Sterling 360 Driver's And Maintenance Manual
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Sterling 360 Driver's And Maintenance Manual

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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

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Summary of Contents for Sterling 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): SELLING DEALER IMPRINT HERE...
  • Page 2 Foreword Thank you for purchasing a Sterling 360 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.
  • Page 3 Symbols and alert messages Descriptions 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.

  • Page 4: Table Of Contents

    CONTENTS 1. About your vehicle ............. . . 1-1 2.

  • Page 5: About Your Vehicle

    1. About your vehicle Chassis and engine numbers ............1-2 Power line label .

  • Page 6: Chassis And Engine Numbers

    About your vehicle Chassis and engine numbers 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. Example: FE84DD - Chassis number Vehicle model 2 Engine number...

  • Page 7: Vehicle Identification Number (Vin)

    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...

  • Page 8: 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: •...

  • Page 9: Fuel

    Fuel 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.
  • Page 10 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. •...
  • Page 11 • 33-gallon fuel tank <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. Fuel tank capacity 33.0 gallons (125 liters) •...

  • Page 12: Reporting Safety Defects

    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);...

  • Page 13: Warning Labels

    2. Warning labels Locations in cab ..............2-2 Locations outside cab .

  • Page 14: Locations In Cab

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

  • Page 16: Locations Outside Cab

    Warning labels Locations outside cab Z12496...
  • Page 17 Engine oil Radiator pressure cap Z10084 Z08670 Automatic transmission fluid (ATF) Z12549 Battery Z11680 ATF cooling fan <Automatic transmission> ATF cooler <Automatic transmission> Z11844 Z11773...
  • Page 18 Warning labels High-amp fuse box Air conditioner Z11803 Z13208 Cab tilt reference Cab tilt safety Z11804 Z14891 33-gallon (125-liter) fuel tank Limited-slip differential Z11678 Z10707...
  • Page 19 Warning labels 30-gallon (113-liter) fuel tank Z12494...

  • Page 20: Vehicle Access

    3. Vehicle access Doors ................3-2 Master door locks .

  • Page 21: Doors

    Vehicle access Doors WARNING • To prevent injuries, before opening either door, check for vehicles and pedestrians approaching from behind. • Driving with a door ajar can cause an injury. Make sure the doors are completely closed before starting the vehicle. •...
  • Page 22 1 From the outside • To open, pull the outer handle toward you. • Use the ignition key to lock or unlock the door. • It is possible to lock each door without using the ignition key. On the driver’s door or passenger’s door, push the lock button forward, then close the door as you pull out on the exterior door...

  • Page 23: Master Door Locks

    Vehicle access Master door locks • When the “LOCK” side of the switch pressed, both doors are locked. When the “UNLK” side of the switch is pressed, both doors are unlocked. • When the lock button on the driver’s door is pushed forward, the passenger’s door is also automatically locked.

  • Page 24: Entering And Exiting The Vehicle

    Entering and exiting the vehicle WARNING • Always face in when exiting the cab. Do not attempt to exit with your back to the cab, as you would when going down a flight of stairs. Never put your foot on the wheel or tire.

  • Page 25: Door Window

    Vehicle access 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. 1 Power window switches WARNING •...
  • Page 26 2 Power window lock switch 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 or head trapped.

  • Page 27: Seat And Steering Wheel Adjustments

    4. Seat and steering wheel adjustments Seats ................4-2 Seat belts .
  • Page 28 Seat and steering wheel adjustments 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 Z11863 performing any adjustment to the seat.
  • Page 29 Making adjustments • Slide the seat forward or backward while raising the seat slide lever . After making the adjust- ment, release the lever and move the seat back and forth slightly to lock it in position. • To adjust the angle of the backrest , raise the backrest tilt lever •...

  • Page 30: In An Emergency

    Seat and steering wheel adjustments Seat belts • To help prevent injury in the event of a sudden stop or accident, the driver and all passengers must wear their seat belts properly fastened. • Before fastening your seat belt, sit back in your seat with your back straight.
  • Page 31 1 Shoulder belt fastening and unfastening NOTE: It is not necessary to adjust the length of these seat belts. A seat belt with ELR extends and retracts automati- cally as its wearer moves. In the event of a sudden stop or shock, it locks automatically to protect its user.

  • Page 32: Seat Belt Safety

    Seat and steering wheel adjustments 3 Seat belt safety Children and infants • When carrying children or infants, restrain them properly. This will minimize the risk of injury in the event of a sudden stop or accident. Never allow children to stand or kneel on the seats. For maximum safety, we recommend fitting and using a restraint system that complies with Fed- eral Motor Vehicle Safety Standards.

  • Page 33: Steering Wheel

    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.

  • Page 34: Switches And Controls

    5. Switches and controls Arrangement of switches and controls ........... . 5-2 Ignition switch .

  • Page 35: Arrangement Of Switches And Controls

    Switches and controls <Manual transmission vehicles> Arrangement of switches and controls Ignition switch Engine idle control Accelerator pedal Brake pedal Clutch pedal Shift lever <manual transmission> Parking brake Hazard flashers Multifunction switch, R/H side (wiper/washer switch, exhaust brake switch <manual transmission>) Multifunction switch, L/H side (headlight switch, headlight high beam dimmer, turn signal switch)

  • Page 36: Ignition Switch

    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. • Braking force would be greatly reduced. •...

  • Page 37: Engine Warm-Up Switch

    Switches and controls • LOCK The ignition key can be inserted and removed only in the “LOCK” position. To place the key in “LOCK,” turn it to the “ACC” position, then press it in, and keep it pressed in while turning it to “LOCK.”...

  • Page 38: Engine Idle Control

    NOTE: • Before driving, turn OFF the engine warm-up switch. This deactivates the exhaust brake. • The exhaust brake is used when the vehicle is not moving to make the engine warm up more quickly and to make the heater work more effec- tively on cold days.

  • Page 39: Starting The Engine

    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.

  • Page 40: In Cold Weather

    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. • In a cold-weather area, use a high-capacity bat- tery to improve engine startability. 1 Pre-starting steps Do the following steps before starting the engine to make sure the vehicle does not move inadvertently.
  • Page 41 Switches and controls NOTE: For safety, the engine in a manual transmission vehicle cannot be started unless the shift lever is in the neutral position. In an automatic transmission vehicle, the engine cannot be started unless the shift selector is in “P” (park) or “N”...
  • Page 42 3. After the engine has started, let it warm up until the needle on the coolant temperature gauge begins to move. P. 5-10 Z08917 3 Starting the engine when the vehicle has been parked for an extended period When the vehicle is not used for a week or more, or the engine oil and oil filter are replaced, the engine becomes starved for oil.

