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2011 13 Owner Manual
2011 13 Owner Manual
1206-20710-K1
All rights reserved. Reproduction by any means, electronic or mechanical including photocopying,
recording or by any information storage and retrieval system or translation in whole or part is not per-
mitted without written authorization from UD Trucks Corporation. UD Trucks may change the contents
without notice and without incurring obligation.
© 2012 UD Trucks Corporation
i
CLEAN IDLE CERTIFIED CALIFORNIA PROPOSITION 65 FEDERAL HIGHWAY
LABEL FOR U.S. WARNING ADMINISTRATION
Make sure that the following clean REGULATION
engine idling certified label is affixed Various regulations relating to vehi-
to the left side of the corner back WARNING cle performance, equipment, and
outer. By the CARB regulation listed safety have been issued by the
Engine exhaust, some of its
below, the label must be affixed Department of Transportation. These
constituents, and certain vehi-
there to prove that the new vehicle regulations include, but are not lim-
cle components contain or
with diesel engine manufactured ited to the Federal Motor Vehicle
emit chemicals known to the
from Jan., 2008 conforms to this reg- Safety Standards and the Federal
State of California to cause
ulation. Motor Carrier Safety Regulations.
cancer and birth defects or
other reproductive harm. In Other federal, state and local regula-
CARB § 1956.8. Exhaust addition, certain fluids con- tions may also apply. Final stage
Emission Standard and tained in vehicles and certain manufacturers and motor carriers
Test Procedure products of component wear are responsible for knowing and
(a) (b) Heavy-Duty Diesel contain or emit chemicals complying with all regulations that
Engine Idling Requirements known to the State of California may apply to the vehicle. A finished
to cause cancer and birth vehicle may also require devices that
defects or other reproductive are not specified in the regulations.
harm. Body builders, subsequent stage
manufacturers and carriers must
determine what safety devices are
necessary for the safe operation of
the vehicle.
ii
WARNING
Making modifications to vari-
ous parts, components and
systems of the vehicle, such
as brake and steering system
can adversely affect the qual-
ity, reliability and operation of
your vehicle and could result
in property damage, serious
injury or death. Such modifica-
tions must be avoided.
iii
iv
TABLE OF CONTENTS
INTRODUCTION AND SAFETY..................... 1-1 Door Window (Power Window) .......................... 5-4
When Reading the Manual................................. 1-1
New Vehicles Break-in Period............................ 1-2
DRIVING POSITION........................................6-1
Seats .................................................................. 6-1
Keys ................................................................... 1-2
Seat Belts ........................................................... 6-5
Fuel .................................................................... 1-3
Steering Wheel ................................................... 6-7
Metric Mismatch ................................................. 1-3
Abbreviation ....................................................... 1-4 INSTRUMENTS AND CONTROLS .................7-1
Ignition Key Switch ............................................. 7-3
IDENTIFICATION............................................ 2-1
Meters and Gauges............................................ 7-5
Vehicle Identification Number (VIN) ................... 2-1
Multi-display Monitor ........................................ 7-15
Unit Identification................................................ 2-2
Warnings and Indicators................................... 7-26
BEFORE DRIVING YOUR VEHICLE ............. 3-1 Buzzers ............................................................ 7-30
Overloading........................................................ 3-2 Warnings .......................................................... 7-31
Towing Trailers ................................................... 3-3 Warning and indicator lights ............................. 7-43
Safety Reminders............................................... 3-6 Switches and Buttons....................................... 7-53
Daily Maintenance.............................................. 3-6 DPF System ..................................................... 7-69
EGR System Operation.....................................3-11 Levers and Control ........................................... 7-75
UD Trucks, US2010 Emissions solution............3-11
Handling of the exhaust emission
ACCESSORIES...............................................8-1
control system .................................................. 3-12 HEATER OR AIR CONDITIONER CONTROL .........9-1
Vehicle Labels .................................................. 3-24 Air Conditioner.................................................... 9-1
ENTERING AND LEAVING THE CAB ........... 4-1 VEHICLE OPERATION .................................10-1
Operating Precautions...................................... 10-1
DOORS AND WINDOWS ............................... 5-1
Break-in Precautions ........................................ 10-2
Door ................................................................... 5-1
Vehicle Loading ................................................ 10-2
Keyless Entry System ........................................ 5-2
v
Towing Trailers ................................................. 10-3 Steering System ............................................. 11-60
Starting the Engine........................................... 10-4 Service Brake System .................................... 11-62
Warming up Engine.......................................... 10-7 Clutch ............................................................. 11-65
Stopping the Engine ......................................... 10-9 Suspension..................................................... 11-67
Driving on Grades .......................................... 10-10 Windshield Washer Fluid................................ 11-68
Driving in Difficult Conditions ..........................10-11 Outside Mirrors............................................... 11-69
Operating with Manual Transmission ..............10-11 Emission Control Systems ............................. 11-70
Operating with Automatic Transmission......... 10-14 Noise Control System..................................... 11-73
Brake Operation ............................................. 10-33 Battery ............................................................ 11-75
Parking your Vehicle ...................................... 10-35 Lights.............................................................. 11-78
After Parking Your Vehicle.............................. 10-36 Fuses.............................................................. 11-80
In Cold Weather ............................................. 10-36 Blower Motor Filters ....................................... 11-82
Idle Shutdown ................................................ 10-38 Wheels and Tires ........................................... 11-83
Appearance Care ........................................... 11-89
VEHICLE SERVICE AND MAINTENANCE...11-1
Clean Air Act .....................................................11-1 IN CASE OF EMERGENCY/
Maintenance Intervals .......................................11-3 TROUBLESHOOTING............................................12-1
Grease Lubrication Points...............................11-16 Engine Overheating.......................................... 12-1
Before Performing Maintenance .....................11-19 Jump Starting ................................................... 12-3
Cab..................................................................11-20 Tire Change...................................................... 12-6
Engine Cooling System...................................11-24 Towing .............................................................. 12-9
Engine Oil and Oil Filters ................................11-31 Troubleshooting.............................................. 12-13
Fuel System ....................................................11-37
Air Cleaner Element ........................................11-44 SERVICE DATA.............................................13-1
Maintenance Standard ..................................... 13-1
Drive Belt.........................................................11-46
Tightening Torque............................................. 13-3
Aftertreatment DEF Filter ................................11-48
Bulbs ................................................................ 13-5
CCV Filter........................................................11-50
Recommended Lubricants ............................... 13-5
Transmission Gear Oil.....................................11-51
Recommended SAE Viscosity Chart................ 13-6
Differential Gear Oil.........................................11-59
vi
Refill Capacities ............................................... 13-7
Conversion Factors .......................................... 13-8
REPORTING SAFETY DEFECTS ................ 14-1
INDEX............................................................ 15-1
vii
INTRODUCTION AND SAFETY
AND SAFETY In this manual, read very carefully those sections which have signs
“DANGER”, “WARNING”, “CAUTION” and “NOTE”. They are particularly
important.
Indicates an imminently hazardous situation which, if not
DANGER
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not
WARNING
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
CAUTION
avoided, could result in minor or moderate injury.
Indicates a situation which, if not avoided, could result in
CAUTION
property damage to the vehicle.
NOTE Indicates good practice.
1-1
INTRODUCTION AND SAFETY
1-2
INTRODUCTION AND SAFETY
NOTE:
When leaving the car, be sure
to remove the key and lock the
doors. This will prevent theft.
1-3
INTRODUCTION AND SAFETY
ABBREVIATION
In this manual, the following abbrevi-
ations are used.
1-4
IDENTIFICATION
2-1
IDENTIFICATION
2-2
IDENTIFICATION
2-3
IDENTIFICATION
UD2300DH
2-4
BEFORE DRIVING YOUR VEHICLE
BEFORE
DRIVING YOUR WARNING
VEHICLE Be sure this vehicle includes required safety features. This vehicle
may be put to many uses, and UD Trucks Corporation cannot antici-
pate all of them. Always consult safety regulations in effect for loca-
tion and type of use of the vehicle. Below are two safety adaptations
required under certain circumstances. Other measures may be
required depending on the type of body built on the chassis and the
uses expected for the final vehicle. Neglecting good safety measures
could cause a serious accident.
