Sterling 360 Driver'S And Maintenance Manual Download Page 207

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14-4

Maintenance schedule

SUSPENSION SYSTEM

Suspension

inspection

Check for broken springs.

Check the vehicle body for

tilt toward either side.

11-13

U-bolt torque

checking

At the first 600 miles/1 000

km, remove and tighten the

U-bolt nuts.

13-4

BRAKING SYSTEM

Service brake

pedal checking

Check brake pedal free play

and stroke.

11-42

Service brake

performance

checking

Depress the brake pedal

and check that the brakes

work effectively and evenly

on all wheels.

11-43

Disc brake

checking

Check brake pad and disc.

11-42

Parking brake

lever stroke

checking

Check parking brake lever

stroke.

11-44

Brake system

inspection

Inspect the brake lines and

hoses for signs of leakage.

Inspect the brake master

and slave cylinders.

11-42

STEERING SYSTEM

Steering wheel

free play checking

With the engine running,

check the steering wheel

free play.

11-41

Steering wheel

operation check-

ing

While driving slowly, check

steering wheel operation.

11-41

Steering system

inspection

Inspect the steering system

for looseness, steering

wheel play, and operating

condition.

Check for oil leaks.

Check the booster and oil

pumps for proper function.

11-41

CAB

Defroster opera-

tion checking

Make sure that warm air

blows properly onto the

windshield.

8-3,

8-7

Operation/

description

Time of inspection and maintenance

Remarks

Ref.

page

Pretri

p inspe

ctio

Initial Main

nan

at 2

500

mil

es/4

Inspection interval

Every 6

000

mile

10 00

0 km

Every 1

2,000

mile

20 00

0 km

Every 1

8,000

mile

30 00

0 km

Every 2

4,000

mile

40 00

0 km

Every 3

0,000

mile

50 00

0 km

Every 5

4,000

mile

90 00

0 km

Every 1

50,000

mil

es/

250

Summary of Contents for 360

Page 1: ...OWNER AND VEHICLE INFORMATION OWNER NAME USER COMPANY NAME MAILING ADDRESS CITY STATE ZIP VEHICLE IDENTIFICATION NUMBER DATE OF DELIVERY WARRANTY START DATE MO DAY YR SELLING DEALER IMPRINT HERE ...

Page 2: ...ntal Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regu lations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with ...

Page 3: ...that contains relevant information about the subject Q This manual contains important hazard messages under the following four headings that identify the nature and importance of the information Q California Proposition 65 Warning DANGER Imminent hazards that will result in severe personal injury or death WARNING Hazards or unsafe practices that could result in severe personal injury or death CAUT...

Page 4: ...nt cluster gauges and lights 6 1 7 Starting and driving 7 1 8 Heating and air conditioning 8 1 9 Interior equipment and accessories 9 1 10 In cold weather 10 1 11 Pretrip inspection and maintenance 11 1 12 In an emergency 12 1 13 Service data 13 1 14 Maintenance schedule 14 1 15 Alphabetical index 15 1 Each chapter has a table of contents on its first page ...

Page 5: ...1 1 Chassis and engine numbers 1 2 Power line label 1 2 Vehicle identification number VIN 1 3 Maintenance 1 4 Fuel 1 5 Reporting safety defects 1 8 Obtaining service 1 8 1 About your vehicle ...

Page 6: ...gine number The engine number is located on the left hand side of the crankcase The power line label is located on the passen ger s B pillar door post It gives the vehicle model chassis number and information about the compo nents of the powertrain engine transmission and axle Chassis and engine numbers Power line label Z11767a Example FE84DD Vehicle model Chassis number Example 4M50 Engine number...

Page 7: ...lic D 19 501 to 26 000 lb Air over hydraulic E 26 001 to 33 000 lb Air over hydraulic F 26 001 to 33 000 lb Full air Line A Sterling 360 COE 30 B Sterling 360 COE 40 45 C Sterling 360 COE 50 Series wheel base C 2 60 to 2 89 m D 2 90 to 3 19 m E 3 20 to 3 49 m F 3 50 to 3 79 m G 3 80 to 4 09 m H 4 10 to 4 39 m J 4 40 to 4 69 m K 4 70 to 4 99 m L 5 00 to 5 29 m M 5 30 to 5 59 m N 5 60 to 5 89 m P 5 ...

Page 8: ...ach working day This will ensure continued safe and comfort able operation P 11 7 3 Initial maintenance After you have traveled the first 2500 miles 4000 km your vehicle needs a free initial maintenance procedure When this mileage has been reached bring your vehicle to an authorized Sterling dealer and show them this manual At 2500 miles 4000 km have the dealer do the fol lowing Replace the engine...

Page 9: ... of diesel fuel The fuel supplier and the vehicle operator are both responsi ble for keeping the fuel clean 2 Danger of fire and explosion resulting from fuel mixtures Fuel containing 5 gasoline has a flash point as low as 32 F 0 C which can lead to a fire or explosion while the engine is running Fuel Use condition Recommendation Normal operation at temperatures above 10 F 12 C ASTM D 975 Grade Lo...

Page 10: ...tion system Be sure to clean the fuel tank cap and breather regularly If they become so dirty that the breather gets blocked the fuel tank may suffer damage and the fuel injection system may fail 4 Refueling NOTE If the vehicle runs out of fuel and air enters the fuel lines bleed the fuel system before starting the engine P 12 23 WARNING Do not refuel with the engine running Shut down the engine b...

Page 11: ...liters WARNING When filling the fuel tank using a gun type fuel pump do not continue pumping after the pump automatically stops The tank is full at this point When filling the fuel tank using any other method stop as soon as the fuel level becomes visible through the fill opening If the fuel level reaches the bottom of the opening fuel may leak though the check valve when the vehicle starts and st...

Page 12: ...nth St SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Canadian customers who wish to report a safety related defect to Transport Canada Defect Investi gations and Recalls may telephone the toll free hotline 1 800 333 0510 or contact Transport Can ada by mail at Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa...

Page 13: ...2 1 Locations in cab 2 2 Locations outside cab 2 4 2 Warning labels ...

Page 14: ...ed Sterling dealer The warning and caution labels apply only to the vehicle itself For vendor equipment mounted on the vehicle please refer to the equipment manufacturer s manual The locations of the caution and warning labels are shown in the illustration below Samples of each label are supplied on this and the following pages Locations in cab Z15073 Limited slip differential 30 gallon 113 liter ...

Page 15: ... Towing Automatic transmission Parking Automatic transmission Hydraulic brake booster Sterling 360 COE 50 Hydraulic brake system bleeding Sterling 360 COE 50 Main fuse box Z11770 Z11666 Z14889 Z11693 Z11694 Z12564 ...

Page 16: ...2 4 Warning labels Locations outside cab Z12496 ...

Page 17: ...2 5 Engine oil Automatic transmission fluid ATF Battery Radiator pressure cap ATF cooling fan Automatic transmission ATF cooler Automatic transmission Z10084 Z12549 Z08670 Z11680 Z11844 Z11773 ...

Page 18: ...2 6 Warning labels High amp fuse box Cab tilt reference 33 gallon 125 liter fuel tank Air conditioner Cab tilt safety Limited slip differential Z11803 Z14891 Z11678 Z13208 Z11804 Z10707 ...

Page 19: ...2 7 Warning labels 30 gallon 113 liter fuel tank Z12494 ...

Page 20: ...3 1 Doors 3 2 Master door locks 3 4 Entering and exiting the vehicle 3 5 Door window 3 6 3 Vehicle access ...

Page 21: ...trong wind Otherwise the wind could catch the door and suddenly blow it open causing a personal injury Exercise caution when opening a door on a downward slope Otherwise the inclina tion of the vehicle could cause the door to suddenly fall open causing a personal injury Never leave a child alone in the cab A child left in the cab could inadvertently operate the controls causing an accident or inju...

Page 22: ... lock button the passenger s door remains locked Only the driver s door is unlocked When you leave your vehicle be sure to remove the ignition key from the ignition switch to pre vent theft Be careful not to lock the doors with the ignition key inside the vehicle 2 From the inside To close use the door grab handle Close the door completely To lock the driver s door or passenger s door push the loc...

Page 23: ... forward the passenger s door is also automatically locked If the lock button on either door is subsequently pushed rearward only that door is unlocked When the driver s door is locked from the out side using the ignition key the passenger s door is automatically locked at the same time If the ignition key is subsequently used to unlock either door the other door remains locked Master door locks Z...

Page 24: ...ere is a greater likelihood of personal injury Always maintain three point contact with the vehicle while entering and exiting the cab Three point contact means both feet and one hand or both hands and one foot Do not hold luggage or other items in your hands when entering or leaving the vehi cle This could cause an injury Do not jump down from the vehicle Jump ing down from the vehicle could caus...

Page 25: ...s If water or any other liq uid gets on a window switch it can cause a mal function Door window WARNING Do not allow anyone to put their hands or head out of a window The head or hands could hit an object outside the vehicle and cause a serious injury WARNING When closing the window always make sure that there is nothing in the way of the window glass as it rises A closing window could cause a per...

Page 26: ...n in rainy weather and be careful not to spill liquid on any of the window switches If water or any other liq uid gets on a window switch it can cause a mal function WARNING When a child is in the cab be sure to press the power window lock switch to prevent the child from opening and closing the passen ger s window Otherwise the child may acci dentally operate the power window switch and get hands...