  • Page 43: Warming Up The Engine

    If exhaust gases that have leaked from the exhaust pipe come into the cab, ventilate the cab with fresh air by opening the windows fully or by opening the doors. Be sure to bring the vehicle to an authorized Sterling service agency for inspection and repairs.
  • Page 44 5-11 NOTE: Idling the engine for a long time wastes fuel. It wastes natural resources and causes air pollution. Shut down the engine whenever you leave the vehi- cle, even for a short period. If the engine has been idling for a relatively long time, the muffler may give off white smoke during acceleration.

  • Page 45: Shutting Down The Engine

    5-12 Switches and controls 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 braking efficiency, and make steering extremely difficult. This could cause an injury accident or loss of life.
  • Page 46 If the warning light illuminates while the vehicle is being driven, the disc brake pads may need replacement. Have the disc brake pads inspected at an authorized Sterling service facil- ity. • As a bulb check, the warning light illumi- nates when the ignition switch is turned on and goes off approximately three seconds later.
  • Page 47 5-14 Switches and controls Shift lever <Manual transmission vehicles> WARNING When backing up, always double check to make sure that there is nothing in your path. If there are pedestrians in the area, or haz- ards are present, use a backing guide. This could prevent an injury accident and loss of life.
  • Page 48 This problem can be caused by an electrical fault. Shift lock Bring the vehicle to an authorized Sterling service release knob facility for inspection. 2 Ranges P: Use “P”...
  • Page 49 5-16 Switches and controls 3: Use “3” to drive at low speed or when engine braking is needed on a downhill grade. The transmission shifts automatically from 1st through 3rd gears. 2: Use “2” for driving on steep hills and through mud and snow.

  • Page 50: Parking Brake Lever

    5-17 Overdrive lockout switch <Automatic transmission vehicles> Overdrive can be switched on and off with the switch located on the shift selector. When the switch is in the “OFF” position, an indicator illuminates. Z11854 • Overdrive ON Overdrive should be switched on as desired for nor- mal driving and always for high-speed driving.

  • Page 51: Multifunction Switches

    5-18 Switches and controls Parking To set the parking brake, pull the lever all the way out. The warning illuminates at the same time. Releasing Raise the lever slightly, press and hold the release button , and lower the lever with the release but- ton still pressed.

  • Page 52: Headlight High Beam Dimmer

    5-19 Position Auxiliary lights Headlights DRLs* DRLs* DRLs are illuminated by the daytime running light system. NOTE: This vehicle is equipped with daytime running lights. (DRLs). The headlights remain on (although at diminished brightness), even when the vehicle is operated with the headlight switch in the “OFF” or auxiliary light position.

  • Page 53: Exhaust Brake

    5-20 Switches and controls 5 Exhaust brake WARNING Do not use the exhaust brake on slippery road surfaces. The vehicle may skid, causing an injury accident or loss of life. The exhaust brake enhances engine braking. Use it as an auxiliary braking device on downhill stretches or during high-speed driving.
  • Page 54 5-21 Full exhaust brake function will return as soon as the original conditions have been restored. Wiper/ washer switch WARNING In cold weather, use the heater to warm the windshield before operating the washers. Washer fluid could freeze on the windshield, obstruct your vision, and cause an accident.

  • Page 55: Hazard Flashers

    5-22 Switches and controls Hazard flashers CAUTION If the hazard flashers are operated for an extended period of time, this can discharge the battery and make the engine impossible to start. The hazard flashers are used to warn other traffic if you find it necessary to stop your vehicle in an emergency.

  • Page 56: Rearview Mirrors

    5-23 Rear view mirrors The side rear view mirrors can be moved by hand in the direction of the arrow. Swing the mirror inward if the mirror is obstructing vehicle movement, for example, when turning a tight corner, passing an oncoming vehicle, or park- ing in a narrow place.

  • Page 57: Instrument Cluster Gauges And Lights

    6. Instrument cluster gauges and lights Instrument cluster layout ............. . 6-2 Speedometer .

  • Page 58: Instrument Cluster Layout

    Instrument cluster gauges and lights Instrument cluster layout Speedometer Tachometer Coolant temperature gauge Fuel level gauge Warning and indicator lights Z11892 Speedometer 1 Speedometer The speedometer indicates vehicle speed in miles and kilometers per hour. Odometer/Tripmeter Z11893 2 Odometer/tripmeter With the ignition switch in the “ON” position, either “ODO”...

  • Page 59: Coolant Temperature Gauge

    CAUTION The term “overspeed condition” is used when engine speed (RPM) exceeds the maximum safe limit. This can occur when the engine is driven by the wheels during downhill driving or down- shifting. Persistent engine overspeed can cause an engine breakdown. <Manual transmission vehicles>...

  • Page 60: Fuel Level Gauge

    Instrument cluster gauges and lights <Manual transmission vehicles> Fuel level gauge The fuel level gauge indicates the amount of fuel 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 <Automatic transmission vehicles>...

  • Page 61: Warning And Indicator Lights

    Bring the vehicle to a complete stop and investigate the cause of the problem. If necessary, have your vehicle repaired by an authorized Sterling service facility. NOTE: Red warning lights may also come on if the engine is started when the battery is not sufficiently...
  • Page 62 Instrument cluster gauges and lights Symbol Warning/indicator light Indication Ref. page Turn signal The turn signals flash 5-19 Headlight high beam indicator Headlight high beams illuminate 5-19 5-4, The engine brake operates, or the engine Exhaust brake indicator 5-11, warm-up system operates 5-20 Engine preheat indicator Engine preheat is on...
  • Page 63 As a bulb check, these warning/indicator lights come on, and quickly go off, when the ignition switch is turned from “ACC” to “ON,” or when the engine is started. Symbol Light Operation Goes off when the engine is started and the Brake warning parking brake is released.

  • Page 64: Vacuum Pressure Warning

    3. If the light does not go out, or comes on again soon after it has gone out, the vacuum system is defective. Bring the vehicle to an authorized Sterling service facility for repairs. 2 Brake warning WARNING Do not continue to operate the vehicle if the brake warning illuminates while driving.

