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

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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

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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)

Trailer Jockey Operators Handbook
3
1-3 M AJOR C OMPONENTS
Figure 2 illustrates the major components of the Trailer
Jockey.
Figure 2. Major Components

Capacity of Texas, Inc.
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1-4 F UEL R ECOMMENDATIONS
Your Trailer Jockey’s engine is manufactured by Cummins,
Inc. To ensure optimum reliability and performance from your
vehicle, follow these recommendations regarding fuel.
Due to the precise tolerances of diesel injection systems, it is
extremely important that your fuel be kept clean and free of
dirt or water. Dirt or water can cause severe damage to both
the fuel pump and the fuel injectors.
Lighter fuels can reduce fuel economy and possibly damage
fuel system components.
Cummins recommends the use of ASTM number 2D fuel for
optimum engine performance. The engine in your vehicle has
been optimized to meed U.S. Environmental Protection
Agency (EPA) regulations. To meet these regulations, ultra-
low sulfur diesel fuel is required. If ultra-low sulfur diesel fuel
is not used, the engine may not meet EPA emission regula-
tions and damage to your engine’s aftertreatement system
may result.
Ultra-low sulfur diesel is defined by ASTM S-15 as diesel not
exceeding 0.0015 (15 ppm) mass percent sulfur content. There
is no acceptable substitute.

Trailer Jockey Operators Handbook
5
S ECTION 2.
C
ONTROLS & I NDICATORS
2-1 I NTRODUCTION
The controls and indicators for the Trailer Jockey are illus-
trated on the following pages. The name and function of each
control and indicator are listed in Table XREF. The index
numbers in the figure correspond to the item numbers in the
table. The operator should know the location and function of
each control and indicator and have a thorough knowledge of
their functions before operating the tractor.
REMEMBER!
A careful operator is the best safety device!
The Trailer Jockey is equipped with an operator seat belt. The
seat belt should be worn at all times during operation to
prevent injury to the operator in the event of an accident.

Capacity of Texas, Inc.
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Figure 2-1 Controls and Indicators.
Table 2-1 Controls & Indicators
Item Name Function
1 Status LED Panel 1 Multiple LEDs indicate various conditions.
Refer to Figure 2-2 for more information
2 Tachometer Indicates engine speed in RPM

Trailer Jockey Operators Handbook
7
3 Speedometer /
Alphanumeric Display Indicates vehicle speed in MPH and KPH. Digital alphanumeric display below
speedometer dial displays additional
information. Refer to XREF for more
information
4 Status LED Panel 2 Multiple LEDs indicate various conditions.
Refer to Figure 2-2 for more information
5 Oil Pressure Gauge Indicates engine oil pressure. Red indicator
light indicates potentially damaging low
pressure.
6 Water Temperature
Gauge Indicates temperature of engine coolant in ºF and ºC. Normal reading should be 180 ºF
to 205 ºF.
7 Voltmeter Indicates voltage in electrical system. Low
voltage may indicate problem with battery
and/or alternator.
8 Fuel Gauge Indicates fuel remaining in tank.
9 Air System Pressure
Gauge 1 Indicates pressure in air brake system in PSI and KPa. Normal reading should be
10 Key Switch Three-position, key-operated switch. In
OFF position, electrical system is de-
energized and key can be removed. In ON
position, the electrical system is energized.
In START position, starter is engaged to
start engine. Release to ON position when
engine is started.
11 Air System Pressure
Gauge 2 Indicates pressure in air brake system in PSI and KPa. Normal reading should be
12 Windshield Wiper
Control Knob Turns to activate variable speed wipers. Push to activate windshield washers.
13 Auxiliary Fan Switch Rocker switch that controls the auxiliary
fan .
14 Mirror Heat Switch Rocker switch that contols the outside rear-
view mirror heaters
15 LH Mirror Motor
Switch Rocker switch that adjusts the left hand rear view mirror.
16 RH Mirror Motor
Switch Rocker switch that adjusts the right hand rear view mirror.
17 Trailer Brake Lever Activates the trailer brake.
18 Beacon Light Switch Rocker switch that activates the beacon
light.
Table 2-1 Controls & Indicators (Cont.)
Item Name Function