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

Page 28: ...ms slightly bent Seats WARNING To prevent injury do not adjust the seat while the vehicle is in motion The seat may move more than you intend Stop the vehicle and set the parking brake before performing any adjustment to the seat After you have adjusted the seat gently move or rock the seat to ensure that it is locked in the desired position If the seat moves while driving it could result in an in...

Page 29: ...ition Up Down 2 Passenger s seat Passenger s seat Middle seat Pull the backrest tilt lever to adjust the back rest angle While holding the lever grasp the top of the backrest and move it forward or backward to adjust the backrest angle as desired After adjusting the backrest angle or returning the backrest to its original position after tilting it forward gently rock the backrest to make sure it i...

Page 30: ...he left and right seats are equipped with 3 point lap and shoulder belts with Emergency Locking Retractor ELR while the middle seat has a 2 point lap belt Seat belts WARNING To prevent injury passengers must never be in the cargo area while the vehicle is in motion Do not move the vehicle unless all passengers are seated with their seat belts properly fastened Seat belts should be worn as low as p...

Page 31: ...d 4 Adjust the belt so it is across your hips and shoulder 1 2 Unfastening 1 Press the release button to unlock the buckle 2 The belt automatically retracts when unlocked To prevent the link causing damage or injury hold it while the belt retracts 3 Adjust the slide to put the link in an easy to reach position and prevent it from slipping 2 Lap belt 2 1 Fastening 1 Take care that the belt does not...

Page 32: ...about the use of seat belts before riding in the vehicle A pregnant woman should wear her seat belt as low as possible across the hips not across her abdomen 4 Seat belt care Periodically check the action of the mechanical parts such as the buckles links and emer gency locking retractor ELR units Check also for any damage that could stop the seat belts from functioning properly Replace the seat be...

Page 33: ...e steering column Release Lock Steering wheel WARNING After every adjustment try to move the steering wheel back and forth to make sure that it is securely locked Unless the adjusting lever returns to its original locked position the steering wheel may move while the vehicle is in motion This could cause an accident Make adjustments to the steering wheel with the vehicle stationary Adjusting the s...

Page 34: ... engine 5 10 Shutting down the engine 5 12 Pedals 5 13 Shift lever manual transmission 5 14 Shift selector automatic transmission 5 15 Overdrive lockout switch 5 17 Parking brake lever 5 17 Multifunction switches 5 18 Hazard flashers 5 22 Panel light switch 5 22 Dome light switch 5 22 Rearview mirrors 5 23 Mirror heat switch 5 23 5 Switches and controls ...

Page 35: ...ansmission Multifunction switch L H side headlight switch headlight high beam dimmer turn signal switch Low oil level switch P 11 18 Master door lock switch P 3 4 Engine warm up switch Shift selector automatic transmission Overdrive lockout switch Shift lock release knob Panel light switch Dome light switch Mirror heat switch optional Arrangement of switches and controls Z15080 Manual transmission...

Page 36: ...ld run down the battery Avoid using the ACC position for long periods since this could completely dis charge the battery Example listening to the radio with the engine shut down Ignition switch WARNING Never turn the ignition switch to any position other than ON while driving the vehicle Turning the ignition switch to the ACC position would create the following prob lems The engine would shut down...

Page 37: ...for cranking and start ing the engine Once the engine is running release the key and the switch will automatically return to ON NOTE Do not turn the key until it is fully inserted into the ignition switch If you are unable to turn the key gently turn the steering wheel back and forth as you turn the key To warm up the engine quickly or to make the heater work more effectively when the vehicle is n...

Page 38: ... the idle speed is correct NOTE If the engine idle control is used to increase engine speed while the engine warm up switch is ON the engine may produce black smoke Before turning ON the engine warm up switch be sure to set the engine idle control to AUTO Automatic control Engine speed is automatically controlled by moni toring the engine coolant temperature The engine speed automatically decrease...

Page 39: ...es are leaking have the exhaust pipe inspected by an authorized Sterling service facility If exhaust gases come into the cab ventilate the cab with fresh air by opening the doors and win dows Be sure to bring the vehicle to an authorized Sterling service agency for inspection and repairs Starting the engine WARNING Diesel exhaust will replace the air in an enclosed area possibly resulting in uncon...

Page 40: ...eplacement of the engine oil or the engine oil filter be sure to crank the engine before starting it If the engine pre heat indicator does not illu minate in cold weather the fuse for the preheat ing circuit may have blown and should be inspected P 12 13 If the engine pre heat indicator flashes the preheating circuit is malfunctioning Have it inspected by an authorized Sterling service facil ity I...

Page 41: ...sary for example if the engine stops while the vehicle is on a railroad crossing 2 Starting procedure 1 Turn the ignition switch to the ON position 2 Check whether or not the engine pre heat indicator illuminates If the engine pre heat indicator does not illu minate hold down the clutch pedal and turn the ignition switch to the START position to start the engine Do not depress the accelerator peda...

Page 42: ...engine CAUTION Pre cranking the engine is essential to protect the turbocharger 1 Make sure the parking brake is fully applied 2 Manual transmission vehicles Place the shift lever in neutral Automatic transmission vehicles Move the shift selector to P park 3 Without depressing the accelerator pedal place the ignition switch in the START position and pre crank the engine for about 15 seconds If the...

Page 43: ... you smell exhaust gases inside the cab inspect the exhaust pipe and check whether exhaust gases are leaking through holes or cracks caused by cor rosion or damage If exhaust gases are leaking have the exhaust pipe inspected by an authorized Sterling service facility If exhaust gases that have leaked from the exhaust pipe come into the cab ventilate the cab with fresh air by opening the windows fu...

Page 44: ...opriate value With the engine idle control turned to the automatic control position the engine s idle speed is adjusted automatically To make the engine warm up more quickly take the following steps 1 After the engine starts turn ON the engine warm up switch The exhaust brake indi cator will illuminate the engine speed will start to increase and the exhaust brake will operate NOTE Before turning O...

Page 45: ...g uphill or high speed driving Therefore allow some time for the engine to idle before shutting it down 4 To shut down the engine turn the ignition switch to the ACC position To remove the key turn the ignition switch to the LOCK position Shutting down the engine WARNING Never allow the vehicle to coast with the engine shut down This could cause dam age to the fuel injection system diminish brakin...

Page 46: ...edal This can shorten the service life of the clutch Riding the clutch pedal could pre vent the engine brake and exhaust brake from taking effect Depress the clutch pedal fully when changing gears If you do not depress the clutch pedal far enough the clutch will slip possibly damaging the clutch discs Pedals WARNING If you use a floor mat lay it correctly and make sure it is suitable for the size ...

Page 47: ...the clutch pedal fully before operating the shift lever Shifting with the clutch partly engaged can damage the transmission The gear pattern is inscribed on the top surface of the shift lever When the shift lever is placed in reverse R the backup lights illuminate At the same time the backup buzzer sounds Shift lever WARNING When backing up always double check to make sure that there is nothing in...

Page 48: ... out of P park unless the brake pedal is depressed Even with the brake pedal depressed the shift selector cannot be moved if the ignition switch is in the LOCK position or ACC position If the shift selector cannot be moved out of P park even with the ignition switch in the ON posi tion and the brake pedal depressed move the shift selector while pushing the shift lock release knob This problem can ...

Page 49: ...temperature of the transmission fluid is low a cold weather pro gram is implemented to accelerate transmission warm up Note that this program will be terminated when the fluid reaches a suitable temperature As a result of this program It may become difficult to make automatic gear shifts When the fluid temperature is extremely low the transmission may remain locked in 3rd gear when the gearshift l...

Page 50: ...ched off when engine brak ing is needed on a downhill grade or on long uphill grades In D drive the transmission shifts auto matically from 1st through 4th gears NOTE Even with the overdrive lockout switch in the OFF position the transmission will select 5th and 6th gears if there is any risk of engine overspeed Overdrive lockout switch Parking brake lever WARNING Do not use the parking brake when...

Page 51: ...educed effectiveness and the risk of a fire 1 Arrangement of switches Headlight switch Headlight high beam dimmer Turn signal switch Exhaust brake switch manual transmission Wiper washer switch 2 Headlight switch CAUTION Keeping the headlights on for a long period without the engine running can drain the bat tery making the engine difficult to start The headlight switch operates at any position of...

Page 52: ...igh beams and pull it back to the original position to return to the low beams When the high beams are on the high beam indicator illuminates 4 Turn signal switch Turn signal Move the lever downward to activate the left turn signal Move the lever upward to activate the right turn signal At the same time the corresponding turn signal indicator or flashes When the steering wheel is returned to the n...

Page 53: ...t lever remains in neutral for 10 seconds or longer The antilock brake system ABS is operating Full exhaust brake function will return as soon as the original conditions have been restored Automatic transmission vehicles CAUTION Do not place the shift selector in P park or N neutral while the vehicle is moving This would disable the exhaust brake but could cause transmission damage To turn ON the ...

Page 54: ...luid in the reservoir could damage the washer motor 1 Rotating the knob at the end of the lever acti vates the windshield wipers in one of the follow ing three modes INT Wipers operate intermittently at 3 to 5 sec ond intervals LO Wipers operate at slow speed HI Wipers operate at fast speed 2 If the wipers do not clean the windshield effec tively replace the wiper blades P 11 55 CAUTION Wiper blad...