  • Page 65: Alternator No Charge Warning

    3. If the fluid level drops, it indicates fluid leakage. Bring the vehicle to an authorized Sterling ser- vice facility for repairs. 3 Alternator no charge warning The alternator no charge warning illuminates as a bulb check when the ignition switch is turned to “ON.”...

  • Page 66: Transmission Temperature Warning

    (located on the left-hand side of the vehicle). Bring the vehicle to an authorized 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.

  • Page 67: Abs Warning

    If the light stays off, there is no problem. If the light illuminates again, bring the vehicle to an authorized Sterling service facility as soon as possible. Check engine warning (red) The red check engine warning illuminates when there is a serious malfunction in the electronic con- trol circuitry of the fuel injection system.

  • Page 68: Automatic Transmission Warning

    If the fault does not clear, or the light soon comes back on, have the vehicle checked by an authorized Sterling service facility. Even with a fault in the electronic control system, the vehicle can still be driven in a “derate” mode.

  • Page 69: Starting And Driving

    7. Starting and driving Vehicle start-up ..............7-2 Vehicle operation .

  • Page 70: Vehicle Start-Up

    Starting and driving Vehicle start-up • Do not carry containers of fuel or spray cans in the cab. WARNING Z11316 Do not carry fuel in the cab. An increase in cab temperature could cause the fuel vapor to catch fire, with risk of personal injury or loss of life.

  • Page 71: Vehicle Operation

    P. 6-5 • If you are unable to identify the cause of the problem, contact an authorized Sterling service facility. • Be especially careful during high-speed driving. Avoid sharp turns and hard braking except in emergencies.
  • Page 72 Starting and driving • While driving, keep your eyes moving. Keep a clear view ahead, behind, and to both sides of the vehicle. • Do not keep the steering wheel turned all the way to either side for more than 10 seconds. This could cause the power steering system to malfunction.
  • Page 73 • Do not release the clutch pedal suddenly. This places undue stress on the vehicle and shortens the service life of the clutch. • Do not operate the vehicle with the clutch disen- gaged or the gearshift lever in neutral. This makes the exhaust brake ineffective.

  • Page 74: Improving Fuel Economy

    Starting and driving Improving fuel economy Observe the following precautions to achieve maxi- mum fuel economy and to extend tire life. • When the needle on the coolant temperature gauge begins to move upward, the engine is warm enough. Further warming wastes fuel. •...

  • Page 75: Braking

    Braking On downhill grades, use the engine brake and the exhaust brake to slow the vehicle, before using the service brakes to stop the vehicle. Do not rely exclusively on the service brakes. P. 7-9 Z01416 WARNING • If any of the brake warning lights illumi- nate, there is a possibility of brake failure.
  • Page 76 Starting and driving NOTE: On slippery surfaces, the wheels could lock when the brakes are applied. This could cause a skid. ABS controls the braking force applied to each wheel in order to minimize skids. • If the warning light illuminates during driv- ing, it indicates an ABS fault.

  • Page 77: On Uphill And Downhill Grades

    • Before you install radio transmitter/receiver equipment or tires of a size different from the original ones, be sure to consult an authorized Sterling service facility. • Even if the ABS system fails and the warn- ing light illuminates, the service brakes can still stop the vehicle, although brake performance may be reduced under certain conditions.
  • Page 78 7-10 Starting and driving • Never coast downhill with the shift lever in neu- tral <manual transmission vehicles> or the shift selector in “N” (neutral) <automatic transmission vehicles>. This eliminates the effect of both the engine brake and the exhaust brake. This causes the service brakes to overheat and the brake linings to wear prematurely.

  • Page 79: On Rough Roads And In Bad Weather

    If water has entered the high-amp fuse box, remove the water and have the vehicle inspected by an authorized Sterling service facil- ity. Water in the high-amp fuse box could cause a short circuit that results in a fire.

  • Page 80: Parking

    7-12 Starting and driving 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. • engine exhaust pipe extremely hot immediately after the vehi- cle has been driven.
  • Page 81 7-13 WARNING Brake faults that would cause the warn- ing light to illuminate have no effect on the parking brake. If the warning light illumi- nates, the parking brake will stop the vehicle if necessary and prevent an injury accident. 2.

  • Page 82: Limited-Slip Differential

    7-14 Starting and driving Limited-slip differential A limited-slip differential performs a special func- tion. When one wheel begins to spin on a slippery surface, a limited-slip differential diverts torque to the wheel which is not spinning, providing more traction to the vehicle. This function is effective when driving on bumpy or Z09030 snow-laden roads, and useful when moving the...

  • Page 83: Loading Cargo

    7-15 Loading cargo WARNING • Overloading the vehicle can cause an injury accident or loss of life. • Do not carry passengers in the cargo area while the vehicle is in motion. This can cause an injury. 1 Do not overload the vehicle. •...
  • Page 84 7-16 Starting and driving 2 Load the cargo correctly. • Improperly loaded cargo is unstable. If the weight distribution is uneven, this could damage the cargo deck and frame. • When spreading a tarpaulin, take care not to let it cover, or be drawn into, the engine air intake.

  • Page 85: Heating And Air Conditioning

    8. Heating and air conditioning Front air outlets ..............8-2 Heater .

  • Page 86: Front Air Outlets

    Heating and air conditioning Front air outlets Z14908 1 Adjusting the airflow direction • 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.

  • Page 87: Heater

    Heater NOTE: • The heater uses the heat produced by the engine. Therefore, warm air is not available until the engine is warm. • As the engine warms up with the vehicle parked, use the engine warm-up switch to heat the cab faster.
  • Page 88 Heating and air conditioning Recirculation button The recirculation button allows you to choose between fresh outside air or recirculated inside air. Press the button to select recirculated air. When recirculated air is selected, the recirculation indica- in the switch illuminates. With recirculated air selected, press the button again to toggle back to fresh air.
  • Page 89 • For airflow toward the feet: Place the air selection switch in the foot position. Z14912 • For airflow toward the feet and toward the windshield: Place the air selection switch in one of the two floor/defrost 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...
  • Page 90 Heating and air conditioning 2 Using the heater controls To heat the cab Place the air selection switch in the foot/defrost 75- position or in the foot position. Z11307 For cool airflow toward the head and warm airflow toward the feet Place the air selection switch in the bi-level position or in the foot position.

