Capacity TJ5000 OFF ROAD Service manual

Operator’s Handbook
Trailer Spotting Tractor
Capacity of Texas, Inc.
401 Capacity Drive
Longview, TX 75604
1-800-323-0135
WARNING!
Failure to read, understand, and fully comply with the important information
contained in this Operator’s Handbook mayresult in hazardous conditions or
cause a hazardous condition to develop.
CAPACITY

i
Table of Contents
Section 1. Introduction. .................................................... 1
1-1 General ...................................................................................................1
1-2 Specifications. ......................................................................................2
1-3 Major Components ...........................................................................3
1-4 Fuel Recommendations ..................................................................4
Section 2. Controls & Indicators. .................................. 5
Section 3. Operation. ...................................................... 17
3-1 Safety Precautions .........................................................................17
3-2 Service On Reciept .........................................................................18
3-2.1 Preliminary Service .............................................................18
3-2.2 Operator Orientation .........................................................18
3-3 Pre-Operation Inspection ............................................................19
3-4 Vehicle Refueling .............................................................................19
3-5 Vehicle Start Up ..............................................................................20
3-5.1 Engine and Transmission Warmup ............................21
3-5.2 Cold Weather Starting Aids ...........................................21
3-6 Pre-Operation Checks ...................................................................22
3-6.1 Proper Seat Belt Usage ...................................................22
3-6.2 Steering ...................................................................................22
3-6.3 Brakes and Transmission ...............................................23
3-6.4 Final Checks ...........................................................................23
3-7 Driving Precautions .......................................................................24
3-8 If You Have A Problem ..................................................................25
3-9 Engine Operation .............................................................................26
3-9.1 Stopping the Engine ...........................................................26
3-10 Transmission Operation ...........................................................27
3-10.1 Pushbutton Shift Selector Operation ......................28
3-10.2 R - Reverse ..........................................................................29
3-10.3 N - Neutral ...........................................................................29
3-10.4 D - Drive ................................................................................29
3-11 Power Take-Off (PTO) .................................................................30
3-12 Trailer Pickup and Movement ................................................31
3-13 Trailer Spotting (Parking) .........................................................33
3-14 Shutdown .........................................................................................33
3-15 Towing ...............................................................................................33
3-16 Dash Gauge Operation ..............................................................34
3-16.1 Odometer Mode ...............................................................34
3-16.2 Trip Odometer Mode ......................................................34

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Section 3. (Continued)
3-16.3 Hourmeter Mode ............................................................. 34
3-16.4 Diagnostic Mode .............................................................. 34
Section 4. Service & Diagnostics. .............................. 35
4-1 Minor Maintenance ....................................................................... 35
4-2 Tilting the Cab .................................................................................. 35
4-3 Regular Maintenance Schedule .............................................. 36
4-3.1 General .................................................................................... 36
4-3.2 Daily Maintenance .............................................................. 36
4-3.3 Weekly Maintenance ........................................................ 37
4-3.4 Monthly Maintenance ....................................................... 37
4-3.5 Quarterly Maintenance .................................................... 37
4-3.6 1000-Hour Maintenance ............................................... 38
4-3.7 2000-Hour Maintenance ............................................... 38
4-3.8 Overhead Set Adjustment .............................................. 38
4-3.9 Three-Year / 6000 Hour Checks .............................. 38
4-4 Service Procedures ....................................................................... 39
4-4.1 Fluid Levels ............................................................................. 39
4-4.2 Engine Oil and Filter Changes ........................................ 39
4-4.3 Regeneration ........................................................................ 40
4-4.4 Checking Transmission Fluid Level ............................. 42
4-4.5 Transmission Fluid and Filter Changes .................... 43
4-4.6 Hydraulic System Fluid ..................................................... 43
4-4.7 Battery Service .................................................................... 43
4-5 Diagnostics ........................................................................................ 44
4-5.1 System Diagnostics ........................................................... 44
4-5.2 Driver -Initiated Diagnostics ........................................... 44
4-5.3 Manual Diagnostic ............................................................. 44
4-5.4 Fault Display .......................................................................... 45
4-5.5 Transmission Diagnostics .............................................. 91
4-5.6 ABS System Diagnostics ................................................. 97
4-6 Lubrication ...................................................................................... 103
Section 5. Specifications & Capacities. ................ 105
5-1 General ............................................................................................. 105
5-2 TJ5000 Off Road ........................................................................ 105
5-3 TJ5000 DOT ................................................................................. 106
5-4 TJ6500 DOT ................................................................................. 106
5-5 TJ7000 Off Road ........................................................................ 107
5-6 TJ9000 Off Road ........................................................................ 107
5-7 TJ9000 Off Road/On Road ................................................... 108

v
Cautions & Warnings
Procedures throughout this manual contain cautions and
warnings to alert the operator to the following conditions:
A warning advises the operator of conditions that may result
in damage to the vehicle, property, serious injury or possibly
death. Pay special attention to items identified with the
warning label.
A caution advises you of conditions that could result in dam-
age to your vehicle or property.
Study this manual carefully. Do not operate your vehicle until
you are completely familiar with the contents of this manual.
Always retain this manual in your vehicle for reference. If you
sell the vehicle, make sure the manual goes with it.