Page 55: ...instrument cluster illuminated press and hold the rocker switch to make the lights brighter or dimmer as shown in the illustration When the lights have reached the desired brightness release the switch NOTE The panel lights can be brightened and dimmed only within a fixed range Once the lights have been brightened or dimmed to their full extent further pressing of the panel light switch has no eff...

Page 56: ...or heat when the engine is not running This can drain the battery and make it impossible to start the engine Rear view mirrors WARNING During normal driving adjust the mirrors so that a clear view to the rear is available When turning right or left use the rear view mirrors to ensure a safe clearance behind you Pay attention to the side rear view mirrors when driving on narrow roads Take partic ul...

Page 57: ...6 1 Instrument cluster layout 6 2 Speedometer 6 2 Tachometer 6 2 Coolant temperature gauge 6 3 Fuel level gauge 6 4 Warning and indicator lights 6 5 6 Instrument cluster gauges and lights ...

Page 58: ...ipmeter The distance covered by the vehicle from a selected point to its present location is shown to the nearest 0 1 mile The tripmeter has two indications TRIP A and TRIP B which can be set and displayed indepen dently of each other To return the current indication to zero press the trip knob for approximately 1 second or longer The indication will return to 0 0 The tachometer indicates engine s...

Page 59: ...on as it is safe to do so Use the engine idle control to run the engine at a speed slightly higher than normal idle If the vehicle has air conditioning turn it off When the gauge needle comes down to near the center of the scale shut down the engine and per form the checks and corrective actions described under If the engine overheats on this reference page P 12 7 CAUTION If the engine overheats d...

Page 60: ...el still remaining in the fuel tank F Full E Empty When the needle approaches the E mark refuel as soon as possible If the vehicle runs completely out of fuel air must be bled from the fuel system P 12 23 Fuel level gauge Manual transmission vehicles Automatic transmission vehicles Z12504 ...

Page 61: ...sufficiently charged Charge or replace the battery Warning and indicator lights WARNING A red warning light if illuminated warns you of a serious problem with the vehicle and possible accident danger Do not continue to drive the vehicle if a red warning light illumi nates Bring the vehicle to a complete stop and investigate the cause of the problem If necessary have your vehicle repaired by an aut...

Page 62: ...ow 6 9 Cab tilt warning The cab is tilted or not locked down 11 4 Transmission temperature warning Automatic transmission vehicles The automatic transmission fluid ATF is too warm 6 10 Water in fuel warning There is too much water in the fuel 6 10 Disc brake wear warning Vehicles with disc brakes The disc brake pads are worn 6 10 Green Engine oil level indicator Engine oil level is normal 11 17 Am...

Page 63: ...d Low engine oil pressure level warning Goes off when the engine is started Amber Check engine indicator Goes off when the engine is started Red Check engine warning Automatic transmission warning Automatic transmission vehicles Goes off a few seconds after the ignition switch is turned to ON Transmission temperature warning Automatic transmission vehicles Goes off a few seconds after the ignition...

Page 64: ...arning The brake warning illuminates as a bulb check when the parking brake is set With the ignition switch ON and the engine not running the brake warning stays on even when the parking brake is released The light will go out when the engine is started If this light illuminates while driving the brake fluid level has dropped below the safe limit On COE 50 the warning also illuminates accompanied ...

Page 65: ...ve turned out OK the problem is probably in the vehicle charging system Bring the vehicle to an authorized Ster ling service facility for repairs 4 Low engine oil pressure level warning The low engine oil pressure level warning illumi nates as a bulb check when the ignition switch is turned to ON Normally it goes out soon after the engine has started If the warning illuminates while the engine is ...

Page 66: ...rized Sterling ser vice facility for repairs 6 Water in fuel warning If the water in fuel warning is illuminated there is an excessive amount of water in the fuel filter Pull off the road as soon as it is safe to do so and drain the water from the fuel filter P 11 32 If the light does not go out or lights up frequently have the vehicle checked by an authorized Sterling service facility CAUTION Nev...

Page 67: ...rt the engine If the light stays off there is no problem If the light illuminates again shut down the engine and contact an authorized Sterling service facility 9 ABS warning The ABS warning illuminates as a bulb check when the ignition key is turned to ON It should go out a few seconds later If the light comes on again there is a malfunction in the antilock braking system ABS Should this light il...

Page 68: ...g The coolant temperature warning illuminates if the engine overheats With the engine overheated the needle in the coolant temperature gauge is in the red zone Stop the vehicle promptly Use the engine idle con trol to run the engine at a speed slightly higher than normal idle This allows the engine to cool When the gauge needle comes down to near the center of the scale shut down the engine and pe...

Page 69: ...ation 7 3 Improving fuel economy 7 6 Braking 7 7 Antilock braking system ABS 7 7 On uphill and downhill grades 7 9 On rough roads and in bad weather 7 11 Parking 7 12 Limited slip differential 7 14 Loading cargo 7 15 7 Starting and driving ...

Page 70: ...rain on the vehicle When pulling away do not race the engine and suddenly engage the clutch Do not ride the clutch for extended periods This can cause clutch damage automatic transmission Depress the brake pedal and move the shift selector out of P park If the engine s idle speed is too high the vehicle may lurch when selecting D drive or R reverse Make sure the engine is idling at normal speed be...

Page 71: ...cially careful during high speed driving Avoid sharp turns and hard braking except in emergencies When driving on narrow streets or when making a turn keep in mind that the tracking of the front and rear inner wheels is different Use the rear view mirrors to gain a clear view to the rear Remember that the mirrors protrude from the vehicle body Be careful not to hit pedestrians and obstructions wit...

Page 72: ...igh speeds in the rain it some times happens that the tires ride on a film of water and lose contact with the road surface This is known as hydroplaning If this should happen you will lose control of both steering and braking Slow down on rainy days Hydroplaning is more likely if tire tread is worn to the point where the tread pattern is very shallow Do not use the exhaust brake on slippery road s...

Page 73: ...the D range and use the overdrive lockout switch as road conditions permit P 5 17 It is possible to shift up using the shift selector the same as with a manual gearshift lever start ing in 2 then upshifting through 3 to D Do not place the shift selector in P park or N neutral while the vehicle is moving This would disable the engine brake and exhaust brake and lead to overuse of the service brakes...

Page 74: ...vehicle with an automatic transmission use overdrive as road conditions permit This will increase fuel economy Try to drive at moderate and constant speeds Unnecessary acceleration and deceleration wastes fuel In a vehicle with a manual transmission do not leave the exhaust brake switch ON all the time Too much use of the exhaust brake reduces fuel economy Use the exhaust brake as necessary depend...

Page 75: ... that operates automatically without the need for driver intervention Braking WARNING If any of the brake warning lights illumi nate there is a possibility of brake failure Brake failure could cause an injury acci dent or loss of life Do not use the exhaust brake on slippery road surfaces The vehicle may skid caus ing an injury accident or loss of life Avoid sudden braking except in emergen cies S...

Page 76: ...t vibration noticeable in the vehicle body and also in the brake pedal The sound of the solenoid in operation may be heard These sounds indicate ABS is operating normally Continue to apply the brakes When ABS starts to function after sudden brak ing the steering wheel may be pulled slightly to one side because of braking power distribution control made by the system Especially in a situ ation wher...

Page 77: ...reasing the engine speed 2 Downhill grades Before driving down a long or steep downhill grade test the service brakes and exhaust brake to make sure that they are OK Downshift into the same gear used on the uphill grade Use the engine brake and exhaust brake to help slow the vehicle Never drive downhill at high speeds On vehicles with automatic transmission do not leave the shift selector in D dri...

Page 78: ...ich the brake pads overheat This reduces friction significantly and results in poor braking Reduce engine speed before downshifting Do not downshift more than two gears at a time This could cause engine overspeed tachometer needle in the red zone As a rule reduce engine speed to roughly 2 000 rpm before downshifting Make sure the tachom eter needle does not enter the red zone In an automatic trans...

Page 79: ...kes together to slow the vehicle Sudden use of the engine brake by itself can cause a skid Drive at a com fortable speed and stay in control of the vehicle If the brakes become wet either from driving into water or after a washing braking perfor mance can be reduced With wet brakes drive slowly and put light pressure on the brake pedal This will dry out the brakes If you cannot avoid driving the v...

Page 80: ...ke automatic transmission Set the parking brake with the brake pedal depressed Then move the shift selector to P park Parking WARNING Park the vehicle on a level surface if avail ble Avoid parking on slopes The vehicle could roll and cause an injury accident The engine and exhaust pipe are extremely hot immediately after the vehi cle has been driven Do not park the vehi cle in any place where ther...

Page 81: ... or ACC position This could discharge the battery Be sure to turn off all lights after parking to prevent discharging the battery 5 If parking on a slope is unavoidable chock all the tires securely and turn the wheels in the direction of roll Take any other necessary mea sures to prevent the vehicle from moving WARNING Brake faults that would cause the warn ing light to illuminate have no effect o...

Page 82: ...on It requires no driver intervention However it cannot prevent all skids Follow safe driving practices to minimize opportunities for skidding On slippery road surfaces do not accelerate through turns This could cause the vehicle to skid Keep your tires inflated to the same air pres sure Unevenly inflated tires may cause the vehicle to pull to one side during acceleration They will also eventually...