REAR IMPACT PROTECTION
Section 393.86 of the Federal Motor Carrier Safety Regulations
requires certain vehicles to be equipped with rear impact protection
guards. Such guards must be installed in accordance with the Federal
Motor Carrier Safety Regulations. Make sure your vehicle has rear
impact protection that meets or exceeds all applicable regulations for
wherever it will be driven and that it is installed correctly.
VISIBILITY DEVICES
Federal Motor Vehicle Safety Standards and Federal Motor Carrier
Safety Regulations require certain vehicles to be equipped with ret-
roreflective sheeting or other devices to insure the vehicle is clearly
visible. Be sure you have visibility devices in compliance with the reg-
ulations and take any other steps necessary to ensure that the vehicle
is sufficiently conspicuous at night or in low lighting conditions.
3-1
BEFORE DRIVING YOUR VEHICLE
OVERLOADING
WARNING Model Tire GVWR GAWR-Front GAWR-Rear
NOTE:
UD2300 LP
Tire specification: 245/70R19.5 (G)
UD2300 DH
Tire specification: 9R22.5 (G)
UD2600
Tire specification: 11R22.5 (G)
UD2600 LP
Tire specification: 255/70R22.5 (H)
3-2
BEFORE DRIVING YOUR VEHICLE
TOWING TRAILERS GVWR of the towing vehicle. The GCW must never
exceed the GCWR.
WARNING
Towing trailers beyond the maximum recom-
GVWR (Gross Vehicle Weight Rating) — is the maxi-
mended trailer weight which exceeds the limit of mum allowable weight of the fully loaded vehicle (includ-
the vehicle’s GCWR, GVWR, GAWR(s) or tire rat- ing all options, equipment, passengers, and cargo).
ings could result in engine damage, transmission
damage, structural damage, loss of vehicle con-
CAUTION
trol, vehicle rollover and personal injury.
Exceeding the Tire Rating or Simplified Final-
stage Vehicle Certification Label vehicle weight
Definitions: rating limits could result in substandard vehicle
GAWR (Gross Axle Weight Rating) — is the maximum handling or performance, engine, transmission
allowable weight that can be carried by a single axle and/or structural damage, serious damage to the
(front or rear). These numbers are shown on the Simpli- vehicle, loss of control and personal injury.
fied Final-stage Vehicle Certification Label that can be
found on the inside of the driver’s door or the door frame.
The total load on each axle must never exceed its
GAWR.
3-3
BEFORE DRIVING YOUR VEHICLE
The following chart indicates the allowable GCWR for your UD Trucks vehicle based on the specific transmission
model and specific rear axle ratio:
Maximum GCWR - Ib. (kg.)
Vehicle Model Engine Type Rear Axle Ratio * MTM ATM
UD1800 3.90 / 4.11/ 4.33 29,000 (13,154) 26,000 (11,793)**
UD2000 3.90 / 4.11/ 4.33 29,000 (13,154) 26,000 (11,793)**
4.11 33,135 (15,029) 26,000 (11,793)**
UD2300LP
D (245hp) 4.33 / 4.56 34,000 (15,422) 26,000 (11,793)**
UD2300DH 4.88 / 5.29 34,000 (15,422) 26,000 (11,793)**
5.14 34,945 (15,850) 26,000 (11,793)**
5.57 41,000 (18,597) 26,000 (11,793)**
4.63 48,065 (21,800) N/A
UD2600 4.88 50,715 (23,000) N/A
E (280hp) 5.57 57,770 (26,200) 57,770 (26,200)**
5.86 N/A 58,430 (26,500)**
6.17 N/A 57,990 (26,300)**
UD2600LP D (245hp) 4.88 40,225 (18,246) 26,000 (11,793)**
3-4
BEFORE DRIVING YOUR VEHICLE
3-5
BEFORE DRIVING YOUR VEHICLE
3-6
BEFORE DRIVING YOUR VEHICLE
Check that seat belts are intact, Check the horn for proper opera- are sounding and no warning
undamaged and properly adjusted. tion. lights, warnings are on except for
Check that head restraints are Check the operation of windshield the PARKING BRAKE warning
intact and properly adjusted. wipers and washer and the condi- light.
With engine started tion of the wiper blades. Check that all lights and turn sig-
Refer to “INSTRUMENTS AND Check that each gauge on the nals function properly.
CONTROLS”. instrument panel is functioning
properly. Be sure that no buzzers
Check points
Items Check points Reference
page
Check for belt tension, wear or cracks. If required, have the belt replaced
Drive belt by your authorized UD Trucks dealer or qualified service facility. 11-46
Always replace the two belts as a set.
Engine oil leakage and Check for oil leakage from engine. Also check for traces of oil on the road
directly under the engine. Check engine oil level and contamination. 11-33
engine oil level
Check for leakage from engine. Also check for traces of water on the road
Coolant leakage and directly under the engine. If leakage is noticed, check the coolant level.
11-25
engine coolant level Check that the ENGINE COOLANT LEVEL warning light remains off while
the engine is in operation.
Air cleaner service indica- Check whether a red signal shows on the service indicator. When the red
signal is shown, replace the air cleaner element. 11-44
tor
Check all radiator and heater hose clamps for tightness. Inspect all hoses;
Water hoses and clamps –
if they are swollen, cracked or otherwise worn, replace them.
Check for water accumulation. Drain water from the fuel filter before water
reaches the upper portion of the transparent case. When water has accu-
Primary fuel filter 11-41
mulated in the fuel filter, it has also accumulated in the fuel tank. Drain
water from fuel tank when the fuel filter is drained.
3-7
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items Check points Reference
page
Check the amount of fuel using the fuel gauge. It is advisable to keep the
Fuel quantity 7-12
fuel tank full.
Check the amount of fuel using the DEF gauge. It is advisable to keep the
DEF quantity 7-10
DEF tank full.
Check engine for smooth starting. If engine operation is erratic or noisy,
Starting ability and noise –
immediately stop and check the cause of the problem.
Check the transmission and differential, brake system, clutch system,
power steering system, fuel system and DEF dosing system for leakage of
oil, fluid, fuel, DEF, grease and/or air. Fuel and air leakage is sometimes
Oil, fluid, fuel, DEF, grease
hard to detect so careful checks are needed. Leakage may be present –
and air leakage only when the engine/vehicle is in operation. If leakage is noticed, check
the level of oil/fluid/coolant, repair the leaking point and correct the level
as necessary.
Check all wheel nuts for proper tightness. If any nut is missing or loose,
Wheel nut 11-86
check that all wheel nuts are tightened to the specified torque.
Disc wheel Check for deformity, cracks or damage. –
Check the air pressure using a tire gauge. Note that air pressure differs
Tire between the allowable load capacities of tires. 11-83
Also check tread depth and for cracks or foreign matter caught in grooves.
Check for the specified air pressure of the air pressure gauge on the
instrument panel. With the vehicle stopped, depress the brake pedal.
7-8,
Service brake operation Then, release the pedal to ensure the sound is accompanied by discharg-
10-33
ing air. Next, drive the vehicle at low speeds and check for braking perfor-
mance.
3-8
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items Check points Reference
page
Open the drain cocks and drain condensation completely from air reser-
Draining water condensa-
voir. Close the drain cocks completely.
If a large quantity of water accumulates, the air dryer may be faulty and 11-63
tion from air reservoir
should be repaired. Drain the condensation before and after the day’s
operation.
Apply the parking brake on an upgrade. Ensure the PARKING BRAKE
Parking brake operation warning light illuminates with the ignition key in the ON position and that 7-76
the brake firmly operates on the wheels.