  • Page 91: Air Conditioner

    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...
  • Page 92 Heating and air conditioning 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 Z05610 Temperature control switch The temperature control switch allows you to adjust...
  • Page 93 A/C (air conditioner) button The A/C button provides cool, dry air to the cab. Press the button to turn on the air conditioning. When air conditioning is selected, the A/C indicator in the center of the switch illuminates. With the A/C indicator on, press the button again to turn off the air conditioning.
  • Page 94 A/C on. If bubbles are visible, the refrigerant level is too low. Have your system charged at any authorized Sterling service facility. Refrigerant level low Refrigerant level normal...

  • Page 95: Outside Air Inlets

    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.
  • Page 96 9. Interior equipment and accessories Cigarette lighter ..............9-2 Ashtrays .

  • Page 97: Cigarette Lighter

    If the lighter remains in its socket for more than 30 Z14918 seconds, pull it out by hand. Have the lighter inspected by an authorized Sterling service facility. Do not use a cigarette lighter if the case is deformed or misshapen. A deformed lighter will not pop out properly.

  • Page 98: Ashtrays

    Ashtrays Remove and empty the ashtrays when they become full. Be sure to extinguish any flammable materials before putting them in ashtrays. WARNING • To prevent fires, close the lids on the ash- trays completely. • Use the ashtray only for smoking materi- als.

  • Page 99: Coat Hooks

    Interior equipment and accessories Coat hooks Use the coat hooks to hang clothing or similar items. CAUTION Z08840 Do not pull the coat hooks with excessive force or hang heavy items on them. This could cause them to break. Sun visors The sun visor screens your eyes from sunlight.

  • Page 100: Storage Compartments

    Storage compartments Z14919 1. Accessory box 6. Rear panel box 10. Map compartment 2. Hook 7. Cup holder 11. Parcel tray 3. Door pocket 8. Seatback trays 12. Card holder 4. Bottle holder 9. Glove compartment 13. Appliance cases 5. Center console WARNING Always close the storage compartments before operating the vehicle.
  • Page 101 Interior equipment and accessories Accessory box Use the accessory box to keep small articles. Hook There is hook on the front of the bottle holder in the center console. Use this hook to hang a trash bag or other small container. Door pocket There is a pocket in the driver’s door.

  • Page 102: Radio

    Card holder Use the card holder to hold tollway tickets and other similar items. Appliance cases The appliance cases provide space to mount a radio or other audio equipment. Z11989 Radio The radio can be used with the ignition switch in the “ON”...

  • Page 103: Accessories

    Interior equipment and accessories Accessories • See an authorized Sterling dealer if you are con- sidering adding accessories to your vehicle. • Your vehicle contains electronic devices. Even though these are protected against interference from electromagnetic emissions, you should consult an authorized Sterling dealer before...
  • Page 104 10-1 10. In cold weather Coolant ................10-2 Engine oil .

  • Page 105: Engine Oil

    • This coolant contains corrosion-inhibiting anti- freeze to protect the cooling system. For added safety, have an authorized Sterling service facil- ity check that the coolant mixing ratio is correct before the onset of winter. • Be sure to use fully-formulated antifreeze with corrosion inhibitors and add it in the correct mix- ing ratio.

  • Page 106: Cold Weather Operation

    10-3 Cold weather operation • If the engine fails to start, return the ignition switch to the “ACC” or “LOCK” position. Wait for the battery to recover before trying to start the engine again. • As the temperature falls, battery performance decreases.
  • Page 107 10-4 In cold weather Installing tire chains • Make sure that tire chains are installed properly so that they do not become loose and interfere with other vehicle parts while the vehicle is in motion. • Use triple chains corresponding to tire size. CAUTION •...
  • Page 108 10-5 3. Temporarily connect the hook on the outside chain as shown. Z11190 4. Pull the middle chain as tight as possible and connect it to the hook. 5. Pull both ends of the outside chain as tight as possible and close the hook Z11191 6.

  • Page 109: Pretrip Inspection And Maintenance

    11-1 11-4 11. Pretrip inspection and maintenance General service precautions ............11-2 Tilting the cab .

  • Page 110: General Service Precautions

    11-2 Pretrip inspection and maintenance General service precautions WARNING • Never run the engine in a poorly ventilated area. Diesel exhaust will replace the breathable air within an enclosed space, possibly resulting in unconsciousness or death. • Batteries release a gas mixture that is explosive.
  • Page 111 Replace filters and filter elements regularly. Blocked or damaged filters can reduce the engine’s power and impair its operation. Always use genuine Sterling parts for replacements. Use the service products rec- ommended in this manual. Use of any other parts or service products may lead to com- ponent failure.

  • Page 112: Tilting The Cab

    11-4 Pretrip inspection and maintenance Tilting the cab 1 Preparation WARNING • Never tilt the cab when the vehicle is on any kind of slope. The cab will move too quickly under the effect of inertia if it is tilted on a slope, possibly causing compo- nent damage and personal injury.
  • Page 113 11-5 2 Raising the cab CAUTION Raise the cab slowly and gradually. Raising it quickly and using too much force could damage the cab tilt mechanism. 1. Pull out the primary release (lever A) . While holding lever A, lift the secondary release (lever Z10672 2.
  • Page 114 11-6 Pretrip inspection and maintenance 3 Lowering the cab 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.

  • Page 115: Pretrip Inspection

    If you find any problem which you are unable to correct yourself, bring the vehicle to an authorized Sterling service facility. 1 Before starting the engine Z15024a...
  • Page 116 11-8 Pretrip inspection and maintenance Coolant level Check that the coolant level is between the “FULL” and “LOW” marks on the surge tank. P. 11-35 Z11188a 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.
  • Page 117 11-9 Shift selector <Automatic transmission> Turn ON the ignition switch but do not start the engine. • 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 indicates the correct range.
  • Page 118 11-10 Pretrip inspection and maintenance Brake fluid level Check that the brake fluid level is between the “MAX” and “MIN” marks on the reservoir. P. 11-25 Z12050a Windshield washer fluid level Check that the windshield washer fluid level is above the bottom of the inspection window. P.
  • Page 119 11-11 Defroster operation Make sure that warm air blows properly onto the windshield. P. 8-3, 8-7 Z11696 Lighting system Make sure that each lamp illuminates or flashes properly. Check each lens for dirt and damage. P. 5-18 Z12505 Instrument cluster Check that all gauges and telltale (warning and indicator) lights are working properly.
  • Page 120 11-12 Pretrip inspection and maintenance Seat belts Confirm that the seat belt fastens correctly. P. 4-4 Z11943 3 While walking around the vehicle Z15025a Wheel and tire Check the disc wheels for cracks and other damage. Check the tire inflation pressure and tread groove depth.
  • Page 121 11-13 Suspension Look for broken springs. Check the vehicle body for tilt to either side. Z10753 License plate and reflector Check the license plate and reflectors for loose installation, damage, and dirt. Z15026a 4 While driving at slow speeds Perform the following checks while driving in a safe place at speeds lower than 12 mph (20 km/h).