Page 83: ...Ratings GAWR To find the vehicle s GVWR front GAWR and rear GAWR look on the vehicle identification plate located inside the driver s door as shown NOTE If the vehicle is loaded to a weight almost equal to a total of the front and rear GAWRs it may exceed the GVWR If either weight limit is exceeded the vehicle is overloaded Example a vehicle has a GVWR of 12 000 lb 5 445 kg and also has a front GA...

Page 84: ...of the cargo deck To prevent cargo from falling strap it down securely and cover it with a tarpaulin Secure the tarpaulin ends neatly so they do not flap WARNING When securing a load with rope or cover ing it with a tarpaulin make sure that nei ther the rope nor the end of the tarpaulin hang down between the cab and the cargo deck A rope or tarpaulin that hangs down below the frame could catch fir...

Page 85: ...8 1 Front air outlets 8 2 Heater 8 3 Air conditioner 8 7 Outside air inlets 8 11 8 Heating and air conditioning ...

Page 86: ...ction Adjust the left right airflow direction from each outlet as desired by moving the knob to the left or right Adjust the up down airflow direction from each louvered outlet as desired by pressing the top or bottom of the louver Front air outlets Z14908 Z14909 ...

Page 87: ... Temperature control switch Recirculation button 1 1 Fan switch The fan switch allows you to adjust the fan speed To increase fan speed turn the dial clockwise in the direction of arrow To reduce fan speed turn the dial counterclockwise in the direction of arrow 1 2 Temperature control switch The temperature control switch allows you to adjust the cab temperature To make the cab warmer turn the di...

Page 88: ... or smoky This setting can be used when parking to prevent dust from entering the cab CAUTION Do not use the recirculated air setting for a long period of time 20 minutes or more This will cause the air in the cab to become stale If this happens toggle to the fresh air setting NOTE Select fresh air during normal driving Do not select recirculated air when the humidity is high This makes the window...

Page 89: ...frost positions 1 With the switch in the floor defrost 75 25 position most of the air is directed toward the feet and the rest of the air is directed toward the windshield 2 With the switch in the floor defrost 50 50 position air is directed equally toward the feet and windshield For airflow toward the windshield Place the air selection switch in the defrost position Z14912 Z14913 Z14914 Z14915 ...

Page 90: ...sition If you wish to defog the windshield quickly turn the dial on the fan switch clockwise to maximum fan speed To defrost the windshield faster also turn the dial on the temperature control switch clockwise to maxi mum temperature 2 4 To ventilate the cab Press the recirculation button to select fresh air and turn the dial on the air selection switch to the face position 3 Cleaning the HVAC air...

Page 91: ...e control to raise the engine s idle speed when the air conditioner is operating A fast idling device can be installed by any authorized Sterling service facility 1 Using the climate control panel A C air selection switch Fan switch Temperature control switch Recirculation button Air conditioner button Air conditioner WARNING Do not leave children alone in the cab even with the air conditioner A C...

Page 92: ...ab warmer turn the dial clockwise in the direction of arrow To make the cab cooler turn the dial counterclockwise in the direction of arrow 1 3 Recirculation button The recirculation button allows you to choose between fresh outside air or recirculated inside air Recirculated air is automatically selected when the air conditioner is on When recirculated air is selected the recirculation indicator ...

Page 93: ...et as desired For cool airflow toward the upper body Place the air selection switch in the face position For cool airflow toward the upper body and toward the feet Place the air selection switch in the bi level position For cool airflow toward the feet Place the air selection switch in the foot position For cool airflow toward the feet and toward the windshield Place the air selection switch in on...

Page 94: ...g the refrigerant level If the level of the refrigerant is too low the A C will not work as well Check the refrigerant level when ever a problem appears Set the air conditioner to maximum turn the dial of the fan switch to maxi mum speed position and the dial of the temper ature control switch to maximum cooling position Observe the sight glass through the grille Check for the presence of bubbles ...

Page 95: ... ozone layer Since charging the system with this refrigerant requires a method different from the conventional method be sure to contact an authorized Sterling service facility to service your A C 4 Cleaning the HVAC air filters Clean the air filters in the heating ventilation and air conditioning HVAC system every 6 months A dust loaded HVAC filter can cause malfunction of the blower motor P 11 6...

Page 96: ...9 1 Cigarette lighter 9 2 Ashtrays 9 3 Coat hooks 9 4 Sun visors 9 4 Dome light 9 4 Storage compartments 9 5 Radio 9 7 Accessories 9 8 9 Interior equipment and accessories ...

Page 97: ... plug a cigarette lighter from another vehicle into your vehicle s socket Your vehicle s cigarette lighter is designed for a 12 V power supply Do not use a 24 V cigarette lighter Cigarette lighter WARNING Do not allow a child to touch the cigarette lighter This could cause a burn injury Do not touch the metallic parts of the ciga rette lighter This could cause a burn injury Do not hold the cigaret...

Page 98: ... the ashtray be careful not to strike it too hard since it could break Replace a broken ashtray with a new one Ashtrays WARNING To prevent fires close the lids on the ash trays completely Use the ashtray only for smoking materi als Empty the ashtray regularly An over crowded ashtray could cause a fire Do not throw smoking materials out of the windows This endangers the environment and could start ...

Page 99: ...k of the driver s sun visor The dome light can be used with the ignition switch in any position CAUTION Always turn off the lights before you leave the vehicle Do not leave the dome light illuminated for a long period of time when the engine is not running This can discharge the battery and pre vent the engine from starting 1 Dome light ON position The light illuminates with the door open or close...

Page 100: ...ll while the vehicle is moving Rolling items could dam age the cab interior Storage compartments WARNING Always close the storage compartments before operating the vehicle Open storage compartment covers could cause an injury in the event of a collision or sudden stop Z14919 1 Accessory box 2 Hook 3 Door pocket 4 Bottle holder 5 Center console 6 Rear panel box 7 Cup holder 8 Seatback trays 9 Glove...

Page 101: ...in the tray When not in use keep the cup holders retracted inside the dash A fuse box is located below the cup holder Be careful not to splash liquids on the fuse box cover Seatback trays The passenger s seat and the middle seat each have a tray in the back of the seat To use the tray tilt the backrest forward Glove compartment Map compartment Parcel tray Use the glove compartment map compartment ...

Page 102: ... audio equipment The radio can be used with the ignition switch in the ON position or ACC position CAUTION Using the radio for an extended period of time without the engine running could discharge the battery Extend the antenna before using the radio Retract the antenna when it is likely to cause an obstruction Example when tilting the cab Radio Z11989 Z12007 ...

Page 103: ... these are protected against interference from electromagnetic emissions you should consult an authorized Sterling dealer before adding equipment that emits electronic signals such as mobile telephones Accessories WARNING To avoid the risk of personal injuries caused by overheating fire or electrical damage have accessories connected by an autho rized Sterling service facility Z00020 ...

Page 104: ...10 1 Coolant 10 2 Engine oil 10 2 Fuels 10 2 Cold weather operation 10 3 Installing tire chains 10 4 10 In cold weather ...

Page 105: ... the cooling system before adding a new brand of coolant At low temperatures the viscosity of engine oil increases This can make it hard to start the engine especially early in the morning Therefore choose engine oil with a viscosity that is appropriate for the weather conditions P 11 17 Ordinary summer grade 2 D diesel fuel reaches its cloud point in freezing weather making it impos sible to star...

Page 106: ...icle If the brakes freeze either from driving on snow covered roads or while parked in cold weather braking performance can be reduced Drive carefully and be alert to other traffic With frozen brakes drive slowly and put light pressure on the brake pedal This will warm the brakes When parking your vehicle select a site not directly exposed to wind or snow Face it away from the wind Do not apply th...

Page 107: ...age the chains and the road sur face Remove your chains as soon as possi ble after you come back on dry road Make sure that the chains and their spring bands are not excessively worn or otherwise damaged If you hear an abnormal noise while driving stop the vehicle in the nearest safe place and check the tire chains 1 Place the chains over the tires with the hook ends of the cross chains facing out...

Page 108: ...e tire side walls Also make sure that the chains are not twisted 7 Fasten extra chain links with a metal wire to pre vent them from hitting against other vehicle components 8 Fit the spring band Attach the hooks of the spring band to the chain at regular intervals with the hook ends facing outward 9 After driving the vehicle for 5 to 10 minutes check the chains Tighten any loose chains and connect...

Page 109: ...hift selector checking automatic transmission 11 40 Steering wheel checking 11 41 Service brake checking 11 42 Parking brake checking and adjusting 11 44 Clutch checking 11 44 Tire checking 11 45 Tire replacing 11 48 Wheel nut tightening 11 53 Tire rotation 11 54 Wiper blade replacing 11 55 Windshield washer fluid level checking and refilling 11 56 Battery inspection 11 57 HVAC filter cleaning 11 ...

Page 110: ...ted accesso ries Use extreme care when tilting the cab with the engine running Chock all the tires fore and aft set the parking brake and place the transmission in park If the engine is running the vehicle could move causing an accident that could result in personal injury or property damage After lowering the cab check that it is locked securely in position P 11 5 To avoid burns do not touch the ...

Page 111: ...ontainer ready to catch the drained fluid Water emitted by the exhaust pipe is slightly acidic and could cause your hands to be chapped If you touch this water rinse it off under a faucet Take great care when working near the fan and fan belt Never touch them when they are mov ing The transmission cooling fan in an automatic transmission vehicle switches on automatically when the fluid temperature...

