be he fan belt is no lt i...

Page 182: ...cover ver align and i align and insert t nsert the tabs he tabs at the top Press the bottom of the cover into at the top Press the bottom of the cover into place place 2 2 Rem Remova oval an l and in...

Page 183: ...of a blown fuse cannot be deter mined or the same fuse blows frequently mined or the same fuse blows frequently bring the vehicle to an authorized Sterling bring the vehicle to an authorized Sterling...

Page 184: ...in nd do ow w d dr ri iv ve er r s s B B8 8 3 30 0A A Power window passen Power window passen ger s ger s B B9 9 2 20 0A A E En ng gi in ne e c co on nt tr ro ol l u un ni it t B B1 11 1 2 20 0A A H...

Page 185: ...y c co on nt tr ro ol l M M6 6 1 10 0A A A Au ut to om ma at ti ic c t tr ra an ns sm mi is ss si io on n M M8 8 1 10 0A A E Ex xh ha au us st t b br ra ak ke e M M9 9 5 5A A E En ng gi in ne e c co...

Page 186: ...cover place it on the box and press it straight down place it on the box and press it straight down ward ward Align Align the the holes holes of of the the latches latches with with the the catches c...

Page 187: ...S1 A1 A5 Fuse box S1 A1 A5 M1 M12 M1 M12 F FH H2 2 6 60 0A A y ye el ll lo ow w Fuse box Fuse box B1 B12 B1 B12 F FH H3 3 4 40 0A A g gr re ee en n Fuse box Fuse box B13 B16 B13 B16 F FH H5 5 6 60 0A...

Page 188: ...f one of these substances gets on a plastic lens immedi substances gets on a plastic lens immedi ately wipe it or rinse it ately wipe it or rinse it off with water off with water Burnt bulbs should be...

Page 189: ...V 2 21 1 5 5W W M MS S8 82 20 00 04 40 0 2 2 R Re ea ar r t tu ur rn n s si ig gn na al l 1 12 2V V 2 21 1W W M MS S8 82 20 00 04 46 6 2 2 B Ba ac ck ku up p l li ig gh ht t 1 12 2V V 2 21 1W W M MS...

Page 190: ...nd side side turn turn signal signal lens lens and and the the keeper keeper screw screw behind behind the the reflector reflector Continue Continue loosening loosening the the screws screws until unt...

Page 191: ...rew Turning the beam adjusting screw would Turning the beam adjusting screw would change the beam setting and could impair change the beam setting and could impair visibility for drivers of other vehi...

Page 192: ...d tighten tighten the the bottom bottom screw screw until until firm firm CAUTION CAUTION Do not tighten the bottom screw too much This Do not tighten the bottom screw too much This could damage the m...

Page 193: ...wise ise in in the the direction direction of of arrow arrow 2 2 Pull Pull the the conn connector ector towar toward d you you to to remo remove ve it it 3 3 Move Move the the wire wire reta retainer...

Page 194: ...the the lens lens 2 2 Push Push the the bulb bulb reta retainer iner in in the the direc direction tion of of the the arrow arrow and and remove remove the the bulb bulb 3 3 T To o inst install all th...

Page 195: ...s soon as it is safe to do so With the vehicle stopped try to it is safe to do so With the vehicle stopped try to start the engine start the engine Avoid Avoid sudden sudden braking braking Hold Hold...

Page 196: ...to th le to the posi e posi tive tive terminal terminal of of the the booster booster battery battery Con Con nect the other end of the nect the other end of the cable to the positive cable to the pos...

Page 197: ...l system can prevent the engine from starting In all the engine from starting In all of these cases bleed of these cases bleed the fuel system before starting the engine the fuel system before startin...

Page 198: ...d remove the ho ove the hose and c se and contai ontainer ner Wipe up any spilled fuel and dispose of used Wipe up any spilled fuel and dispose of used fuel properly fuel properly 9 9 St Start th art...

Page 199: ...operator towing vehicle operator CAUTION CAUTION Do not attach the towing device to the Do not attach the towing device to the bumper This could damage the bumper bumper This could damage the bumper B...

Page 200: ...commended lubricants hydraulic lubricants hydraulic fluids and quantities fluids and quantities 13 2 13 2 Service specifications Service specifications 13 4 13 4 13 Service data 13 Service data https...

Page 201: ...5 5 9 9 0 0 O Oi il l f fi il lt te er r 1 1 1 1 1 1 0 0 Manual transmission Manual transmission 5 5 s sp pe ee ed d 3 3 8 8 3 3 6 6 6 6 s sp pe ee ed d 4 4 6 6 4 4 4 4 Automatic Automatic transmissio...

Page 202: ...F3309 or Mobil ATF3309 or equivalent equivalent Axle housing Axle housing 1 1 G Ge ea ar r o oi il l A AP PI I G GL L 5 5 Below 104 Below 104 F 40 F 40 C C 9 90 0 Above 104 Above 104 F 40 F 40 C C 1 1...

Page 203: ...sed belt when inspected Used belt when inspected or reinstalled or reinstalled 0 39 to 0 43 in 0 39 to 0 43 in 10 to 11 mm 10 to 11 mm Coolant quantity Coolant quantity About 17 quarts About 17 quarts...

Page 204: ...14 1 14 1 Maintenance schedule Maintenance schedule 14 2 14 2 Lubrication schedule Lubrication schedule 14 6 14 6 14 Maintenance schedule 14 Maintenance schedule https www besttruckmanuals com...

Page 205: ...v v e e r r y y 5 5 4 4 0 0 0 0 0 0 m m i i l l e e s s 9 9 0 0 0 0 0 0 0 0 k k m m E E v v e e r r y y 1 1 5 5 0 0 0 0 0 0 0 0 m m i i l l e e s s 2 2 5 5 0 0 0 0 0 0 0 0 k k m m ENGINE ENGINE Coola...

Page 206: ...re in service man ual ual FRONT AND REAR AXLE FRONT AND REAR AXLE Wheel bearing Wheel bearing checking checking Check wheel hub bearing Check wheel hub bearing for play procedure in ser for play proce...

Page 207: ...ith the engine running With the engine running check the steering wheel check the steering wheel free play free play 11 41 11 41 Steering wheel Steering wheel operation check operation check ing ing W...

Page 208: ...fluid spray direction proper fluid spray direction and the wipers for normal and the wipers for normal operation operation 5 21 5 21 Lighting system Lighting system checking checking Make sure that e...

Page 209: ...Engine oil changing Manual transmission oil level checking Manual transmission oil level checking 11 20 11 20 Manual transmission oil changing Manual transmission oil changing Automatic transm Automat...

Page 210: ...15 1 15 1 15 Alphabetical index 15 Alphabetical index https www besttruckmanuals com...

Page 211: ...ns mendations 10 3 10 3 Controls ar Controls arrangement of rangement of 5 2 5 2 Coolant Coolant 10 2 10 2 11 33 11 33 Coolant c Coolant changing hanging 11 37 11 37 Cup Cup holder holder 9 6 9 6 Dang...

Page 212: ...locks 3 4 3 4 Mirror heat switch Mirror heat switch 5 23 5 23 Multifunction sw Multifunction switches itches 5 18 5 18 New New vehicle vehicle inspection inspection 1 4 1 4 Obtaining Obtaining service...

Page 213: ...6 8 Vehicle c Vehicle cleaning leaning 11 62 11 62 Vehicle identification number VIN Vehicle identification number VIN 1 3 1 3 Vehicle Vehicle operation operation 7 3 7 3 Vehicle operation Vehicle ope...

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Sterling Trucks 360 2006, Manual

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