Turn all switches of the lighting and signal system on and off to ensure
Lighting and signal system 7-57
headlights, turn signal lights, etc. operate properly. Clean dirty light lenses.
Horn Operate the horn button to ensure the horn sounds. 7-68
Check cluster meters (such as the air pressure gauge and engine coolant
temperature gauge), to ensure they register the specified ranges. The
engine coolant temperature gauge should be checked after warming up
Meters, indicator light,
the engine sufficiently or while the vehicle is being driven. 7-1
warning and warning light
Also check the indicator light for proper operation in response to the oper-
ation of the corresponding control. Check that warnings and warning lights
remain off while the engine is in operation.
Operate the wiper and washer switches to ensure the windshield wiper
and washer operate. Check the level of washer fluid and add fluid as nec-
Windshield wiper and
essary. 7-55
washer
If the wiper does not wipe the windshield sufficiently or does not contact
the windshield well, the wiper blades need to be replaced.
3-9
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items Check points Reference
page
Check mirrors for proper angle of view, damage and cleanliness; clean if
Mirror and front windshield dirty and replace if damaged. Check the windshield for cleanliness; clean 11-69
if dirty.
Operate the car heater to check the condition of hot-air discharge from the
Heater defroster defroster. This check should be carefully performed especially in rainy 9-8
weather.
Fasten the seat belt to check for proper operation of the buckle. Also
Seat belt 6-5
check the belt for damage.
Door lock Check door locks for proper operation. 5-1
Cab tilt lock mechanism Check the condition and operation of the cab tilt lock mechanism. 11-21
3 - 10
BEFORE DRIVING YOUR VEHICLE
3 - 11
BEFORE DRIVING YOUR VEHICLE
mance diesel engine oil and Ultra HANDLING OF THE EXHAUST The following must be observed to
Low Sulfur Diesel (ULSD) fuel. EMISSION CONTROL prevent malfunctioning of this sys-
SYSTEM tem.
The exhaust emission control sys-
tem reduces PM (Particulate Mat-
ter) and NOx by collecting PM
through the filter that is installed in
the PM reduction device and by
dissolving NOx into water and
nitrogen using the aftertreatment
SCR system.
When a certain amount of soot
accumulates in the DPF, the DPF
system automatically switches into
the cleaning mode to burn (regen-
erate) the collected soot. The fre-
quency of the occurrence of the
aftertreatment DPF regeneration
differs according to the manner in
which the vehicle is driven.
The aftertreatment SCR system
reduces NOx by adding a mixture
of air and diesel exhaust fluid
(DEF) in the exhaust muffler to
make NOx that is included in
exhaust gas and is dissolved into
water and nitrogen.
3 - 12
BEFORE DRIVING YOUR VEHICLE
WARNING
Immediately after the vehicle is
stopped or while the system is
in the regeneration, the area
around the muffler and
exhaust gas are extremely hot.
Do not stop the vehicle in a
location where there are flam-
mable materials such as dried
grass or paper waste.
3 - 13
BEFORE DRIVING YOUR VEHICLE
3 - 14
BEFORE DRIVING YOUR VEHICLE
3 - 15
BEFORE DRIVING YOUR VEHICLE
Do not touch the water that comes The muffler has the following char- Do not modify the tailpipe.
from the muffler. acteristics.
NOTE:
The aftertreatment system CAUTION
WARNING cleans and discharges the Changing the orientation or
Do not touch the water that exhaust gas, so the exhaust gas length of the tailpipe could
comes from the muffler. The smells differently than that of degrade the exhaust gas
action of the oxidizing catalyst conventional diesel vehicles. cleaning effect, so do not mod-
contained in the catalyst inte- Some white smoke might come ify the tailpipe. When the con-
grated muffler makes the water from the exhaust pipe when the struction of the body requires
slightly acidic. If it gets on the engine is started, but this is just that the tailpipe be modified,
skin, etc., flush well with water steam and is not a problem. contact the nearest authorized
to wash it off. White smoke may be emitted UD Trucks dealer for advice.
from the area around the muffler
Do not kick or strike the muffler. during the soot burning (DPF
regeneration) process. This is
due to the emission of water
CAUTION vapor from the area around the
muffler, and it does not indicate
The muffler contains a cata- a malfunction.
lyst, so do not kick or strike When manual DPF regeneration
the muffler. Doing so could is performed while driving in
damage the catalyst inside. rain or after washing the vehicle,
water vapor may be observed
around the muffler. This does
not indicate a malfunction.
3 - 16
BEFORE DRIVING YOUR VEHICLE
NOTE:
13.2 gal (50 liter) tank Spilled DEF should been
cleaned up in accordance with
local regulation.
CAUTION
If something other than the Only use DEF that satisfies the
specified substance (diesel, ISO22241-1 specification.
kerosene, etc.) is mistakenly Only use DEF specified by UD
5.3 gal (20 liter) tank added to the DEF tank, it could Trucks that satisfies the
cause a fire, so have it ISO22241-1 specification.
inspected and serviced by the The specified DEF is colorless and
nearest authorized UD Trucks odorless (urea 32.5%, water
dealer.
67.5%) and begins to freeze at
12.2°F (–11°C). When the ambi-
ent air temperature (AAT) is low
and the vehicle has been exposed
to cold temperatures for a long
time, the indicator in the cab might
not show the correct DEF level.
3 - 17
BEFORE DRIVING YOUR VEHICLE
Precautions for handling of the DEF <Temporary Measures> not lose water due to evaporation,
<Handling Precautions> DEF is a very safe liquid, but it might etc., so as long as the container is
Handle in accordance with good cause a very slight irritation for some sealed, there is no particular concern
industrial hygiene and safety prac- people. If it is spilled on the body, about an expiration date.
tices. wash it off with water, and if it is Fuel for the vehicle equipped with
drunk mistakenly, drink 1 or 2 cups the aftertreatment DPF
Only use DEF specified by UD
of milk. if milk is not available, drink
Trucks that satisfies the water. In all case, consult physician. Do not use any fuel other than the
ISO22241-1 specification. specified fuel.
<When Fires or Leaks Occur>
Use the UD Trucks genuine part
DEF is nonflammable, but quickly CAUTION
5.3 qt (5 liter) portable tank or a
special container recommended by move it to a safe location if there is Use ultra low sulfur diesel
the DEF dealer to hold the DEF. a fire. (ULSD) fuel only. Use of any
If DEF is spilled, wash it away with other fuel may adversely affect
General containers, containers
that have been used for other water. It can be disposed of with- the engine, exhaust gas clean-
applications, and dirty containers out a problem by first diluting it ing device, etc., resulting in
will not maintain the quality of the with a large amount of water and aftertreatment DPF clogging
DEF, so absolutely do not use then pouring it into the sewage and so on.
system. It must be treated as Refer to "Fuel requirements"
them. on page 11-38.
industrial waste in areas with nitro-
gen restrictions.
<Storage Method>
Seal the container and store it in a
covered area with good ventilation.
Even if it freezes, there will be no
change in its quality after it thaws, so
it can be used as is.
There are no problems with deterio-
ration, etc., of DEF as long as it does
3 - 18
BEFORE DRIVING YOUR VEHICLE
3 - 19
BEFORE DRIVING YOUR VEHICLE
3 - 20
BEFORE DRIVING YOUR VEHICLE
The status of DPF soot accumula- The status of DPF soot accumula-
tion: Level 0 tion: Level 1 WARNING
When the Level 0 indication is When the DPF clogging warning
Make sure that there are no
shown, the manual DPF regenera- light blinks, immediately perform the
flammable materials around or
tion is not required. However, the manual DPF regeneration (before
under the exhaust system
optional manual DPF regeneration is the driving distance reaches 125
components.
available. miles [200 km]).
2. Turn the power takeoff (PTO)
switch off if the vehicle is
equipped with a PTO.
3. Keep the engine running.
4. Press the manual forced regener-
ation switch to activate the after-
treatment DPF regeneration.
DPF regenerating warning and
message are displayed.