  • Page 122: Use Of Lubricants

    Consult an authorized Sterling service facility for the maintenance schedule appropriate to your vehicle operating conditions. •...
  • Page 123 11-15 <FE> Z12034 1. Rear spring pin, forward 3. King pin bearing 5. Propeller shaft slip joint 2. Rear spring pin, aft 4. Propeller shaft universal joint Recommended lubricant: Chassis grease NLGI No. 1 (Li soap) Rear spring pin, forward (2 points total, one on each side) Z09225 Rear spring pin, aft (4 points total, 2 on each...
  • Page 124 11-16 Pretrip inspection and maintenance King pin bearing (4 points total, 2 on each side) Recommended lubricant: Wheel bearing grease Z09227 NLGI No. 2 (Li soap) Propeller shaft (driveshaft) universal joint Z09228 Propeller shaft (driveshaft) slip joint NOTE: The number of grease fittings on the propeller shaft differs from model to model.

  • Page 125: Oils And Fluids

    11-17 Atmospheric temperatures when engine is started. Oils and fluids 1 Engine oil The performance, service lifetime, and startability of the engine depend to a large degree on the quality of the engine oil. Always use oil of the correct grade and viscosity.
  • Page 126 11-18 Pretrip inspection and maintenance Level checking using the low oil level switch (simplified method) 1. Press the switch before starting the engine. Esti- mate the oil level from the color of the engine oil level light that comes on when the engine is started.
  • Page 127 11-19 CAUTION • Add oil of the same grade and viscosity as the original engine oil fill. Mixing oil can damage the engine. • Do not add more than the necessary quantity of oil. The engine can be severely damaged if the correct oil level is not maintained.

  • Page 128: Manual Transmission Oil

    11-20 Pretrip inspection and maintenance CAUTION • Do not add more than the necessary quantity of oil. The engine can be severely damaged if the correct oil level is not maintained. • If the engine is frequently run at high speed or under heavy load, the engine oil will suffer viscosity breakdown and must be replaced sooner than scheduled.
  • Page 129 11-21 Quantity required (approximate): Model Quantity 5-speed transmission 3.8 quarts (3.6 L) 6-speed transmission 4.6 quarts (4.4 L) Checking transmission oil level 1. Remove the fill plug and make sure that the oil is level with the lower edge of the fill opening. 2.

  • Page 130: Automatic Transmission Fluid

    Automatic transmission fluid (Exxon Mobil: Mobil ATF3309 or equivalent) Have automatic transmission fluid (ATF) changed by an authorized Sterling service facility. Check the fluid level when the fluid is at operating temperature. Use the “HOT” range on the ATF dip-...

  • Page 131: Axle Oil

    11-23 CAUTION • Operating the vehicle with the ATF level higher or lower than recommended can result in transmission damage. Do not over- fill the transmission. • To prevent damage to the automatic trans- mission, add ATF from a clean container. 4 Axle oil Every 6000 miles Inspection interval...
  • Page 132 11-24 Pretrip inspection and maintenance Checking axle oil level 1. Remove the fill plug and make sure that the oil is level with the bottom of the fill opening. 2. If the level is too low, add oil through the fill hole until it is at the level of the fill opening.

  • Page 133: Brake Fluid

    • If the fluid level drops abnormally, there may be a brake fluid leak. Have the brake system inspected by an authorized Sterling service facility. • If brake fluid is not changed regularly, com- ponents of the brake system can be dam- aged.

  • Page 134: Power Steering Fluid

    “MIN” lines on the brake fluid reservoir . If you see contamination of any kind in the reservoir, have it inspected and cleaned by an authorized Sterling service facility. If the fluid level is unusually low, there may be a fluid leak in the brake line.
  • Page 135 If power steering fluid leaks out, it could cause a fire, resulting in burn injuries. • If the power steering fluid level drops abnormally, there may be a fluid leak. Have the steering system inspected by an authorized Sterling service facility.

  • Page 136: Filter Element Replacing

    11-28 Pretrip inspection and maintenance Filter element replacing 1 Engine oil filter replacing WARNING • Wipe up spilled engine oil. Oil remaining on the engine surface could catch fire and cause a burn injury. • Engine components are extremely hot immediately after vehicle operation.
  • Page 137 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.
  • Page 138 11-30 Pretrip inspection and maintenance 1. Set the parking brake and chock the front tires. 2. Clean the area around the filter to prevent dirt from entering the new element. 3. Place a suitable container under the fuel filter to catch any fuel.
  • Page 139 11-31 CAUTION Do not tighten the filter case too much. Over- tightening could damage the filter case. 13. Install the sensor on the filter case and attach the connector. 40 to 60 lbf·in Sensor torque (400 to 600 N·cm) 14. Bleed the fuel system. P.

  • Page 140: Fuel Filter Draining

    11-32 Pretrip inspection and maintenance Fuel filter draining If the water in fuel warning illuminates, there is too much water in the fuel filter. Drain the fuel filter as follows: WARNING Z12062 • Diesel fuel is combustible and can ignite if exposed to open flame, intense heat, or other source of ignition.
  • Page 141 11-33 Coolant checking and replacing Inspection interval Daily pretrip inspection Replacement interval Every 24 months If the coolant becomes very dirty, replace it immedi- ately regardless of the specified replacement inter- vals. 1 Recommended coolant Use a coolant containing fully-formulated antifreeze and soft water in the correct mixing ratio.
  • Page 142 11-34 Pretrip inspection and maintenance DANGER • COOLANT IS TOXIC. IF A PERSON HAS ACCIDENTALLY SWALLOWED IT, FORCE HIM/HER TO VOMIT AND CONSULT A DOCTOR IMMEDIATELY. IF IT SPLASHES IN THE EYES, IMMEDIATELY FLUSH THE EYES WITH WATER FOR MORE THAN 15 MINUTES, AND SEEK MEDICAL ATTEN- TION.