Page 112: ...any other control in the cab while the cab is tilted Before tilting the cab make sure there is ade quate clearance in front of the cab and above it see table and that the area is free of people and all objects If there are any obstructions within the clear ance areas shown above remove them Retract the radio antenna Tilting the cab WARNING Never tilt the cab when the vehicle is on any kind of slop...

Page 113: ... the safety release lever C The cab will rise slightly 3 Use the tilt grip to raise the cab After confirming that the lock lever is hooked onto the cab stay and the stay is secured fit the hold down into the notch in the lock lever The cab stay must be completely straight for the hold down to engage in the notch WARNING Be sure to fit the hold down into the notch in the lock lever to prevent the c...

Page 114: ...e hook on the safety release lever C engages with the cab mount WARNING Before lowering the cab make sure that you have not left flammable objects inside the engine compartment This could cause a fire and result in burn injuries The cab could drop suddenly causing a personal injury if there are heavy objects inside or on the roof deck Always lower the cab slowly and provide adequate sup port When ...

Page 115: ... the cab again repeat the lowering procedure from the beginning and lock it again NOTE Sometimes the switch that activates the cab tilt warning does not pop out when lever B is locked in place If you continue to get a warning light with lever B locked move the switch manually if neces sary if this does not work replace the switch Use the following pretrip inspection checklist to help ensure that t...

Page 116: ...OW marks on the surge tank P 11 35 Drive belt Check the belt for proper deflection when a force of 22 lb 98 N is applied to the point mid way between the pulleys Tighten it if neces sary Check the belt for nicks or other damage Replace it if necessary P 11 39 Engine oil level Check the engine oil level using either the dip stick or the low oil level switch P 11 18 Coolant fuel and oil leaks Check ...

Page 117: ... condition Check the engine for smooth starting and quiet running Parking brake lever stroke Check that the parking brake lever stroke is between 7 and 9 notches P 11 44 Service brake pedal With your hand depress the brake pedal and make sure it has 0 004 to 0 118 in 0 1 to 3 0 mm of free play Check also that when the brake pedal is fully depressed there is a gap of 0 79 in 20 mm or more between t...

Page 118: ...he bottom of the inspection window P 11 56 Steering wheel Gently turn the steering wheel from side to side Make sure that it has free play of more than 0 2 in 5 mm and less than 2 0 in 50 mm P 11 41 Horn operation Press the horn button to check that the horn is working properly Windshield wiper and washer Check the washer for proper fluid spray direc tion and the wipers for normal operation P 5 21...

Page 119: ... 18 Instrument cluster Check that all gauges and telltale warning and indicator lights are working properly P 6 2 Rear view mirrors Seated in the driver s seat adjust the mirrors for clear views to the sides and rear Make sure the mirrors are clean Door lock operation Push the lock button and verify that the door does not open even when the inner handle is operated P 3 3 Z11696 Z12505 Z11949a Z119...

Page 120: ...rectly P 4 4 Wheel and tire Check the disc wheels for cracks and other damage Check the tire inflation pressure and tread groove depth Check the tires for foreign objects in the tread grooves cracks in the tread and signs of uneven wear P 11 45 Crack in tread Properly inflated Overinflated Underinflated Z11943 Z10752b Z15025a ...

Page 121: ...icense plate and reflectors for loose installation damage and dirt Steering wheel operation While driving slowly check that the steering wheel does not vibrate or pull to one side and that it is not hard to turn Also make sure that the steering wheel returns to its neutral position smoothly P 11 41 Brake function Depress the brake pedal and check that the brakes work effectively and evenly on all ...

Page 122: ...perature lubricants must be used if the vehicle is operated at temperatures below 10 F 23 C For details consult an authorized Sterling service facility CAUTION Apply and replace lubricants regularly Use of lubricants beyond their designed service life could cause bearings or other compo nents to seize and cause an accident Wipe all lubricant inspection windows and filling ports carefully to preven...

Page 123: ...p Rear spring pin forward 2 points total one on each side Rear spring pin aft 4 points total 2 on each side Z12034 FE 1 Rear spring pin forward 2 Rear spring pin aft 3 King pin bearing 4 Propeller shaft universal joint 5 Propeller shaft slip joint Z09225 Z09226 ...

Page 124: ...eshaft slip joint NOTE The number of grease fittings on the propeller shaft differs from model to model 2 Door hinge 8 places total 4 on each side Recommended lubricant Chassis grease NLGI No 1 Li soap 3 Anchor hooks two places Recommended lubricant Chassis grease NLGI No 1 Li soap Lubrication interval Every 6000 miles 10 000 km Lubrication interval Every 6000 miles 10 000 km Z09227 Z09228 Z09392 ...

Page 125: ...will damage the engine Be sure to use engine oil with a classification of CD or higher Quantity required approximate The engine oil level can be checked by using either the dipstick or the low oil level switch on the instru ment panel The low oil level switch is for a quick check Use the dipstick for a more accurate check NOTE To check the engine oil level park the vehicle on a level surface and s...

Page 126: ... dipstick into the crankcase and slowly draw it out 4 The oil level that appears on the dipstick should be in between the two notches as shown in the illustration If necessary add the recommended engine oil If the engine oil is extremely dirty change it 5 After the check insert the dipstick into the guide tube and secure it properly 1 3 Adding oil 1 Clean the area around oil filler cap to prevent ...

Page 127: ...rain plug hole 4 Install the drain plug 5 Carefully add fresh engine oil through the oil filler hole 6 Wait for more than 5 minutes and check the oil level using the dipstick 7 Crank the engine with the ignition switch then start the engine P 5 8 8 Let the engine idle allowing oil to circulate throughout the engine Then shut down the engine and wait for more than 30 minutes before checking the oil...

Page 128: ...al transmission oil Change the transmission oil for the first time at the initial maintenance period of 2500 miles 4000 km Recommended oil Gear oil API classification GL 3 SAE80 general GL 3 SAE90 warm weather region GL 4 SAE90 tropical region Engine oil API Classification CC SAE30 or 40 for long periods of high speed driving Inspection interval Every 6000 miles 10 000 km Replacement interval Ever...

Page 129: ... and dispose of it properly NOTE After operation let the transmission cool for about 30 minutes before draining the oil The oil will drain more quickly while it is still warm 2 Clean the magnetic drain plug before installing it Use a piece of key stock or any other conve nient steel slug to short the two magnetic poles and divert the magnetic field 3 Add oil through the fill plug hole until it is ...

Page 130: ...ed leave the shift selector in P park Remove the ATF dipstick and wipe it clean with a shop towel NOTE The ATF dipstick is located behind the cab If it is difficult to remove tilt the cab 3 Fully insert the dipstick into the gear case and slowly draw it out 4 The fluid level that appears on the dipstick should be between the two notches in the HOT range 5 If the fluid level is too low add fluid th...

Page 131: ...r SAE85W 140 if the vehicle is to be driven under heavy load Example when driving long uphill grades This oil is to be used only when the temperature is higher than 50 F 10 C On vehicles with a limited slip differential fill the differential with Genuine Gear Oil Part No 8149630EX GL 5 SAE90 Quantity required approximate These oil quantities are given only as guidelines Be sure to check the correc...

Page 132: ...used axle oil in a suitable container and dispose of it properly NOTE After operation let the transmission cool for about 30 minutes before draining the oil The oil will drain more quickly while it is still warm 2 Clean the magnetic drain plug before installing it Use a piece of key stock or any other conve nient steel slug to short the two magnetic poles and divert the magnetic field 3 Add oil th...

Page 133: ...ooner Inspection interval Daily pretrip inspection Replacement intervals Every 30 000 miles 50 000 km or every two years WARNING Hydraulic brake fluid is hazardous and can cause blindness if it gets into your eyes Always wear safety glasses when handling brake fluid or bleeding brake components Brake fluid may also be a skin irritant If you get it on your skin wash it off as soon as possible The h...

Page 134: ...2 If the fluid level is lower than the MIN line remove the reservoir cover and clean the sur faces around the reservoir cap Remove the cap and add recommended brake fluid up to the MAX line 3 Close the cap and tighten it until firm Install the reservoir cover 6 Power steering fluid Have power steering fluid changed by an autho rized Sterling service facility Recommended fluid Automatic transmissio...

Page 135: ...7 The fluid level should be between the MAX and MIN lines If the fluid level is below the MIN line clean the area around the power steering reservoir cap Remove the cap and add power steering fluid until it reaches the MAX line 8 Install the cap and tighten it until firm Wipe up any spilled fluid 9 Lower the cab and remove the chocks from the tires CAUTION Operating the power steering with the flu...

Page 136: ...e filter head for dirt and contamination If necessary clean it 6 Replace the filter element assembly with a new one Use only genuine replacement parts 7 Install the filter element assembly Apply a thin coat of engine oil to the gasket on the mounting surface of the filter element assembly Turn the assembly counterclockwise in the direction of arrow until the gasket touches the sealing surface of t...

Page 137: ...uel could leak and the filter itself could become damaged If you do not have the special tool please contact an authorized Sterling service facility Be careful not to damage the filter case as this could cause a fuel leak Oil filter capacity About 1 1 quart 1 0 L Replacement intervals Every 12 000 miles 20 000 km or every 12 months WARNING Diesel fuel is combustible and can ignite if exposed to op...