NOTE: Operation procedure Idling speed will increase and the
Press the mode select switch 1. Stop the vehicle at a safe place, exhaust brake will be activated.
(located on the left side knob in apply the parking brake firmly
the combination meter) to check and put the shift lever in the N
the DPF soot accumulation level (neutral) position. For automatic
that will be shown with the DPF transmission with the P (Park)
soot level gauge.
position, put the selector lever
The DPF clogging warning light
may blink when soot does not into the P (Park) position.
accumulate in the DPF. This may
occur in order to maintain the
performance of the muffler.
3 - 21
BEFORE DRIVING YOUR VEHICLE
NOTE:
Place the manual forced regen-
eration switch to the “CANCEL”
side to deactivate the cleaning
operation.
If the vehicle is driven before the
cleaning is completed, the DPF
clogging warning light will blink
again.
3 - 22
BEFORE DRIVING YOUR VEHICLE
ated and the engine is forced to run Handling of the diesel particulate White smoke may be emitted from
at the idling speed. filter (DPF) the surface of the exhaust muffler
Vehicle speed is gradually if the aftertreatment DPF regener-
decreased to protect the engine, The following phenomena does not
indicate trouble. ation is operated manually in the
which will be shut down (automati- rain.
cally stopped) when the vehicle is The idle speed varies and the
stopping or completely stops. exhaust brake operates the same ・This is due to the fact that water
Contact your nearest UD trucks time. adhering on the surface of the
dealer immediately. When the vehicle is stopped for a exhaust muffler evaporates.
traffic signal or other reason the If any fuels other than the specified
engine shifts to idle running. (Auto- one are used, the emission of
CAUTION matic DPF regeneration is in prog- white smoke may continue.
When the DPF system warning ress.) Always use ultra-low sulfur diesel
(red) appears, immediately When the engine is idled continu- (ULSD) fuel (S15) because any
stop the vehicle in a safe loca- ously for a long time. (The idle other fuel may adversely affect or
tion and contact your nearest speed increases from time to time damage the engine and the DPF.
UD trucks dealer. to prevent the emission of white The exhaust gas odor will not be
smoke.) same as that of previous diesel
vehicles.
White smoke may sometimes be
emitted. The odor is different because the
White smoke may be emitted from exhaust gas is passed through a
the end of the exhaust muffler. catalytic converter and cleaned.
・This is due to the emission of
Regularly clean the aftertreat-
water vapor.
ment diesel particulate filter (DPF)
・This will not occur when the
engine exhaust gas temperature The DPF should be cleaned every
increases to a sufficient level. 155,000 miles (250,000 km) or
4,500 hours, which occurs first as
3 - 23
BEFORE DRIVING YOUR VEHICLE
necessary to ensure proper perfor- Always use genuine engine oil. VEHICLE LABELS
mance. Always use the specified engine oil Products safety labels are affixed to
If the DPF Maintenance warning is to maintain the performance of the your UD Trucks vehicle at the fac-
illuminated, the vehicle should be DPF. tory.
taken to the nearest UD Trucks Labels with DANGER, WARNING or
dealer as soon as possible. CAUTION are related to safety. You
must follow the precautions in these
labels. In addition, you must replace
any labels that have been removed
or are damaged. Contact your autho-
rized UD Trucks dealer or UD Trucks
North America, Inc. for replacement
labels.
3 - 24
ENTERING AND LEAVING THE CAB
WARNING
Be careful when entering or
leaving cab so you don’t slip
or fall.
Always keep your shoe soles 3. Bring your right foot up to the 2nd
and hands clean. Keep the cab step.
steps and handles clean and
free of ice, snow, oil, grease
and/or debris. Use extra care
in bad weather.
Use 3 POINT CONTACT at all
2. Firmly grasp either the lower or
times with at least 2 feet and 1 upper handle on the front of the
hand or 2 hands and 1 foot door opening with your left hand
firmly placed during all phases and place your left foot on the 1st
of entering or leaving the cab. step.
4-1
ENTERING AND LEAVING THE CAB
4. Bring your left foot up to the 2nd 6. Bring your right foot to the cab
step next to your right foot. floor.
If you grasped the lower handle 7. Position yourself in the driver’s
with your left hand then move seat and release your left hand
your left hand to the upper han- from the front upper handle.
dle.
8. Close door.
5. Step to the cab floor with your left
9. To leave the cab, open the door
foot.
and reverse the procedure for
entering the cab, using both
hands on the handles.
10.For passenger side, use opposite
hand and foot positions.
4-2
DOORS AND WINDOWS
5-1
DOORS AND WINDOWS
5-2
DOORS AND WINDOWS
NOTE: The battery of the remote control is UD Trucks dealer for battery
As many as 4 remote controls completely discharged. replacement. (The battery used
can be used. Contact an autho- The ignition key is in the ON or is a CR1620 lithium battery.)
rized UD Trucks dealer for pur- ACC position.
chasing or how to start using NOTE:
additional remote controls. The operating range of the
remote control depends upon
How to use remote control
the conditions around the vehi-
Door lock button (LOCK): cle. Make sure that the remote
All doors will be locked by pushing control is within 9.9 ft (3 m) from
the button, and the hazard lights will the door to make it surely func-
blink once. tion.
After locking the doors using the Though the remote control is
remote control, operate the door waterproof, it can be damaged
handle to confirm the door has been when it gets wet. If the remote
securely locked. control gets wet, immediately
wipe it off.
Door unlock button (UNLOCK):
Contact an authorized UD
All doors will be unlocked by pushing Trucks dealer if the remote
the button, and the hazard lights will control was washed in a wash-
blink twice. All doors will be locked ing machine or if it was soaked
automatically unless any door is in water for a long time.
opened within approximately 30 sec- Do not drop or strike the remote
onds after pressing the UNLOCK control.
button. Do not leave the remote control
The remote control will not function for a long time in a hot area.
under the following conditions. In case the remote control does
Any door is not completely closed. not function when pushing a
The remote control is too far away button, the battery may be dis-
from the vehicle. charged. Contact an authorized
5-3
DOORS AND WINDOWS
WARNING
When closing the windows,
make sure that no one has
their head or hands extended
outside the window before
operating the switch. Not
Driver’s side doing so could result in some-
one being pinched and injured
by the windows.
Do not leave children alone in
the vehicle. If children must be
left in the vehicle, be sure to
remove the ignition key.
5-4
DOORS AND WINDOWS
5-5
DRIVING POSITION
DRIVING SEATS
Fore and aft adjustment
Front seat base adjustment
POSITION
WARNING
To prevent loss of vehicle con-
trol, never adjust the driver’s
seat while driving.
6-1
DRIVING POSITION
The rear of the driver’s seat can be Riding comfort adjustment Reclining adjustment
raised by pulling up the lever at the <Up-down air suspension>
left side of the seat base. This improves riding comfort by
To lower the seat downward, pull the automatically adjusting the up-down
lever and push down on the seat. movements of the vehicle body.
Lumbar support adjustment <Seat with fore-aft suspension>
Driver’s seat
Turn the knob on the outside of the Riding comfort in the fore-and-aft
seat toward the front so that the cen- direction is automatically adjusted.
ter portion of the seatback will come
Operate the lever on the front side
out slightly to support the lumbar
portion of the body. This may be use- of the seat to lock the fore-aft sus-
ful in reducing fatigue during long pension of the seat.
distance driving. The support is Passenger seat
adjustable continuously within the
adjusting range. To tilt the seatback rearward, pull up
the lever located on the left side of
the driver’s seat base (right side for
passenger seat) and apply a slight
6-2
DRIVING POSITION
force to the seatback. To return the Forward and backward Headrest adjustment (Passenger
seatback to the upright position lift adjustment of cushion seat)
up the lever while leaning forward.