  • Page 143: Coolant Level Checking

    If you find water on the ground underneath your vehicle, there could be a coolant leak. • If the coolant level is abnormally low and quickly drops again when coolant has been added, there may be a coolant leak. Bring the vehicle to an authorized Sterling service facility.
  • Page 144 11-36 Pretrip inspection and maintenance 5 Adding coolant CAUTION • Under normal conditions, add coolant to the surge tank without opening the pressure cap on the radiator. • When adding coolant, use new coolant of the same kind. Do not mix different types of coolant.

  • Page 145: Coolant Changing

    11-37 6 Cooling system inspection 1. Inspect the radiator and radiator mounts for con- dition. 2. Visually check that the radiator pressure cap seals properly on the cap seat. 3. Visually inspect the coolant hoses for leaks. 7 Charge air cooler and radiator cleaning Remove dust and deposits from the radiator and charge air cooler.
  • Page 146 CAUTION If the radiator lines are clogged or the coolant is badly contaminated, bring your vehicle to an authorized Sterling service facility. 8. Make sure the radiator petcock and engine drain plug are securely fitted. 9. Tilt the cab.

  • Page 147: Drive Belt Checking And Adjusting

    11-39 Drive belt checking and adjusting An excessively loose or tight belt could cause the engine to overheat, the battery to be inadequately charged, or the alternator or water pump to mal- function. Always keep the belt adjusted to the proper tension.

  • Page 148: Shift Selector Checking

    4. Return the shift selector to “P” (park). Turn the ignition key to LOCK and make sure the key can be removed from the switch. 5. If any problem is found, do not drive the vehicle. Contact an authorized Sterling service facility.

  • Page 149: Steering Wheel Checking

    The steering wheel is critical to vehicle safety. If an inspection reveals any problem, contact an autho- rized Sterling service facility to solve the problem before operating the vehicle. Conduct these checks on a level surface with good visibility to all sides.

  • Page 150: Service Brake Checking

    Service brake checking The service brakes are critical to vehicle safety. If an inspection reveals any problem, contact an authorized Sterling service facility to solve the prob- lem. Inspection interval Daily pretrip inspection 1 Brake pedal free play <COE 40, 45: vacuum pressure booster>...
  • Page 151 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>...

  • Page 152: Parking Brake Checking And Adjusting

    3. If there is any problem, contact an authorized Sterling service facility. Clutch checking <Manual transmission vehicles> Inspection Daily pretrip inspection and intervals every 6000 miles (10 000 km) Check the clutch for condition. If there is any prob- lem, contact an authorized Sterling service facility.

  • Page 153: Tire Checking

    4. Measure the amount of clutch pedal movement between these two points. This is the clutch pedal free play . If the free play is not within these limits, contact an authorized Sterling ser- Z11613 vice facility. Clutch pedal free play 0.008 to 0.157 in...
  • Page 154 11-46 Pretrip inspection and maintenance Standard inflation pressure Inflation Model Tire size pressure psi (kPa) COE 40, 45 LT215/85R16-10PR 80 (550) (Load Range E) 215/75R17.5 124/ COE 50 123L (Load Range F) 100 (690) • A sign affixed to the driver’s door B-pillar indi- cates standard inflation pressure.
  • Page 155 11-47 2 Checking tread depth Check the entire circumference of each tire to make sure that the remaining tread is deep enough. Tread groove depth 0.063 in (1.6 mm) limit When the tread wears down, interruptions in the groove pattern, or wear bars (see illustration) appear across the tire at the locations correspond- ing to the...

  • Page 156: Tire Replacing

    11-48 Pretrip inspection and maintenance Tire replacing 1 Prepare for tire replacement NOTE: If you get a flat tire while on the road and need to change it right away, pull the vehicle to the side of the road as soon as it is safe to do so. Turn on the hazard flashers and set up a reflective triangle or flare behind the vehicle.
  • Page 157 11-49 Rear axle • Bottom surface of the axle housing Z12086 3 Removing the wheel WARNING • After raising the vehicle slightly, confirm that the jack is firmly seated at the jacking point and will not move when the vehicle is raised.
  • Page 158 11-50 Pretrip inspection and maintenance 3. Slightly loosen the wheel nuts by turning them in the illustrated direction. Do not remove the nuts yet. For right-hand threaded wheel nuts, turn counterclockwise For left-hand threaded wheel nuts, turn clockwise NOTE: The wheel nuts on the right-hand side are marked with “R”...
  • Page 159 11-51 4 Mounting the wheel 1. Clean the following areas before mounting the wheel. Dirt or debris in these areas could cause the wheel nuts to become loose during opera- tion. Threads of the wheel studs and nuts The spherical surface of the wheel nuts Inner wheel and hub mounting surfaces Dual wheel mating surfaces Wheel nut seating surfaces...
  • Page 160 11-52 Pretrip inspection and maintenance 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.

  • Page 161: Wheel Nut Tightening

    11-53 Wheel nut tightening Every 6000 miles Inspection interval (10 000 km) With a new vehicle, perform the first inspection at the initial maintenance period of 2500 miles (4000 km). WARNING After changing a tire, the wheel nuts will loosen somewhat as they wear in, creating a potential for an injury accident.

  • Page 162: Tire Rotation

    11-54 Pretrip inspection and maintenance Same tread pattern on all tires Tire rotation The amount of wear on a tire depends on its posi- tion on the vehicle. To equalize wear and extend life as much as possible, rotate the tires at regular inter- vals.

  • Page 163: Wiper Blade Replacing

    11-55 Wiper blade replacing 1 Replacing the wiper blade 1. Raise the wiper arm , and push the locking clip in the direction of the arrow (see illustra- tion). Z05981 2. With the locking clip held in, press the wiper toward the wiper arm.

  • Page 164: Windshield Washer Fluid Level Checking And Refilling

    11-56 Pretrip inspection and maintenance Windshield washer fluid level checking and filling 1 Washer fluid level checking Check the washer fluid level through the level check window When the level has dropped to the lower part of the window or is no longer visible, refill the tank with Z12091 washer fluid.

  • Page 165: Battery Inspection

    11-57 Battery inspection DANGER PROTECT SKIN AND EYES FROM BATTERY ELECTROLYTE. ELECTROLYTE IS CORRO- SIVE AND COULD RESULT IN SERIOUS PER- SONAL INJURY. If electrolyte is splashed on your skin or in your eye, force the eye open, rinse it with cool, clean water for about five minutes, and call a doctor immediately.
  • Page 166 11-58 Pretrip inspection and maintenance 1 Removal and installation of the battery cover 1. Pull the latch on the left side of the battery to unhook it from the cover , and raise the left end of the cover by about 2 in (50 mm). 2.
  • Page 167 11-59 3 Cleaning the terminals 1. Remove any corrosion with a wire brush, and wash with a weak solution of baking soda and water. Rinse with clean water and dry. 2. To provide corrosion protection, apply pumpable dielectric grease to the battery terminals. 4 Charging a battery NOTE: If the battery is cold, let it warm up.