Page 138: ... case O ring and the sensor O ring Apply a thin coat of engine oil to each of the new O rings and install one O ring on the filter case and one O ring on the sensor 10 Clean the surfaces of the filter head and fil ter case where they come in contact with the fil ter case O ring Make sure that the O ring slot in the filter case is clean 11 Install the element with the open end facing upward Use a g...

Page 139: ...der liners 1 Check the air cleaner hoses and lines for dam age and leaks Check all clamps and make sure they are tight 2 Undo the three clamps and remove the air cleaner cover 3 Pull the element straight down and remove it from the air cleaner 4 Inspect the element and packing for dirt and damage If the packing is damaged or the filter paper is torn worn through or heavily contami nated with oily ...

Page 140: ... sensor 6 Bleed the fuel system P 12 23 7 Start the engine and check for fuel leaks Check the fuel tank cap and lines for leakage Correct any leaks found Fuel filter draining WARNING Diesel fuel is combustible and can ignite if exposed to open flame intense heat or other source of ignition A fire could result in burn injuries or loss of life Be careful when gaining access to the fuel filter Cleara...

Page 141: ...ater with the properties shown in the fol lowing table Do not use hard water from wells and rivers as it is liable to form scale and cause corro sion 3 Using coolant additive To prevent the cooling system from freezing and to minimize corrosion use a fully formulated anti freeze with an ethylene glycol base SAE J814 C an antifreeze with corrosion inhibiting properties Dilute it with soft water to ...

Page 142: ...WIPE IT OFF AND THEN THOROUGHLY WASH YOUR SKIN WITH LOTS OF CLEAN WATER AND SOAP IF YOU FEEL UNWELL OR PAIN ON YOUR SKIN IMMEDIATELY SEEK MEDICAL ATTENTION IN THE EVENT OF CONTACT WITH YOUR CLOTHES IMMEDIATELY FLUSH THE COOLANT WITH WATER AND SOAP DO NOT USE COOLANT IN A CLOSED OR POORLY VENTILATED SPACE SHOULD YOU INHALE A LARGE AMOUNT OF COOLANT VAPOR MOVE TO A PLACE WITH FRESH AIR AND KEEP YOUR...

Page 143: ...nt gets hot it expands making the level appear higher than it actually is Deposition may occur in the surge tank This will not cause any problem Check that the coolant level is between the FULL and LOW marks on the surge tank If the coolant level is below the LOW mark add coolant until the level reaches the FULL mark Check for coolant leakage from the radiator and radiator hoses If you find water ...

Page 144: ...llow the engine to cool down Run it at a speed slightly higher than normal idle P 5 5 2 When the needle in the coolant temperature gauge has come down to the center of the scale shut down the engine and do the follow ing steps Check the cooling system for leaks Inspect the drive belt Replace it if damaged P 11 39 Check the belt tension Correct the belt ten sion if necessary P 11 39 3 Tilt the cab ...

Page 145: ...ge tank NOTE To drain coolant without splashing connect a hose to the nozzle below the engine drain plug 6 After the coolant has been completely drained close both the engine drain plug and the radiator petcock 7 Flush the cooling system Pour warm water through the pressure cap opening Refit the pressure cap tightly by turning it clockwise Lower the cab Start the engine Run the engine at a moderat...

Page 146: ...he vehicle and then check the coolant level 12 Lower the cab 13 Fill the surge tank with coolant in the correct mixing ratio to the FULL mark Install the surge tank cap and make sure it is tight 14 Start the engine and keep it running at a speed slightly higher than normal idle This will remove air from the cooling system When the engine reaches normal operating temperature allow the engine to idl...

Page 147: ...n in the table below 4 Check the belt for damage Replace the belt if damage is found Drive belt checking and adjusting Inspection intervals Daily pretrip inspection and every 6000 miles 10 000 km or every 12 months WARNING Always shut down the engine before inspect ing or adjusting belts A moving drive belt can cause a serious injury or loss of life Ensure that the engine cannot be started while y...

Page 148: ...nsmission Do the following checks with the engine shut down 1 Set the parking brake Make sure it is fully applied 2 Turn ON the ignition switch but do not start the engine 3 Move the shift selector through each position and check the following Check that the shift selector operates smoothly and clicks into range at each posi tion P through 2 Check if the shift indicator in the instrument cluster i...

Page 149: ... in the counterclock wise direction 5 Measure the amount of steering wheel move ment between these two points This is the steering wheel free play If the free play is not within these limits contact an authorized Ster ling service facility 2 Steering wheel looseness NOTE Before doing this check make sure that the adjust ing lever is in the locked position 1 Move the steering wheel back and forth o...

Page 150: ... system zero vac uum 5 Press down with one finger on the center of the pedal pad to the point where resistance is felt 6 Measure the amount of brake pedal movement between these two points This is the brake pedal free play If the free play is not within these limits contact an authorized Sterling ser vice facility 1 2 COE 50 hydraulic brake booster 1 Shut down the engine 2 Set the parking brake an...

Page 151: ...f they do not illuminate drive the vehicle at low speed to make sure that the brakes work effec tively and evenly on all four wheels If there is any problem do not continue to operate the vehicle Contact an authorized Sterling service facility for a more thorough inspection 4 Hydraulic brake booster performance COE 50 only 1 With the engine shut down depress the brake pedal 2 Check that the brake ...

Page 152: ...h a dry road surface 2 Set the parking brake and check that the parking brake can hold the vehicle If an appropriate downgrade is not available drive the vehicle at low speed activate the parking brake and check that it can stop the vehicle at speeds under 10 mph 16 km h 3 If there is any problem contact an authorized Sterling service facility Manual transmission vehicles Check the clutch for cond...

Page 153: ...to gear 4 Release the clutch pedal slowly The clutch should engage smoothly without slipping 5 If the clutch shows signs of wear replace it at an authorized Sterling service facility 1 Inflation pressure check Always check tire pressure before driving when the tires are still cool Make sure that the valve caps are securely fitted on each tire The tire tread profile can give a rough estimate of the...

Page 154: ...rly close attention to the air pres sure in new tires New tires tend to expand slightly with a corresponding decrease in air pressure On dual wheels inflate both inner and outer tires to the same pressure It is not necessary to increase tire pressure before high speed driving Model Tire size Inflation pressure psi kPa COE 40 45 LT215 85R16 10PR Load Range E 80 550 COE 50 215 75R17 5 124 123L Load ...

Page 155: ...n a vehicle hydroplanes tires ride up on and slide over a film of water causing the driver to lose control of both steering and braking 3 Checking for cracks damage and objects embedded in tread Check the tread surface and sidewalls of each tire for cracks damage and excessive or unusual wear Check for metal pieces nails and stones embed ded in the tread or caught between the tires on dual wheel a...

Page 156: ...e 4 Have all passengers get out of the vehicle 5 Chock the tire diagonally opposite to the tire to be replaced Set chocks fore and aft Example If the right rear tire is to be replaced chock the left front tire fore and aft 6 Obtain a replacement tire NOTE Your vehicle is not provided with a replacement tire as standard equipment See the table for a list of approved tires 2 Vehicle jacking points 2...

Page 157: ...r raising the vehicle slightly confirm that the jack is firmly seated at the jacking point and will not move when the vehicle is raised If the jack were to slip out of position with the vehicle fully raised the vehicle could fall and cause a serious injury Never start the engine with the vehicle raised on a jack Likewise do not rock the vehicle or crawl underneath it Movement of the jack could res...

Page 158: ... of the ground 5 Remove the wheel nuts and then the wheel and tire assembly NOTE To remove the tires on a dual rear wheel first loosen the outer wheel nuts and remove the outer wheel Lower the jack loosen the inner wheel nuts and raise the vehicle again to remove the inner wheel CAUTION When removing wheels be careful not to dam age the wheel studs and the threads of the inner wheel nuts WARNING M...

Page 159: ...d the wheel NOTE The studs and nuts have stamped marks for easy identification an R mark for right hand threads and an L mark for left hand threads 3 Lower the vehicle slowly until the tire makes contact with the ground 4 Tighten the wheel nuts in three stages ending with the final torque shown in the table Use the tightening sequence shown in the illustration WARNING Dirt or debris in the wheel m...

Page 160: ... of a dual wheel set tighten the inner wheel nuts to the required torque before mounting the outer wheel WARNING Make sure the socket is firmly seated on the wheel nut If not the wrench could slip off the nut and cause a personal injury Tighten all wheel nuts to the required torque value When replacing the outer wheel in a dual wheel set be sure to tighten the inner wheel nuts before tight ening t...

Page 161: ...easy identification an R mark for right hand threads and an L mark for left hand threads Wheel nut tightening Inspection interval Every 6000 miles 10 000 km WARNING After changing a tire the wheel nuts will loosen somewhat as they wear in creating a potential for an injury accident Tighten the wheel nuts again after you have driven 30 to 60 miles 50 to 100 km Wheel nut torque 325 to 398 lbf ft 440...

Page 162: ...different tread patterns on the front and rear wheels select tires with a ribbed tread for the front wheels and tires with a traction type tread for the rear wheels Tire rotation Tire rotation intervals Every 6000 miles 10 000 km Model Tire size COE 40 45 LT215 85R16 10PR Load Range E COE 50 215 75R17 5 124 123L Load Range F WARNING Be sure to use tires of the approved type Mixing bias and radial ...

