Sterling 360 User manual

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

Foreword

Thank you for purchasing a Sterling 360TM vehicle.

This manual provides information needed to operate and understand the vehicle and its compo-

nents. Not all of the information contained in this manual applies to every vehicle.

For your reference, keep this manual in the vehicle at all times.

Lubrication

When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of

obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check

that the engine, undercarriage, and noise emission control parts are in good working order during

lubrication.

This manual explains when you should lubricate parts and what to look for when checking for wear

or damage.

Environmental 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 used parts. Used parts may have been subjected to collisions or improper use and

have undetected structural damage.

stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, pho-

tocopying, recording, or otherwise, without the prior written permission of Freightliner LLC.

Freightliner LLC

Service Systems and Documentation (POC-SSD)

P.O. Box 3849

Portland OR 97208-3849

Printed in U.S.A.

Symbols and alert messages

QDescriptions and specifications in this manual were in effect at the time of printing. Sterling Truck Corpo-

ration reserves the right to discontinue models and to change specifications or design at any time without

notice and without incurring obligation. Descriptions and specifications contained in this publication pro-

vide no warranty, expressed or implied, and are subject to revisions and editions without notice.

QThe following symbols are used throughout this handbook:

: optional equipment

: cross-reference to another page that contains relevant information about the subject.

QThis manual contains important hazard messages under the following four headings that identify the

nature and importance of the information:

QCalifornia 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.

CAUTION Hazards or unsafe practices that could result in minor personal

injury and/or damage to products or property.

NOTE: Relevant information that is helpful or informative but not associated

with any risk or hazard.

DANGER

THIS PRODUCT CONTAINS OR EMITS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO

CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

CONTENTS

1. About your vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Vehicle access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4. Seat and steering wheel adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. Switches and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6. Instrument cluster gauges and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7. Starting and driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8. Heatingandairconditioning... . ... . .. . ... . .. . ... . .. . ... . .. . ... . .. . ... . .. . ... . .. . ..8-1

9. Interiorequipment 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.

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

1-2 About your vehicle

When ordering replacement parts or requesting

repairs, provide the chassis number and engine

number .

1 Chassis number

The chassis number is located on the left frame rail,

behind the front wheel.

2 Engine 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

Engine model

Z11768

1-3

The VIN is stamped on a plate that is located just

below the kick plate on the driver’s door (see illus-

tration).

The VIN includes 17 coded numbers and letters.

The coding is given below.

Vehicle identification number (VIN)

Z11959

Country J: Japan

Make L: Mitsubishi Fuso

Vehicle type S: Sterling incomplete vehicle

Gross vehicle weight / Brake system

A: 10,001 to 14,000 lb / Hydraulic

B: 14,001 to 16,000 lb / Hydraulic

C: 16,001 to 19,500 lb / Hydraulic

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: 5.90 to 6.19 m

Cab chassis type 1: COE 4X2 chassis cab

Engine E: Proprietary 6M60 7.5 L inline 6 Diesel

S: Proprietary 4M50 4.9 L inline 4 Diesel

Check digit

Model year 7: 2007

Plant K: Kawasaki

Plant sequential serial number

J AASL E 7S1 K

1-4 About your vehicle

Regular maintenance will improve the performance

of your vehicle and extend its service life. It is rec-

ommended that you make a habit of performing the

following inspections.

In this manual, you will find simple maintenance

checks and procedures that can be carried out by

the owner. If you have difficulty, or your vehicle

needs work that is not described in this manual,

please contact an authorized Sterling service facil-

ity.

1 Engine run-in period

To avoid overburdening a new engine, limit engine

speed to 1800 revolutions per minute (rpm) for the

first 600 miles (1000 km).

After this initial run-in period, gradually increase

engine speed, starting with the lower gears.

2 Pretrip inspection

Inspect your vehicle at the start of each 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 oil, manual transmission oil,

and rear axle oil. P. 11-17

•Check and adjust valve lash. P. 13-4

•Tighten the wheel nuts. P. 11-53

•Tighten the suspension U-bolts. P. 13-4

4 Maintenance program

Recurring maintenance lengthens the vehicle’s ser-

vice life and can help prevent accidents. Recurring

maintenance can be based on either distance trav-

eled (odometer reading), or length of service (hour-

meter reading).

Maintenance intervals for each recurring item are

shown in the maintenance schedule. Please follow

the maintenance schedule. P. 14-2

Maintenance

Z11771

Z01367

1-5

Use only diesel fuel conforming to the following rec-

ommendations, without any additives, for diesel

engines installed in the Sterling 360.

1 Diesel fuel properties

The following recommendations concerning diesel

fuel used with Mitsubishi Fuso diesel engines are

given for optimum fuel economy and performance.