  • Page 168: Hvac Filter Cleaning

    1 Outside air filter Disassembly is required to clean the outside air fil- ter. Do not attempt to remove this filter yourself. Bring the vehicle to an authorized Sterling service facility.
  • Page 169 11-61 2 Screen filter (inside cab) • Removal 1. Remove the four screws on the bottom of the lower center panel and the bottom of the pas- senger’s kick panel 2. Release the spring clips on the passenger’s kick panel and lower center panel, and remove the passenger’s kick panel from the dash.

  • Page 170: Exhaust System Inspection

    11-62 Pretrip inspection and maintenance Exhaust system inspection The exhaust system is inspected to control noise and emissions. In addition to inspection at the regu- lar maintenance interval, inspect the exhaust sys- tem if the noise level of the vehicle has increased. 1.
  • Page 171 11-63 Washing • Using a hose, wash the mud and dirt off the body surfaces. Wash not only the surfaces around the cab, but also the wheel wells and the underside of the chassis. • After driving in a coastal area or on a salted road in the winter, give your vehicle a thorough wash- ing.
  • Page 172 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 paint for small chips and scratches. 2 Interior cleaning...
  • Page 173 11-65 Cleaning interior trim Keep the vehicle’s interior trim clean at all times. 1. Remove dust from the trim with a vacuum cleaner or soft brush. 2. Wipe vinyl trim areas carefully with a cloth dampened with water. 3. Wipe dirt and scuff marks from the trim with a commercially available cleaner.
  • Page 174 11-66 Pretrip inspection and maintenance Removing the floor mat for cleaning When removing the floor mat for cleaning, you must raise the accelerator pedal by using the following method. 1. Hold the hooked end of the pedal stop with pliers. As you pull the pedal stop toward the front of the vehicle, twist the hooked end through approximately 15 degrees from vertical.
  • Page 175 12-1 12. In an emergency Troubleshooting ..............12-2 Emergency stops .

  • Page 176: Troubleshooting

    In an emergency Troubleshooting Performing the pretrip inspection and regular main- tenance on your Sterling 360 vehicle will help ensure that it delivers safe, reliable service and opti- mum performance for years to come. Be sure to check and service your vehicle regularly.
  • Page 177 The engine continues to run (diesels) after being shut down Possible cause Remedy Ref. page The fuel injection system is malfunctioning. Bring the vehicle to an authorized Sterling – service facility. The ignition switch is malfunctioning. Bring the vehicle to an authorized Sterling –...
  • Page 178 11-29 Air is present in the fuel system. Bleed the fuel system. 12-23 The clutch disc is worn. Bring the vehicle to an authorized Sterling – service facility. The radiator is damaged or dirty. Clean the front of the radiator.
  • Page 179 The tires are damaged. Replace tires. 11-48 The tires or brakes are not properly balanced. Bring the vehicle to an authorized Sterling – service facility. The brake rotors are worn (vibration is noticed Bring the vehicle to an authorized Sterling –...

  • Page 180: Emergency Stops

    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. WARNING Never attempt to perform repairs on an expressway or in a tunnel.

  • Page 181: If The Engine Overheats

    “FULL” line. P. 12-39 4. Check the front of the radiator for dirt. Clean the radiator if necessary. 5. If there are coolant leaks or the engine repeat- edly overheats, bring the vehicle to an autho- rized Sterling service facility.

  • Page 182: Replacing Fuses

    12-8 In an emergency Replacing fuses • The main fuse box is located in the lower center panel. Fuses are also found in the high-amp fuse box located behind the cab on the left frame rail. • Before checking or replacing fuses, turn the igni- tion switch to the “LOCK”...
  • Page 183 Z11217a • 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.
  • Page 184 12-10 In an emergency <Fuse box> Z15090 Fuse <High-amp fuse box> Amperage Protected circuit Cigarette lighter Audio system Auxiliary power supply (accessory bus) Brake lights Instrument cluster Turn signals Auxiliary power supply (battery bus) Audio system Dome lights Power window (driver’s) Power window (passen- ger’s) Z12082a...
  • Page 185 12-11 Fuse Amperage Protected circuit Air conditioner Air conditioner condenser HVAC blower fan Dome light Automatic transmission cooling fan Engine drive unit Backup lights Instrument cluster Wipers Auxiliary power supply (ignition bus) Relay control Automatic transmission Exhaust brake Engine control unit Starter Spare fuse Automatic transmission...
  • Page 186 Z15038a 2. Check for a blown high-amp fuse. Look into the inside of the fuse through the view window If a high-amp fuse blows, call an authorized Sterling service facility immediately. Z11258...
  • Page 187 12-13 Amperage Protected circuit (casing color) Fuse box (S1, A1 – A5, 60A (yellow) M1 – M12) Fuse box 60A (yellow) (B1 – B12) Fuse box 40A (green) (B13 – B16) Hydraulic brake 60A (yellow) booster 40A (green) ABS motor 40A (green) ABS valve BATT1...

  • Page 188: Replacing Light Bulbs

    12-14 In an emergency Replacing light bulbs Whenever replacing a bulb, be sure to place the ignition switch in the “LOCK” position and all other switches in the OFF position. WARNING Use a bulb of the specified voltage and watt- age shown in the following table.
  • Page 189 12-15 Z15042a Ref. No. Bulb Specification Part Number Qty. Headlight 12V-60/55W MS820970 Parking light 12V-5W Front and side turn signal 12V-21W MS820046 Brake light/taillight (double filament) 12V-21/5W MS820040 Rear turn signal 12V-21W MS820046 Backup light 12V-21W MS820046 License plate light 12V-7.5W MF820181 Clearance and side marker light...