Page 163: ...r arms back into position or operate the wipers without wiper blades This could scratch the windshield 2 Replacing the rubber element 1 Raise the wiper arm and turn it over 2 Pinch both sides of the rubber element with your fingers Pull the element so that the jaws of the blade carrier release from the notches in the tension strip 3 Slide the rubber element out of the blade carrier 4 Replace the o...

Page 164: ...er until the level reaches the top of the check window 3 Close the cap tightly after refilling CAUTION Do not substitute soapy water for washer fluid This could result in clogged washer nozzles or spots on the painted surfaces of the cab Operating the washers continuously for more than 20 seconds or when there is no fluid in the reservoir could burn out the washer motor NOTE When it is very cold i...

Page 165: ...ttery inspection DANGER PROTECT SKIN AND EYES FROM BATTERY ELECTROLYTE ELECTROLYTE IS CORRO SIVE AND COULD RESULT IN SERIOUS PER SONAL INJURY WARNING The batteries generate explosive gases Keep them away from open flames and sparks When handing batteries always wear eye protection Exploding gas can cause blindness or other bodily injury If a metal object connects an ungrounded battery terminal to ...

Page 166: ...top of the battery When the indicator is blue the battery is fully charged If the indicator is white the battery is not fully charged Check the battery fluid level as follows 1 If the battery fluid level is below the LOWER LEVEL line remove the 6 vent plugs and add distilled water via the vent plug holes until the battery fluid level is between the UPPER LEVEL and LOWER LEVEL lines Replace the ven...

Page 167: ...feels hotter than 125 F 52 C or if rapid gassing or spewing of electrolyte occurs lower the charging rate or stop charging the bat tery and allow it to cool 5 After the battery has charged for the recom mended period of time turn the charger off 6 Disconnect the charger from the battery 7 Install the vent plugs in the battery and install the battery on the vehicle 8 Attempt to start the vehicle If...

Page 168: ...led If it is left loose shocks and vibrations from the road could damage the battery case and battery plates shortening battery life To reduce dust and dirt remove and clean the air fil ters in the heating ventilation and air conditioning system HVAC filters at regular intervals every 6 months or so Clean the HVAC filters at shorter intervals if your vehicle is used frequently in dusty areas CAUTI...

Page 169: ...compressed air Installation 1 Insert the screen filter in its holder with its front facing you Press the screen filter securely into the guide clips one on each side near the top and two at the bottom 2 Position the map compartment on the dash Fasten the quick release fastener on the side panel and the two screws that attach to the brackets at the bottom of the front panel as removed 3 Position th...

Page 170: ...mps Once a seal clamp is loosened or removed it must be replaced 1 Exterior cleaning 1 1 Cleaning glass surfaces Keep the vehicle s windows and screens clean at all times Use glass cleaner and wipe it off with a sponge or soft cloth CAUTION Never apply rubbing compound to glass since it leaves scratches that damage the glass Exhaust system inspection Vehicle cleaning WARNING Some cleaning fluids a...

Page 171: ...t hard to open the door After washing remove moisture on and around the doors Apply silicone with antifreeze capabilities to prevent freezing To avoid damaging the vehicle s finish wash it with luke warm or cold water Do not use con centrated soap or synthetic detergents Do not use very hot water and do not allow the vehicle to dry in direct sunlight When washing the underside of the vehicle be ca...

Page 172: ...rial soot They can corrode discolor or stain the vehicle finish If you find them hard to remove use a synthetic cleaner that does not scratch or otherwise damage painted surfaces 1 5 Small chips and scratches Fix small chips cracks and scratches in the finish as soon as possible particularly when body metal is exposed Do not wait for corrosion to set in Your Sterling dealer can supply touch up pai...

Page 173: ...il butter margarine shoe polish coffee with cream chewing gum beauty cream vegetable oil wax crayon tar and asphalt Wipe off the staining agent and apply a fabric cleaning solution Shoe polish wax crayon tar and asphalt can leave stains if not wiped off quickly Use the cleaner carefully because it dissolves the staining agents and can leave behind a smudge 2 4 Organic contaminants Use this method ...

Page 174: ...p from the pedal Use the pliers to twist it while pulling it forward After cleaning the floor mat dry the felt backing before putting the mat back on the floor When fit ting the floor mat back in the vehicle make sure it does not interfere with the accelerator pedal and other moving parts 2 7 Cleaning seat belts Keep your vehicle s seat belts clean and dry at all times Clean them with mild soap an...

Page 175: ...erheats 12 7 Replacing fuses 12 8 Replacing light bulbs 12 14 Difficult braking 12 21 Stalled engine vehicle in motion 12 21 Flat tire vehicle in motion 12 21 Emergency starting with jumper cables 12 22 Bleeding the fuel system 12 23 Towing 12 24 12 In an emergency ...

Page 176: ...ded Remove corrosion and connect the cable correctly 11 59 The engine ground is disconnected Connect the ground cable Engine oil viscosity is too high Replace the oil Use oil of the correct viscos ity 11 18 Possible cause Remedy Ref page The vehicle has run out of fuel Add fuel and bleed the fuel system 12 23 There is air in the fuel system Bleed the fuel system 12 23 The fuel filter is clogged Re...

Page 177: ...y 11 36 The fan belt is loose Adjust the belt tension 11 39 The coolant is contaminated Flush the cooling system and change the coolant 11 33 Possible cause Remedy Ref page The engine oil level is too low Add engine oil 11 19 Engine oil viscosity is too low Replace the oil Use oil of the correct viscos ity 11 19 Engine components are worn Bring the vehicle to an authorized Sterling service facilit...

Page 178: ...l is too low Add brake fluid 11 25 There is a vacuum leak Check the vacuum circuit and retighten con nections as necessary 6 8 The disc brake pads or drum brake linings are worn Bring the vehicle to an authorized Sterling service facility There is air in the brake fluid Bring the vehicle to an authorized Sterling service facility Possible cause Remedy Ref page The brake fluid level is too low Add ...

Page 179: ...ce facility Possible cause Remedy Ref page The steering system components are improp erly lubricated Bring the vehicle to an authorized Sterling service facility Possible cause Remedy Ref page The bulb is out Replace the bulb 12 14 The fuse is blown Replace the fuse with one of the correct amperage 12 8 There is an open circuit or defective ground ing Bring the vehicle to an authorized Sterling se...

Page 180: ...are behind the vehicle 2 Repair Check the cause of the breakdown If you judge it readily repairable fix it while remaining alert to traf fic If you are unable to repair it call an authorized Sterling service facility for help Emergency stops WARNING Do not stop your vehicle in a tunnel This could cause a serious personal injury or death Drive out of the tunnel whenever possible Be sure to chock th...

Page 181: ...own the engine and do the following steps 1 Check that coolant is not leaking from radiator hoses or other parts of the cooling system 2 Check that the fan belt is not broken and that its tension is normal P 12 46 3 Check the coolant level If the level is too low add coolant Remove the radiator pressure cap Add coolant until it reaches the top of the pres sure cap opening P 12 39 Remove the surge ...

Page 182: ...e fuse box cover toward you to remove it 2 To install the cover align and insert the tabs at the top Press the bottom of the cover into place 2 Removal and installation of the high amp fuse box cover 1 Release the clamps and lift the high amp fuse box cover straight upward to remove it 2 To install the cover place it on the box and press it straight downward Align the holes of the latches with the...

Page 183: ...e correct amperage CAUTION If the cause of a blown fuse cannot be deter mined or the same fuse blows frequently bring the vehicle to an authorized Sterling service facility Use care not to splash water on or around the fuse box cover Should water be splashed over the fuse box cover check the inside of the fuse box for water WARNING Be sure to use fuses of the correct amperage A fuse of incorrect a...

Page 184: ... B5 10A Audio system B6 10A Dome lights B7 30A Power window driver s B8 30A Power window passen ger s B9 20A Engine control unit B11 20A Heated mirror B12 10A Automatic transmission B13 15A Tester B14 20A headlights high beam B15 20A Left headlight low beam B16 20A Right headlight low beam B25 15A Taillights B27 10A Horn Z15090 B16 B8 B9 B11 B12 B7 B6 B5 B4 B3 B2 B1 M8 M5 M9 M4 M6 M11 M3 M2 M1 B13...

Page 185: ...ly ignition bus M5 10A Relay control M6 10A Automatic transmission M8 10A Exhaust brake M9 5A Engine control unit M11 10A ABS S1 10A Starter 5A Spare fuse 10A 15A 20A 30A 5A Automatic transmission troubleshooting diagnosis 10A Automatic transmission troubleshooting memory clear 5A ABS troubleshooting diagnosis 10A ABS troubleshooting memory clear 5A Engine ECU troubleshoot ing diagnosis 10A Engine...

Page 186: ...the cover straight upward to remove it To install the cover place it on the box and press it straight down ward Align the holes of the latches with the catches on the box While still pressing the cover downward retain it with the clamps The amperage and protected circuit of each high amp fuse are shown on the inside of the high amp fuse box cover 2 Check for a blown high amp fuse Look into the ins...

Page 187: ...ted circuit FH1 60A yellow Fuse box S1 A1 A5 M1 M12 FH2 60A yellow Fuse box B1 B12 FH3 40A green Fuse box B13 B16 FH5 60A yellow Hydraulic brake booster FH7 40A green ABS motor FH8 40A green ABS valve BATT1 120A white Alternator BATT2 120A white Alternator WARNING Replacement high amp fuses should always be of the correct amperage Using a high amp fuse of incorrect amperage could cause a fire resu...