WARNING
Seat belts are less effective
with the seatback reclined. To
reduce the risk of sliding
under the seat belt during an
accident or sudden stop, do
not recline the seatback any
more than necessary for com-
fort. Adjust the cushion to the desired The height of the headrest can be
position while pushing the lever to adjusted manually. Adjust the head-
the right. It is possible to adjust in rest height while pressing the lock
two stages in the forward direction knob.
from the standard position.
6-3
DRIVING POSITION
To make fully flat / lift up the seat lock to keep the cushion in the
cushion Do not rest on or put your
down position. weight on the headrest or head
In addition to being used as a reg- The cushion is locked when the of the seatback when the seat-
ular assistant seat, the seatback seatback is folded forward. Pull the back is folded forward. Doing
can be folded forward (made fully reclining lever and lift up the seat- so could result in an injury or it
flat) to form part of the bed. The back. Trying to forcefully pull up could damage the seat.
seat cushion can also be lifted up the seatback could result in an When lowering the seat cover
to form a work space for changing injury or it could damage the seat. with items placed in the space
clothes, etc., or space for storage. made by lifting the seat cover,
carefully lower the seat to
CAUTION make sure that it does not
strike any of the stored items.
Make sure that the seat cush-
ion is locked in place when it is
raised. It is dangerous if the
cushion is not locked when
raised because it could fall
down. This could also damage
the seat.
Do not use it as a seat when
the seat cushion is raised.
To lift up the seat cushion, hold the Doing so could result in an
front edge of the cushion and raise injury or it could damage the
it until the lock engages. seat.
To release the cushion to lower it,
pull up the cushion lock release
lever to release the lock and then
support the cushion by the front
edge while lowering it. There is no
6-4
DRIVING POSITION
SEAT BELTS Never use the same belt for <Driver and passenger seat belts>
more than one person. The driver and passenger seat belts
Replace damaged or inopera- are equipped with an ELR (Emer-
WARNING tive belts. gency Locking Retractor). These
Replace belts which were in belts are flexible under normal condi-
Seat belts should be worn at use during an accident unless tions; however, they automatically
all times. Before fastening a the accident was minor. lock in an emergency. Belt length
front seat belt, always adjust Do not modify the seat belts. adjustment is not necessary.
the driver’s seat to the position
NOTE:
in which you will drive. Seat
Slowly pull out the seat belt. If
belts should be worn across
the hips and adjusted snugly. pulled abruptly, it may lock.
Slowly rewind the belt while
Never adjust a seat belt across
the abdomen. holding the tongue.
Never attempt to fasten seat
belts while the vehicle is in If the driver tries to drive without
motion. wearing the seat belt, the warning
Never let a passenger hold a
light will illuminate to warn the driver.
child on his or her lap while If the tongue of the driver’s side seat
the vehicle is moving. belt is not completely locked into the
The passenger cannot protect buckle, the warning light will illumi-
nate when the ignition switch is
the child from injury in a colli- To fasten the belt, position the seat turned to ON or START.
sion. Children should be and fit the seat belt snugly without
seated in appropriate child twisting. Insert the open end of the
restraints. tongue into the buckle until it snaps
Do not wear a twisted or loose and engages.
belt. To unfasten the seat belt, push the
release button and disengage the
belt tongue from the buckle.
6-5
DRIVING POSITION
Seat belt warning light To loosen the seat belt, raise the and restrained by the seat belts
front end of the adjuster and pull the provided.
belt.
NOTE:
<Pregnant woman restraint>
When the seat belt is not in use,
insert the tongue into the Pregnant women should check
buckle. with their doctors before using seat
belts. In you are in an accident and
wearing a seat belt, significant
<Important child restraint pressure can be exerted on the
precautions>
abdominal area.
U.S. law requires you to use safety
Pregnant woman should place the
restraints for children who are rid-
lap belt as low as possible, over
<Center seat belt (Optional)> ing in this vehicle. Many states
the hips and not over the waist.
require that children use a child
restraint system that complies with
the Federal Motor Vehicle Safety
Standards. Check your local and
state laws for specific require-
ments regarding the safety of chil-
dren in your vehicle.
Choose a child restraint system
that complies with federal stan-
dards and fits your vehicle. Install
and use it in accordance with the
To tighten the seat belt, pull the manufacturer's instructions.
loose end toward the belt anchorage Children who are too large for child
until it fits snugly. restraint systems should be seated
6-6
DRIVING POSITION
6-7
INSTRUMENTS AND CONTROLS
7-1
INSTRUMENTS AND CONTROLS
1. Lighting, Dimmer, Passing, Turn sig- 11. Overhead box 24. Accelerator pedal
nal, Accelerate and resume switch, 12. Room light 25. Transmission gear shift lever
Set and coast button 13. Cigarette lighter 26. Parking brake valve
2. Combination meter with multi-display 14. Power socket 27. Cup holder
function 15. Fuse lid 28. Engine warm-up switch
3. Horn 16. Transmission PTO switch 29. Manual forced regeneration switch
4. Windshield wiper, Washer, (Optional) 30. Power mirror switch (Optional)
Hazard warning flasher and 17. Engine throttle control knob 31. Automatic transmission
Exhaust brake switch 18. Ashtray selector lever (Allison 1000, 2000
5. Multi-display select switch 19. Power window switch and 2500 series)
6. Air suspension dump switch (UD2600 20. Front lid knob 32. Automatic transmission
and UD3300 equipped with air 21. Clutch pedal selector switch (Allison 3000 series)
suspension) 22. Ignition key switch 33. Ashtray
7. Power mode switch (Allison 1000, 23. Brake pedal 34. Power window switch
2000 and 2500 series)
8. Cruise Control main switch
9. Mirror heater switch (Optional)
10. Heater or Air conditioner control
7-2
INSTRUMENTS AND CONTROLS
7-3
INSTRUMENTS AND CONTROLS
Engine stop
CAUTION
To avoid damage to the start-
ing system, do not turn the
ignition key to the START posi-
tion during engine operation.
If the engine should turn over
in the reverse direction, oper-
ate the ignition key to stop the
engine. When the engine has
turned over in the reverse
direction, the engine sound
will change and exhaust
Stop the engine using the ignition
smoke will be emitted from the
key switch. When it is turned from
air intake pipe.
ON to LOCK (OFF), the engine will
stop.
NOTE:
Also when the ignition key is turned
If the ignition key is difficult to
from ON to ACC, the engine will
turn when inserting it and turn- stop.
ing it to the ON position, jiggle
the steering wheel back and
forth while turning the ignition
key to release the steering
wheel lock and allow the key to
turn smoothly.
7-4
INSTRUMENTS AND CONTROLS
7-5
INSTRUMENTS AND CONTROLS
NOTE:
Odo/trip change-over switch The maximum display is
1,999,999 miles.
Pushing the reset knob (less than 1 Pushing the odo/trip switch
second) changes the odometer and when the ignition key is in OFF
trip meter displays as follows: position, odometer and TRIP A/
ODO TRIP A TRIP B ODO B are displayed for about 45
... seconds.
If the reset knob is pushed for more
than 1 second in the trip meter
mode, only the displayed mode
meter will be reset. (For example, if
7-6
INSTRUMENTS AND CONTROLS
NOTE:
To reset the trip meter, keep
pushing the reset knob until the
meter displays “000.0”. After
resetting, release the knob to
start measuring. The odometer
7-7
INSTRUMENTS AND CONTROLS
7-8
INSTRUMENTS AND CONTROLS
CAUTION
Do not suddenly stop the
engine when it has overheated.
Doing so could cause the
engine to seize up.
When the gauge indicates nothing, Keep the engine idling until the
the ECT is very cold. it is recommended to idle the
engine coolant temperature
When the gauge indicates engine until the ECT drops, then (ECT) drops before turning off
between 1 to 8 point, the ETC is stop the engine and check the the engine.
normal. engine coolant level (ECL), and
When the ECT becomes high then inspect the cooling system for
while another screen is displayed leaks.
on the multi-display, a beep will
sound twice and the display will
automatically change to the ECT
gauge (except when other warn-
ings are displayed).