  • Page 190: Headlight Bulb Replacement

    12-16 In an emergency 1 Headlight bulb replacement For safety and simplicity, bulb replacement is per- formed with the headlight removed. In order to remove the headlight, the front and side turn signal lens and the reflector must be removed first. Headlight removal and installation •...
  • Page 191 Turning the beam 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,...
  • Page 192 12-18 In an emergency • Install the headlight. 1. Insert the tabs on the headlight into the slots , and position the headlight properly. Z11272 2. Install the headlight bolts and connector Z11625 3. Pull out the reflector keeper screw until it is fully extended.
  • Page 193 12-19 8. Open the door, then tighten the keeper screws behind the front and side turn signal lens and the keeper screw behind the reflector CAUTION • Press the front and side turn signal lens fully in toward the centerline of the vehicle. If the lens was not pressed fully into place and you opened the door, the door could hit the lens Z11624...
  • Page 194 12-20 In an emergency 2 Front and side turn signal bulb replace- ment 1. Open the door. 2. Turn the bulb fixture counterclockwise (in the direction of arrow ) to remove it from the vehi- cle. 3. Press in the bulb and turn it clockwise (in the direction of arrow ) to remove it from the fix-...

  • Page 195: Difficult Braking

    Set the parking brake if necessary. Contact an authorized Sterling service facility right away. Z11281 WARNING •...

  • Page 196: Emergency Starting With Jumper Cables

    12-22 In an emergency Emergency starting with jumper cables WARNING • If you attempt to charge a battery with a very low electrolyte level, it could overheat or explode, causing a severe personal injury. • Do not allow the clamps of one cable to touch the clamps of the other cable.

  • Page 197: Bleeding The Fuel System

    12-23 6. Start the engine of the vehicle with the booster battery, and let the engine run a few minutes. 7. Attempt to start the engine of the vehicle with the discharged battery. Do not operate the starter longer than 15 seconds, and wait at least 30 seconds between starting attempts to allow the starter to cool.

  • Page 198: Towing

    12-24 In an emergency 2. Place a suitable container under the hose to catch the fuel. 3. Loosen the air vent plug on the fuel filter. 4. Operate the hand pump on top of the fuel fil- ter. Fuel containing air bubbles will flow from the air vent plug into the hose.
  • Page 199 12-25 • To prevent damage to the front bumper when raising the front wheels, attach an L-shaped pro- tection plate. • Tow the vehicle only with a truck that is specially designed for towing heavy equipment. • If you disconnect the rear axle shaft to tow the vehicle, the axle lubricant level may be low.

  • Page 200: Service Data

    13-1 13. Service data Recommended lubricants/hydraulic fluids and quantities ........13-2 Service specifications .

  • Page 201: Recommended Lubricants/Hydraulic Fluids And Quantities

    13-2 Service data Recommended lubricants/hydraulic fluids and quantities 1 Quantities of lubricating and hydraulic fluids Item Quantity: quarts (liters) Oil pan 9.5 (9.0) Engine Oil filter 1.1 (1.0) 5-speed 3.8 (3.6) Manual transmission 6-speed 4.6 (4.4) Total quantity 14.0 (12.9) Automatic transmission Replacement quantity (when drained from drain plug)
  • Page 202 13-3 2 Recommended lubricating and hydraulic fluids Be sure to use the specified lubricants. Viscosity Parts Category Classification Driving SAE viscosity condition number Below 32°F (0°C) 10W–30 Above 5°F (–15°C) 15W–40 API CD, CD/SF, CE, 5 to 59°F 20W–20 Engine Engine oil CE/SF, CF-4 or JASO (–15 to 15°C)

  • Page 203: Service Specifications

    13-4 Service data Service specifications Description Standard value Engine idle speed 625 to 675 rpm Intake 0.016 in (0.4 mm) Engine valve lash Exhaust 0.020 in (0.5 mm) Intake manifold bolt torque value 30 lbf·ft (41 N·m) Exhaust manifold nut torque value 17 lbf·ft (23 N·m) Cranking power of 12-volt maintenance-free batteries 799 CCA...
  • Page 204 14-1 14. Maintenance schedule Maintenance schedule ............. . . 14-2 Lubrication schedule .

  • Page 205: Maintenance Schedule

    14-2 Maintenance schedule Performing regular maintenance on your Sterling 360 vehicle will help ensure that it delivers safe, reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down- time.
  • Page 206 14-3 Time of inspection and maintenance Inspection interval Operation/ Ref. Remarks description page Air cleaner Clean the air cleaner Every 3000 miles/5 000 km 11-31 element cleaning element. Air cleaner Replace the air cleaner × 11-31 element replacing element. Inspect the exhaust system Exhaust ×...
  • Page 207 14-4 Maintenance schedule Time of inspection and maintenance Inspection interval Operation/ Ref. Remarks description page SUSPENSION SYSTEM Check for broken springs. Suspension × Check the vehicle body for 11-13 inspection tilt toward either side. At the first 600 miles/1 000 U-bolt torque ×...
  • Page 208 14-5 Time of inspection and maintenance Inspection interval Operation/ Ref. Remarks description page Seated in the driver’s seat, adjust the angles for clear Rear view mirror × views of the sides and rear. 11-11 adjusting Make sure the mirrors are clean.

  • Page 209: Lubrication Schedule

    14-6 Maintenance schedule 2 Lubrication schedule : Exhaust emission items. Time of inspection and maintenance Inspection interval Operation description Reference page × Engine oil level checking 11-17 × × Engine oil changing × Manual transmission oil level checking 11-20 × ×...

  • Page 210: Alphabetical Index

    15-1 15. Alphabetical index...
  • Page 211 15-2 Alphabetical index ABS warning ........... 6-11 Cup holder ............9-6 Accelerator pedal ..........5-13 Danger of fuel mixtures ........1-5 Accessories ............9-8 Diesel fuel properties ........1-5 Adverse effects of fuel mixtures ......1-6 Dimmer switch ..........5-19 Air cleaner element ........
  • Page 212 15-3 Alphabetical index Hazard flashers ..........5-22 Parking ............7-12 Headlight bulb replacement ......12-19 Parking brake ..........11-44 Headlight high beam dimmer ......5-19 Parking brake lever ......... 5-17 Headlight replacing ........12-16 Passenger’s seat ..........4-3 Headlight switch ..........5-18 Passing signal ..........
  • Page 213 15-4 Alphabetical index Tires .............. 11-45 Towing ............12-24 Transmission temperature warning ....6-10 Tripmeter ............6-2 Troubleshooting ..........12-2 Turn signal light bulb replacement ....12-20 Turn signal switch ........... 5-19 Vacuum pressure warning ........ 6-8 Vehicle cleaning ..........11-62 Vehicle identification number (VIN) ....

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