vi
Safety Summary
California Proposition 65 - Diesel engine exhaust and some of
its constituents are known to the State of California to cause
cause cancer, birth defects, and other reproductive harm.
Battery posts, terminals, and related accessories contain lead
and lead components, and other chemicals known to the State
of California to cause cancer, birth defects, and other
reproductive harm.
In order to add electrical devices to your Trailer Jockey, you
must use the circuit breaker protected ignition and battery
power locations on the power distribution center (PDC).
Failure to use these locations for additional electrical
accessories can result in circuit overload conditions and cause
electrical damage and/or fire in your vehicle. Failure to use
these locations for additional electrical connections will void
the factory warranty.
Before welding on any vehicle equipped with an electronic
engine (ISB, ISC, QSB, QSC, CAT3126), power must be
disconnected from the engine computer. This can be done at
the battery or at the power connection to the computer on the
engine. Failure to do so can result in damage to the engine
computer and may cause engine malfunction or failure.
Your Trailer Jockey has gross axle weight, gross vehicle
weight, and gross combination weight ratings. Do not exceed
these ratings. Exceeding maximum weight ratings by
overloading can cause component failure resulting in
personnel injury and property damage.

vii
The Trailer Jockey is designed for efficient one-person
operation by propery trained, experienced operators. Do not
allow passengers in or on the Trailer Jockey while in
operation.
Reporting Safety
Defects
If you believe that your vehicle has a defect that could cause a
crash or cause injury or death, you should immediately notify
the National Highway Traffic Safety Administration (NHTSA)
in addition to notifying Capacity of Texas, Inc.
If the NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in a
group of vehicles, it may order a recall campaign. However, the
NHTSA cannot become involved in individual problems
between you, your dealer, or Capacity of Texas, Inc.
To contact the NHTSA, you may either call the Auto Safety
Hotline toll free at 800-424-9393 or write to them at: NHTSA,
U.S. Department of Transportation, Washington, DC 20590.
You can also obtain other information about motor vehicle
safety from the Hotline or at the NHTSA website at
www.nhtsa.dot.gov.
Notice
To comply with environmental regulations limiting top speed
to 25 miles per hour on industrial engines, your Trailer Jockey
may have transmission gear selections electronically inhibited
or mechanically blocked, preventing operators from shifting
into higher gears.
Restricted range selection will not affect the performance or
the warranty of the transmission. If you have any questions or
require additional information, contact Capacity of Texas at
800-323-0135.

Trailer Jockey Operators Handbook
1
S ECTION 1.
I NTRODUCTION
1-1 G ENERAL
This handbook contains information designed to familiarize
the operator with the controls and operation of the Trailer
Jockey. Be sure the operator is completely familiar with all
controls and indicators and their functions BEFORE attempt-
ing to operate the tractor. Failure to do so could cause hazard-
ous conditions to develop.
Figure 1. Truck Dimensions

Capacity of Texas, Inc.
2
1-2 S PECIFICATIONS .
Item Value
Engines Cummins ISB07-200 HP
Cummins ISB07-220 HP
Cummins ISLG (LNG) 250HP
Cummins QSBT3 6.7 L Elite 167 HP
Cummins QSBT3 6.7 L Elite 183 HP
Transmission Allison RDS3000
Hydraulic System Transmission direct-mounted PTO with direct moutned
gear pump and 8-gallon (30.3 liter) reservoir
Fuel Tank 50 gallon (189.25 liter) step tank
Electrical 12-Volt, negative ground
circuit breaker protection
color-coded wiring
removable harnesses
Cooling Heavy duty fin-and-tube construction radiator filled
with 50/50 solution of permanent type antifreeze
Transmission oil cooler mounted in front of radiator
Air System 15.2 CFM (4.4 cmm) compressor three-tank reservoir
system
Brakes Air brakes on all wheels
Parking/emergency spring-type brakes on rear wheel
Tractor-trailer protection valve and color-coded air
lines with glad-hand brackets
Wheels 22.5 X 8.25 steel disc, 10-hole
Tires 11 X 22.5, 16-ply LRH tubeless,
highway tread
Fifth Wheel Lift Rating: 70,000 lbs (31,750 Kg)
Lift Height: 16 in. (40.64 cm)
Dimensions: Height: 120 in. (304.80 cm)
Length: 186 in. (472.44 cm)
Width: 95.5 in. (242.57 cm)
Wheelbase: 110 in. (279.40 cm)