NOTE:

* ASTM is an acronym for the American Society for

Testing and Materials. ASTM recommends fuel con-

taining 0.05% or less sulfur content.

Sulfur content that exceeds 0.05% causes the per-

formance of the emission control device to deterio-

rate.

To meet precise fuel requirements, obtain coopera-

tion from a reputable supplier 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 Low Sulfur

Grade 2-D*

Operation at tempera-

tures below 10°F

(–12°C), or long-hour

no-load operation.

ASTM D-975

Grade Low Sulfur

Grade 1-D*

DANGER

NEVER MIX DIESEL FUEL WITH GASOLINE,

GASOHOL OR ALCOHOL.

USE OF FUEL MIXED WITH ONE OR MORE

OF THESE COULD LEAD TO A FIRE OR

EXPLOSION INVOLVING SERIOUS INJURY,

DEATH OR PROPERTY DAMAGE. IF YOU

ACCIDENTALLY USE GASOLINE OR ALCO-

HOL WHEN REFUELING THE VEHICLE,

REMOVE ALL OF IT FROM THE FUEL SYS-

TEM.

1-6 About your vehicle

3 Adverse effects of fuel mixtures

Using diesel fuel mixed with gasoline, alcohol, or

both, has the following adverse effects on the

engine:

•Excessive wear, damage, and failure of fuel sys-

tem parts, as a result of lower fuel viscosity.

•Difficulty in starting the engine, as a result of

reduced cetane number.

CAUTION

•The lower the cetane number, the more likely

internal engine damage will occur.

•Do not add antifreeze agents or other sub-

stances to the fuel. They could damage the

engine’s fuel injection 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. 1 2 - 2 3

WARNING

•Do not refuel with the engine running.

Shut down the engine before fueling.

•Diesel fuel is combustible. Wipe up any

spilled fuel. Do not smoke while refueling.

•If you inadvertently put gasoline in the fuel

tank, pump it all out. Do not run the engine

with gasoline in the tank.

Any of these practices can cause a fire or

explosion, which could result in burn injuries

or loss of life.

1-7

•33-gallon fuel tank

This fuel tank is on the left-hand side of the vehicle.

To open the filler cap, slowly turn it counterclock-

wise. To close the cap, turn it clockwise. Be sure the

cap is fully closed.

•30-gallon fuel tank

This optional fuel tank is at the rear of the vehicle.

To open the filler cap, slowly turn it counterclock-

wise. To close the cap, turn it clockwise until you

hear a click.

Fuel tank capacity

33.0 gallons (125 liters)

Fuel tank capacity

29.8 gallons (113 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 stops.

If fuel leaks, carefully wipe it all up.

•If the pointer of the fuel level gauge is

above the “F” mark, do not add any more

fuel.

Overfilling the fuel tank can cause a fire,

which could result in burn injuries and loss

of life.

<33 gallon fuel tank>

<30 gallon fuel tank>

Z11891a

1-8 About your vehicle

If you believe that your vehicle has a defect that

could cause a crash or could cause injury or death,

you should immediately inform the National High-

way Traffic Safety Administration (NHTSA) in addi-

tion to notifying Sterling Truck Corporation.

If 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

and remedy campaign. However, NHTSA cannot

become involved in individual problems between

you, your dealer, or Sterling Truck Corporation.

To contact NHTSA, you may either call the Auto

Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-

800-424-9153); go to http://www.safercar.gov; or

write to: Adminstrator, NHTSA, 400 Seventh 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, Ontario,

Canada K1A 0N5.

For additional road safety information, please visit

the Road Safety website at: http://www.tc.gc.ca/

roadsafety/menu.htm.

Customer Assistance Center

Having trouble finding service? Call the Customer

Assistance Center at 1-800-785-4357 or 1-800-

STL-HELP. Call night or day, weekdays or week-

ends, for dealer referral, vehicle information, or

breakdown coordination. Our people are knowl-

edgeable, professional, and committed to following

through to help you keep your truck moving.

Reporting safety defects

Obtaining service

2-1

Locations in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Locations outside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2. Warning labels

2-2 Warning labels

•The caution and warning labels give important

information. Be sure to read them before using

the vehicle.

•If any label has become so damaged or dirty

that it is difficult to read, please inform an autho-

rized 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) fuel tank

Z10690 Z12494

2-3

Voltage

Towing <Automatic transmission>

Parking <Automatic transmission>

Hydraulic brake booster

Hydraulic brake system bleeding

Main fuse box

Z11770

Z11666

Z14889

Z11693

Z11694

Z12564

2-4 Warning labels

Locations outside cab

Z12496

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

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

2-7 Warning labels

30-gallon (113-liter) fuel tank

Z12494

3-1

Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Master door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Entering and exiting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3. Vehicle access