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Figure 2-1 Controls and Indicators (Cont.
19 Exterior Lights Switch Rocker switch that activates exterior lights
20 Auxiliary Rocker switch that activates auxliliary
lights
21 Fifth Wheel Floodlight
Switch Rocker switch that activates the fifth wheel light on the rear of the cab.
22 Cab Interior Light
Switch Rocker switch that activates the interior cab lights.
23 Headlight/Tail Light
Switch Rocker switch that activates the headlights and tail lights
24 Heater Control Knob Rotary knob that adjusts the temperature
level of the cab heater.
25 Heater Fan Control
Knob Rotary knob that sets the heater fan HIGH, LOW, or OFF
26 Panel Lights Control
Knob Rotary knob that adjusts the brightness of the dash control lights.
27 Brake Pedal Pedal that controls the application of the
brakes. Depress pedal to apply brakes.
Brakes should be applied slowly except in
emergency situations. Trailer brakes are
also operated by the pedal if both trailer air
hoses are connected.
28 Brake Pedal
29 Throttle Control Pedal Pedal that controls the engine throttle.
Depress pedal to increase engine speed.
Release pedal to reduce engine speed.
Table 2-1 Controls & Indicators (Cont.)
Item Name Function

Trailer Jockey Operators Handbook
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Do not depress the fifth wheel lock pushbutton unless the
trailer is properly positioned and does not pose a threat to
personnel or property.
Table 2-1 Controls & Indicators (Cont.)
Item Name Function
30 Fifth Wheel Lock Pushbutton control that releases fifth wheel
locks when pressed, releasing trailer.
31 Transmission Control Pushbutton control pad that controls the
transmission. Refer to Figure 2-3 for
details.
32 Fifth Wheel Control
Lever Three-position control lever that positions the fifth wheel.
LOWER - moves fifth wheel down.
HOLD - Maintains fifth wheel elevation
RAISE - Elevates fifth wheel
33 Trailer Air Supply
Valve Push-pull knob that applies air pressure to trailer brake system when depressed; pull
knob out to evacuate air from trailer brake
system
34 Parking Brake Control Push-pull knob that applies parking brake
when pulled out. Depress knob to release
parking brake.

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Figure 2-1 Controls & Indicators (Cont.)
Due to vertical motion of suspension-type seats the seatbelt
set should be adjusted to allow for adequate head clearance
when the seat is adjusted to the top of upward travel.
SEAT BELTS SHOULD BE WORN AT ALL TIMES TO
AVOID INJURY! ADJUST SEAT POSITION BEFORE
FASTENING SEAT BELT.
Table 2-1 Controls & Indicators (Cont.)
Item Name Function
35 Seat Position Control Lever that is used to adjust front-to-rear
position of the seat
36 Seat Suspension Lock Lever that is used to control the seat
suspension.
37 Seat Back Control
Knob Knob that can be turned to adjust the tilt of the seat back.
38 Lumbar Control Switch Switch that controls the adjustment of the
lumbar support
39 Seat Height
Adjustment Switch Switch that is used to adjust the height of the seat
40 Seat Belt/Shoulder
Harness (not shown) See seat belt notes below

Trailer Jockey Operators Handbook
11
Figure 2-1 Controls & Indicators (Cont.).
Table 2-1 Controls & Indicators (Cont.)
Item Name Function
41 ABS Diagnostic Button Pushbutton control that activates the
diagnostic codes for the anti-lock brake
system (ABS)
42 Engine Diagnostic /
Regeneration Switch Dual-purpose switch. When engine is turned off, activates engine diagnostic
mode (refer to XREF for moreinformation.
When engine is turned on, activates the
engine regeneration cycle (refer to XREF
for more information).
43 Diagnostic Connector Deutsch connector that is used to connect
engine diagnostic computer to truck for
maintenance activities.

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Figure 2-1 Controls & Indicators (Cont.).
Table 2-1 Controls & Indicators (Cont.)
Item Name Function
44 Air Filter Indicator Indicates the restriction (clogging) of
engine air filter, measured in inches of
Mercury (in. Hg). Press reset button on top
of indicator after replacing air filter.