7-9
INSTRUMENTS AND CONTROLS
7 - 10
INSTRUMENTS AND CONTROLS
7 - 11
INSTRUMENTS AND CONTROLS
7 - 12
INSTRUMENTS AND CONTROLS
7 - 13
INSTRUMENTS AND CONTROLS
7 - 14
INSTRUMENTS AND CONTROLS
7 - 15
INSTRUMENTS AND CONTROLS
7 - 16
INSTRUMENTS AND CONTROLS
7 - 17
INSTRUMENTS AND CONTROLS
7 - 18
INSTRUMENTS AND CONTROLS
<Voltmeter display> 1 second while the operation con- If the monitor is displaying a warn-
trol screen is displayed. A cursor ing indicator, the operation control
will be displayed on the thousands notice will not interrupt the warning
digit. indicator display. However, when
Press the mode select switch to the mode switch is pressed to
change a number. change the display or the warning
Press and hold the mode switch to indicator display is cancelled, the
continuously increase a number. operation control notice will inter-
Turn the select switch or return rupt and blink for 14 seconds.
switch to move the cursor. If the ignition key is turned to the
・The distance can be set by 1 mile OFF position while the notice
within the range of 0 to 5,000 appears and blinks, the notice will
<Trip management display>
miles. resume the next time the ignition
・The remaining driving distance is key is turned to the ON position.
decreased by 1 mile. NOTE:
Set the distance to “0” to reset the Whenever the select switch or
operation control function. the return switch is turned for
When the remaining driving dis- more than 1 second while oper-
tance reaches 50%, 10% or 0% of ating, the display will return to
the set distance, a notice will the normal screen.
The cursor returns to the thou-
appear on the screen and blink 14
sands digit after the ones digit.
times.
The indicated remaining driving
While the monitor displays a distance may be different from
To change the display to the dis- screen other than the operation the one that is displayed on trip
tance setting screen, push the control screen, an operation con- meter A or B.
mode select switch or the select trol notice will interrupt the screen Setting is not available while
switch for more than 1 second or and blink for 14 seconds. driving the vehicle.
turn the return switch for more than Park the vehicle in a safe loca-
7 - 19
INSTRUMENTS AND CONTROLS
tion, and then input the dis- When the mode switch is pressed
tance. for more than 1 second while the
hour meter is displayed, the trip
<Hour meter display>
hour meter is reset to “0.0”.
The hour meter indicates the total
running time of the engine at a des- NOTE:
ignated engine speed. This helps The trip hour meter indicates
determine maintenance and inspec- 000.0 while resetting.
tion intervals. The trip hour meter does not
count while resetting.
7 - 20
INSTRUMENTS AND CONTROLS
Engine oil
Tire Coolant
Transmission oil
7 - 21
INSTRUMENTS AND CONTROLS
7 - 22
INSTRUMENTS AND CONTROLS
than 1 second or turn the return been driven for the set distance) or NOTE:
switch for more than 1 second the set date comes, a warning and Whenever the select switch or
while the maintenance and inspec- an item to be replaced are dis- the return switch is turned for
tion screen is displayed. A cursor played while the parking brake is more than 1 second while oper-
will be displayed on the year posi- applied. ating, the display will return to
tion. To reset the maintenance and the normal screen.
When the mode select switch is inspection display, set the distance The number of the set distance
pressed, the number is changed. to “0” or set the date to the present for replacement may be different
or the past date. from the one that is displayed
・The date can be set as follows.
on the trip meter A or B.
Year: 2008 to 2038 Setting is not available while
Month: January to December driving the vehicle.
Day: 1 to 31 Park the vehicle in a safe loca-
・The distance can be set by 1 tion, and then input the replace-
mile within the range of 1 to 6 ment interval.
digits (from 0 to 999,999 miles).
<Settings display>
・The remaining driving distance
is decreased by 1 mile.
When the mode select switch is
pressed and held, the number is
continuously increased.
The remaining driving distance is
When the select switch or the
preliminarily set to 600 miles in the
return switch is turned, the cursor
user setting 1 as a factory default
is moved.
setting.
・The cursor returns to the distance Contact the nearest authorized UD
position after the date position. Trucks dealer for the 600 miles
When the remaining driving dis- inspection.
tance reaches “0” (the vehicle has
7 - 23
INSTRUMENTS AND CONTROLS
7 - 24
INSTRUMENTS AND CONTROLS
CAUTION
tion, and then input the time and while operating, the display will
date. return to the normal screen.
When setting the clock on the Language can be selected from
calendar and clock display, <Language setting screen>
English, Chinese and Japanese.
always place the shift lever
(MTM) or selector (ATM) in the
NOTE:
neutral position. The combina- Setting is not available while
tion meter is equipped with the driving the vehicle.
shift recognition function that Park the vehicle in a safe loca-
automatically recognizes the tion, and then select a language.
transmission specification
while setting the clock.
If the clock is set while the
transmission is shifted in the R
(Reverse) position, the shift
indicator may not be displayed
To select language, push the mode
correctly.
switch or the select switch for more
NOTE: than 1 second or turn the return
Whenever the select switch or switch for more than 1 second
the return switch is turned for while the language setting screen
more than 1 second while oper- is displayed. Press the mode
ating, the display will return to switch to select a language. The
the normal screen. selected language will blink.
The cursor returns to the year When the mode switch or the
position after the minute posi- select switch is pressed for more
tion. than 1 second or the return switch
Setting is not available while
is turned for more than 1 second
driving the vehicle.
Park the vehicle in a safe loca-
7 - 25
INSTRUMENTS AND CONTROLS
7 - 26
INSTRUMENTS AND CONTROLS
Display Display
Name Page Name Page
Mark Color Message Mark Color Message
Insufficient DEF SCR system tamper- Starter overheat Starter overheat
quality or failure Amber warning 10-4
ing warning Waiting time
Contact Dealer (Initial detected)
PTO is operation
Insufficient DEF Amber Engine start is not PTO engine start 10-4
SCR system tamper- interrupt warning
quality or failure possible
ing warning
Amber Engine is derated (1 hour after) 7-35 Transmission oil
Contact Dealer temp too high ATM fluid
Red temperature warning 7-41
Insufficient DEF Reduce oil
quality or failure SCR system tamper- temperature
Vehicle speed ing warning ATM system error ATM system
(4 hours after) Red warning 7-42
limited Check at Dealer
Contact Dealer Engine system
Engine system Red or malfunction DPF system warning
3-22
Amber malfunction SCR system fault 7-37 Amber Contact Dealer (or 7-74
warning
Check at Dealer Check at Dealer)
Vehicle electrical 3-21
Vehicle electrical Amber DPF is regenerating DPF regenerating
warning
Red or sys. malfunction 7-72
Amber Contact Dealer (or system malfunction 7-39
warning
Check at Dealer) Amber Regeneration DPF regeneration
restriction warning 7-72
system is disabled
Communication line Vehicle electrical DPF maintenance
system communica- DPF maintenance 3-23
Amber error tion malfunction 7-40 Amber warning 11-71
Check at Dealer
Check at Dealer warning IDLE Amber Auto engine shut Idle shutdown 10-38
Communication line Meter communica- STOP down information
Amber error tion malfunction 7-39 O/D Amber ATM O/D OFF
Check at Dealer warning OFF - indicator light 7-52
Maintenance and Amber ATM Power mode 7-52
Amber “Item to be replaced” inspection screen 7-23
POWER - indicator light
display
7 - 27
INSTRUMENTS AND CONTROLS
Warning and indicator lights No Tell mark Name Page No Tell mark Name Page
5 Spare 16 Spare
7 - 28
INSTRUMENTS AND CONTROLS
26 Spare 37 Spare
Exhaust brake
27 7-51 38 Spare
indicator light
28 Spare 39 Spare
ATM maintenance
30 7-50 Air pressure
information light 41 7-43
warning light
31 Spare
32 Spare
33 Spare
34 Spare
35 Spare
36 Spare
7 - 29
INSTRUMENTS AND CONTROLS
BUZZERS
Buzzer list in cabin
7 - 30
INSTRUMENTS AND CONTROLS
NOTE:
The multi-display also displays
warning messages, comments,
a calendar, clock, trip manage-
ment, inspection and servicing
message display, range select
position (ATM specification
vehicles) in addition to warning
displays.