Page 188: ... If one of these substances gets on a plastic lens immedi ately wipe it or rinse it off with water Burnt bulbs should be replaced as soon as possible NOTE Condensation can sometimes form on the inside surfaces of the headlight lenses This can happen in rainy weather or just after the vehicle has been washed The condensation forms owing to a tem perature difference between the inside and outside of...

Page 189: ... signal 12V 21W MS820046 2 Brake light taillight double filament 12V 21 5W MS820040 2 Rear turn signal 12V 21W MS820046 2 Backup light 12V 21W MS820046 2 License plate light 12V 7 5W MF820181 1 Clearance and side marker light 12V 7 5W MF820181 2 Identification light 12V 7 5W MF820181 3 Dome light 12V 10W MH056122 1 Z15042a ...

Page 190: ...s 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 3 Pull each keeper screw toward you until it is 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 ...

Page 191: ...am adjusting screw would change the beam setting and could impair visibility for drivers of other vehicles If you accidentally turn the beam adjusting screw have an authorized Sterling service facility adjust the headlights When setting down the removed headlight place it on a soft cloth to avoid scratching the lens 8 Raise the headlight slightly to remove the tabs from the slots then pull it out ...

Page 192: ... reflector into the grommet fit the reflector in place and tighten the bottom screw until firm CAUTION Do not tighten the bottom screw too much This could damage the mounting 5 Install the connector on the front and side turn signal lens 6 Pull out the two turn signal keeper screws until they are fully extended 7 Align the tabs with their slots and press the front and side turn signal lens inward ...

Page 193: ...val 1 Remove the rear cover Press it in and turn it counterclockwise in the direction of arrow 2 Pull the connector toward you to remove it 3 Move the wire retainer away from the bulb 4 Remove the bulb Installation 1 Align the tabs on the bulb collar with the grooves fit the bulb in place and fasten the wire retainer 2 If the packing is dirty clean it If the packing is kinked install it properly 3...

Page 194: ...se it to release the tabs on the bottom of the lens Remove the lens 2 Push the bulb retainer in the direction of the arrow and remove the bulb 3 To install the lens insert the tabs on the bot tom of the lens align the tabs on the top of the lens and press the lens into place 4 Replacing other lights 1 Loosen the lens retaining screws the screws that secure the lens to the fixture Then remove the l...

Page 195: ...e steering wheel Drive the vehicle to the side of the road as soon as it is safe to do so With the vehicle stopped try to start the engine Avoid sudden braking Hold the steering wheel firmly and gradually slow down before pulling over at a safe place To replace the tire select a level surface where your vehicle will not hinder traffic P 12 55 Difficult braking WARNING Do not apply the parking brak...

Page 196: ...of one jumper cable to the posi tive terminal of the booster battery Con nect the other end of the cable to the positive terminal of the discharged battery 5 Connect one end of the second jumper cable to the negative terminal of the booster battery and connect the other end of the second jumper cable to a ground at least 12 inches 300 mm away from the discharged battery The vehicle frame is usuall...

Page 197: ...em before starting the engine CAUTION If the engine shuts down due to lack of fuel it may damage the fuel injection system NOTE Diesel fuel is flammable and can ignite if exposed to open flame intense heat or other source of ignition When working on the fuel system have a fire extin guisher within arm s reach To bleed the fuel system do the following steps 1 Connect a transparent hose with an insi...

Page 198: ...ispose of used fuel properly 9 Start the engine and check for fuel leaks If it becomes necessary to tow the vehicle take the following precautions Disconnect either the propeller shaft driveshaft or the rear axle shaft whichever is easier If you disconnect the rear axle shaft cover the opening to prevent oil and grease from escap ing CAUTION Before towing a vehicle with automatic trans mission dis...

Page 199: ... sole respon sibility of the towing vehicle operator CAUTION Do not attach the towing device to the bumper This could damage the bumper Before raising the front wheels for towing make sure that the towing device will not damage the stabilizer bar or any other part of the vehicle If the towing device looks likely to cause damage use thicker L shaped protection plates to hold the device further from...

Page 200: ...13 1 Recommended lubricants hydraulic fluids and quantities 13 2 Service specifications 13 4 13 Service data ...

Page 201: ...ydraulic fluids and quantities Item Quantity quarts liters Engine Oil pan 9 5 9 0 Oil filter 1 1 1 0 Manual transmission 5 speed 3 8 3 6 6 speed 4 6 4 4 Automatic transmission Total quantity 14 0 12 9 Replacement quantity when drained from drain plug 6 8 6 4 Axle housing All models 4 8 4 5 Power steering COE 40 45 2 0 1 9 COE 50 2 4 2 3 Brake fluid for both brakes and clutch As required ...

Page 202: ...n Automatic transmission fluid Exxon Mobil Mobil ATF3309 or equivalent Axle housing 1 Gear oil API GL 5 Below 104 F 40 C 90 Above 104 F 40 C 140 or 85W 140 Limited slip differential Gear oil for limited slip differential API GL 5 Genuine Gear Oil Part No 8149630EX 90 Power steering Automatic transmission fluid DEXRON DEXRON II or DEXRON III Brake Clutch Brake fluid SAE J1703 FMVSS No 116 Grade DOT...

Page 203: ... when installed 0 28 to 0 35 in 7 to 9 mm Used belt when inspected or reinstalled 0 39 to 0 43 in 10 to 11 mm Coolant quantity About 17 quarts 16 liters Clutch pedal free play at center of pedal pad 0 008 to 0 157 in 0 2 to 4 0 mm Brake pedal free play at center of pedal pad 0 004 to 0 118 in 0 1 to 3 0 mm Fully depressed brake pedal to floor clearance 0 79 in 20 mm or more Parking brake lever str...

Page 204: ...14 1 Maintenance schedule 14 2 Lubrication schedule 14 6 14 Maintenance schedule ...

Page 205: ... 000 km Every 150 000 miles 250 000 km ENGINE Coolant fuel and oil leak checking Check beneath the vehicle for signs of leakage 11 8 Engine condition checking Check that the engine starts smoothly and runs quietly 11 9 Manifold fastener torque checking Check intake and exhaust manifold fastener torques 13 4 Valve lash checking and adjusting Check valve lash with a feeler gauge procedure in service...

Page 206: ...ring for wear damage and play procedure in service man ual FRONT AND REAR AXLE Wheel bearing checking Check wheel hub bearing for play procedure in ser vice manual Wheel bearing seal changing Replace wheel hub bearing grease and seals proce dure in service manual Wheel and tire checking Check the tire inflation pres sure Measure tire tread depth Visually check tire tread and side wall Check wheels...

Page 207: ...aster and slave cylinders 11 42 STEERING SYSTEM Steering wheel free play checking With the engine running check the steering wheel free play 11 41 Steering wheel operation check ing While driving slowly check steering wheel operation 11 41 Steering system inspection Inspect the steering system for looseness steering wheel play and operating condition Check for oil leaks Check the booster and oil p...

Page 208: ...the windshield washer fluid level and add fluid if necessary 11 56 Windshield wiper and washer checking Check the washer for proper fluid spray direction and the wipers for normal operation 5 21 Lighting system checking Make sure that each light works properly Check lenses for dirt and damage 5 18 Instrument cluster checking Check that all gauges and telltales are working prop erly 6 2 Operation d...

Page 209: ...changing Manual transmission oil level checking 11 20 Manual transmission oil changing Automatic transmission fluid level checking 11 22 Automatic transmission fluid changing 11 22 Rear axle oil level checking 11 23 Rear axle oil changing Hub bearing lubrication Brake fluid level checking 11 25 Brake fluid changing 11 25 Power steering fluid level checking 11 27 Power steering fluid changing 11 27...

Page 210: ...15 1 15 Alphabetical index ...

Page 211: ...2 Coolant 10 2 11 33 Coolant changing 11 37 Coolant level checking 11 35 Coolant temperature gauge 6 3 Coolant temperature warning 6 12 Cup holder 9 6 Danger of fuel mixtures 1 5 Diesel fuel properties 1 5 Dimmer switch 5 19 Disc brake wear warning 6 10 Dome light 9 4 Dome light bulb replacement 12 20 Dome light switch 5 22 Door window 3 6 Doors 3 2 Draining the fuel filter 11 32 Drive belts 11 39...

Page 212: ...eter 6 2 On rough roads and in bad weather 7 11 On uphill and downhill grades 7 9 Outside air inlets 8 11 Overdrive lockout switch 5 17 Panel light switch 5 22 Parking 7 12 Parking brake 11 44 Parking brake lever 5 17 Passenger s seat 4 3 Passing signal 5 19 Periodic inspection 1 4 Power steering fluid 11 26 Power window lock switch 3 7 Power window switches 3 6 Power line label 1 2 Precautions fo...

Page 213: ... 11 62 Vehicle identification number VIN 1 3 Vehicle operation 7 3 Vehicle operation automatic transmission 7 5 Vehicle operation manual transmission 7 4 Vehicle start up 7 2 Warming up the engine 5 10 Warning labels 2 1 Warning lights 6 5 Washer switch 5 21 Water in fuel warning 6 10 Wheel mounting 11 51 Wheel nut tightening 11 53 Wheel removing 11 49 Window in door 3 6 Windshield washer 11 56 Wi...

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