7 - 31
INSTRUMENTS AND CONTROLS
7 - 32
INSTRUMENTS AND CONTROLS
7 - 33
INSTRUMENTS AND CONTROLS
Initial detected
Once an insufficient DEF quality is
detected, a warning will be dis-
played, and a warning light will be
illuminated to warn the driver.
7 - 34
INSTRUMENTS AND CONTROLS
7 - 35
INSTRUMENTS AND CONTROLS
7 - 36
INSTRUMENTS AND CONTROLS
7 - 37
INSTRUMENTS AND CONTROLS
7 - 38
INSTRUMENTS AND CONTROLS
7 - 39
INSTRUMENTS AND CONTROLS
7 - 40
INSTRUMENTS AND CONTROLS
7 - 41
INSTRUMENTS AND CONTROLS
mission checked by an authorized ATM system warning 2.When a malfunction occurs and
UD Trucks dealer. shifting becomes impossible in the
The automatic transmission system N position, turn the ignition key to
warning, warning message and com- OFF position to stop the engine
ments will be displayed when the and restart it. When malfunction is
transmission control module (TCM) intermittent, the TCM resets and
detects a malfunction.
driving becomes possible.
3.If the warnings still remains on,
stop the engine. Have the trans-
mission checked by an authorized
UD Trucks dealer.
CAUTION
When a vehicle is stopped and
engine speed is raised for a
long time with the gear shifted
to other than the N position,
1.The automatic transmission sys- fluid temperature increases
tem warnings will be displayed and the transmission will be
when the TCM detects a malfunc- damaged. Do not keep the
tion. At this time a diagnostic trou- engine in that circumstance
ble code (DTC) is set in the TCM more than 30 seconds.
and transmission cannot be
shifted. Depending on the malfunc-
tion, the TCM does not respond to
gear shifting operation and the cur-
rent gear is fixed.
7 - 42
INSTRUMENTS AND CONTROLS
7 - 43
INSTRUMENTS AND CONTROLS
NOTE:
When the amount of aftertreat-
ment diesel exhaust fluid (DEF)
7 - 44
INSTRUMENTS AND CONTROLS
7 - 45
INSTRUMENTS AND CONTROLS
7 - 46
INSTRUMENTS AND CONTROLS
7 - 47
INSTRUMENTS AND CONTROLS
7 - 48
INSTRUMENTS AND CONTROLS
7 - 49
INSTRUMENTS AND CONTROLS
the system from major troubles. Exhaust gas high temperature ATM maintenance information
The SHIFT LIMIT warning light indicator light light
and the ATM SYSTEM warning
This indicator does not indicate a This light will illuminate when the
light illuminate and transmission is system malfunction, however it ATM should be serviced as soon as
fixed to a safety range. When the alerts the driver of the high tempera- possible for its components such as
lock up clutch is engaged, it will be ture of the system. fluid, filter or clutch.
disengaged.
7 - 50
INSTRUMENTS AND CONTROLS
Turn signal and hazard indicator Exhaust brake indicator light Intake air heater indicator light
light The indicator light will come on if the The indicator light will come on when
When the turn signal switch is oper- exhaust brake switch is turned on the ignition key is turned to the ON
ated, the left or right indicator light and the exhaust brake is operating. position to preheat intake air. When
flashes. When the hazard warning the light goes off, the engine is ready
flasher switch is turned to the ON to start.
position, the left and right indicator
lights flash simultaneously.
NOTE:
Do not crank the engine until the
indicator light goes off.
7 - 51
INSTRUMENTS AND CONTROLS
High beam indicator light Automatic transmission O/D OFF POWER MODE indicator light
indicator light (Allison 1000, 2200
This indicator light comes on when The indicator light will come on when
and 2500 series)
the dimmer switch is set to the high the power mode switch is set to the
beam position with the lighting This indicator comes on when the power mode.
switch in the second position or the overdrive switch is turned OFF. The
passing switch is operated. overdrive switch is located on the While operating, the indicator light in
selector lever. the switch come on. (Allison 1000,
2200, 2500 series)
7 - 52
INSTRUMENTS AND CONTROLS
7 - 53
INSTRUMENTS AND CONTROLS
7 - 54
INSTRUMENTS AND CONTROLS
7 - 55
INSTRUMENTS AND CONTROLS
7 - 56
INSTRUMENTS AND CONTROLS
lever is in the ON position and the If the exhaust brake is released by Lighting, dimmer, passing and
exhaust brake is operating. depressing the accelerator pedal turn signal switch
The exhaust brake is activated only suddenly and not by operating the
when both clutch and accelerator lever, it may cause fuel injection into This switch lever mounted on the left
pedals are released. The purpose of the engine with a blocked exhaust side of the steering column operates
these provisions is to protect the system and subsequent puff of black and dims the headlights. It also
engine and to improve driveability. smoke and possible exhaust pipe serves as a turn signal and passing
overheating. switch.
To release the exhaust brake, move
the lever downward to the OFF posi- Lighting
While the vehicle is stationed, con-
tion. Depressing either the accelera- firm exhaust brake actuation by fol-
tor or clutch pedal can release the lowing procedures:
exhaust brake, but it is preferable to
use the lever to release the exhaust 1.Move the exhaust brake switch
brake. lever upward to the ON position
NOTE: 2.Confirm that the exhaust brake
The wheels could slip when indicator light illuminates and
using the exhaust brake while that the engine sound changes
driving on slippery roads or at the same time.
over bumps, etc., which could
cause the ABS to operate and
the exhaust brake to be tempo-
Turn the knob on the end of the
rarily cancelled and the indica-
switch lever to the 1st or 2nd position
tor light to turn off, but this is
to operate the following lights.
normal ABS operation and is
not a problem. Try to drive care-
fully taking into consideration
the road conditions, the inter-
vehicular distance, and other
factors.
7 - 57
INSTRUMENTS AND CONTROLS
Knob * The daytime running lights comes Dimmer, passing and turn signal
Light name position on when:
1st 2nd The ignition key is turned ON.
The headlight is turned off (with
Tail light
the lighting switch in the OFF or
1st position).
License plate light The parking brake is released.
(After the headlight comes on, it
Front position light will not turn off when operating the
parking brake.)
Instrument cluster illumi- NOTE:
nation light
If the lighting switch is in the 1st
position, daytime running light To operate the left turn signal, pull
Heater or Air conditioner
control illumination light does not go out by turning off the turn lever on the left side of the
the key switch. The light goes steering column down beyond the
Automatic transmission out when the lighting switch is
selector control illumina- resistance. To operate the right turn
tion light turned off. signal, push the lever up beyond the
Clearance and identifica- resistance. The lever will automati-
tion light cally return to the neutral position
after the turn is completed. When
Headlight operating the left or right signal, con-
firm that the TURN SIGNAL AND
HAZARD indicator light flashes.
*Daytime running light When the ON-OFF intervals are
unusually short, the bulb is probably
burned out.
7 - 58
INSTRUMENTS AND CONTROLS
7 - 59
INSTRUMENTS AND CONTROLS
7 - 60
INSTRUMENTS AND CONTROLS
7 - 61
INSTRUMENTS AND CONTROLS
<Set and Coast operation> Set and Coast Button to set the
Press and hold the Set and Coast speed.
Button until the preferred speed is
reached, and then release the but- To temporarily cancel the Cruise
Control
ton to set the speed.
Cruise Control will be temporarily
cancelled in the following situations.
When you depress the brake
pedal.
When you depress the clutch
pedal.
When the gear shift lever or selec- NOTE:
tor lever is moved to neutral. Cruise Control will be temporarily
cancelled in the following situa-
When the exhaust brake switch is
tions.
switched to the operation position. When the Set and Coast Button
When the vehicle speed drops and the Accelerate and Resume
NOTE: below approximately 22 mph (35
If you continue to press and
switch are pressed at the same
km/h). time.
hold the Set and Coast Button,
When the Cruise Control is tempo- When a malfunction occurs
the speed will not drop below
rarily cancelled, Cruise Control ON within the system.
approximately 22 mph (35 km/h),
indicator light continues to illuminate
it is set at a speed of approxi-
and Cruise Control SET indicator
mately 22 mph (35 km/h).
light turns off.
<Brake pedal operation>
Depress the brake pedal to
decrease to the preferred speed
quickly. When the preferred speed
is reached, press and release the
7 - 62
INSTRUMENTS AND CONTROLS
7 - 63
INSTRUMENTS AND CONTROLS
7 - 64
INSTRUMENTS AND CONTROLS
7 - 65
INSTRUMENTS AND CONTROLS
CAUTION
Operation procedure
Before operating the air sus-
Operation procedure for lowering pension dump switch, check
the bed that there is no person or
This switch is located at the right 1.Stop the vehicle on a level ground. object under or near the vehi-
side of the heater control. 2.Pull up the parking brake valve cle.
By operating this switch, the vehicle and turn the ignition key to the ON Before turning ignition key to
bed can be lowered by exhausting or ACC position. the OFF position or releasing
air from the air spring at the rear axle 3.Before operating the air suspen- the parking brake, make sure
to facilitate loading/unloading work. sion switch, check that there is no that the bed is in the normal
person or object under or near the driving height.
vehicle. If the ignition key is turned to
4.After confirming the safety, push the OFF position or the parking
the air suspension dump switch. brake is released while the bed
Air is exhausted from the air spring is in the lowered state, the bed
will be automatically returned
at the rear axle and the bed is low-
to the normal driving height.
ered.
7 - 66
INSTRUMENTS AND CONTROLS
7 - 67
INSTRUMENTS AND CONTROLS
7 - 68
INSTRUMENTS AND CONTROLS
7 - 69
INSTRUMENTS AND CONTROLS
DPF system warning (Amber) and warning Contact your nearest UD Trucks dealer for inspection.
Large message are displayed
Procedure
Stop the vehicle in a safe location,
and then perform manual DPF
7 - 70
INSTRUMENTS AND CONTROLS
7 - 71
INSTRUMENTS AND CONTROLS
Manual regeneration (when the NOTE: The approximate time required for
DPF clogging warning light If the vehicle is driven under any manual DPF regeneration
blinks) of the following conditions, the depends on the conditions the last
DPF clogging warning light may time the vehicle was driven and
If the vehicle is driven at a low
blink many times because the the engine idling status, however
speed or the engine is started/ automatic regeneration may not normally it takes 25 minutes.
stopped many times while driving, operate.
the soot in the DPF may not be ・The vehicle is frequently driven 1.Stop the vehicle in a safe location,
burned and cleaned automatically. at a low speed. and then keep the engine idling.
In this case, the DPF clogging ・The engine is started/stopped 2.Be sure to apply the parking brake.
warning light informs the driver many times while driving. Place the gearshift lever in the
that the soot in the DPF must be ・The vehicle is driven many neutral position. Do not depress
burned and cleaned manually. times for only a short distance. the accelerator pedal.
・The engine is always stopped 3.Press the ON side of the manual
CAUTION before it warms up. forced regeneration switch.
Manual DPF regeneration 4.When the DPF regeneration starts,
When the DPF clogging warn-
ing light blinks, operate the operation the warning of DPF regeneration
manual forced DPF regenera- appears on the multi-display moni-
tion switch to perform the When the DPF clogging warning tor. The engine speed at idle will
cleaning manually, and then light blinks, perform manual DPF increase.
burn and clean the soot in the regeneration according to the fol-
DPF. lowing procedure, and then burn
If driving is continued, clog- and clean the soot in the DPF.
ging in the DPF or a system Note that manual regeneration can
malfunction may occur. be performed when the indicator
light blinks or automatic DPF
regeneration is started.
7 - 72
INSTRUMENTS AND CONTROLS
7 - 73
INSTRUMENTS AND CONTROLS
7 - 74
INSTRUMENTS AND CONTROLS
7 - 75
INSTRUMENTS AND CONTROLS
Automatic transmission selector When the selector lever (switch) is Parking brake valve
lever (switch) moved (pushed) into R (Reverse)
position, the backup lights come on
and the backup buzzer sounds and
the back buzzer sounds in the cabin.
The backup lights and buzzer are
located on the rear of the vehicle.
The engine starts in the N (Neutral)
or P (Park) position.
Allison 1000, 2200 and 2500 series The parking brake valve is located to
the rear of the gear shift lever. Pull
the knob up to operate the parking
brake. When the knob is pulled up,
the PARKING BRAKE warning light
comes on. To release the parking
brake, press the knob down. The
warning light will go out.
7 - 76
INSTRUMENTS AND CONTROLS
CAUTION
Release the parking brake
before driving the vehicle. Fail-
ure to release the parking
brake can cause brake dam-
age.
WARNING
Never apply the parking brake
when the vehicle is moving.
Such application will lock the
rear wheels and may result in
loss of vehicle control, could
cause damage to the driveline
and/or brake drum on the
transmission.
Do not operate the parking
brake valve with a person near
the rear axle. The movement of
the parking brake actuating
rod can cause serious injury.
7 - 77
ACCESSORIES
8-1
ACCESSORIES
WARNING
The power socket is located at the The use of any device with a The ashtray is located inside of the
right side of the cigarette lighter. higher current than the allow- right and left doors.
Use the power socket in the cab to able load can heat the socket To open the ashtray, pull the tab
connect commercially available car and cord and cause fire. Use upward.
accessories. Remove the cap before devices with the allowable load To remove the ashtray for cleaning,
use. The following devices can be current. pull the tray upward.
connected to the socket. The socket is for 12 volts only.
Do not use any car accessory
Device Rated current for 24 volts with the socket. A WARNING
trouble may be caused in the
Charger for mobile device. To prevent fire, ensure that any
2A
phone The socket can be used while lit or smoldering materials in
GPS 2A the ignition key switch is in the the ashtray are completely
ACC position. Before leaving extinguished.
TV 9.5A
the vehicle, disconnect the
Wireless device 2.2A
device from the socket.
Computer 7A
8-2
ACCESSORIES
Store only lightweight items, such as This is used to hold bottle and cup
the vehicle inspection certificate and for drinks, etc.
magazines, in the large box with the
lid.
CAUTION
Avoid abrupt starting and brak-
CAUTION ing to prevent a drink from
The standard weight of objects being spilt when it is stored in
stored in the overhead is indi- the cup holder.
cated below. Storing objects
with the weight exceeding the
following limit may damage the
console and lid.
Overhead box: 6.6 Ib (3 kg) or
less
8-3
ACCESSORIES
Close Turn
off
Open Close Turn Turn
on off Turn
Close Open on
Open
Turning on the room light switch This can be used to hold such cards
to ON turns on the room light as telephone cards and highway
regardless of whether or not a cards.
door is open or closed.
The room light turns off when CAUTION
the room light switch is turned To prevent theft, do not leave
to OFF. credit cards in the card holder
When the room light switch is in when away from the vehicle.
the DOOR position, the room
light will turn on when the
driver’s seat door or the pas-
senger seat door is opened,
and will turn off when the door is
closed.
8-4
ACCESSORIES
Door pockets are located in the left When the seatback of the center
and right doors. Place road maps, seat is folded forward, some docu-
magazines, etc. inside it. ments, small items, etc. can be
stored on the reverse side of the
seatback.
8-5
HEATER OR AIR CONDITIONER CONTROL
Air vent
Use the air conditioner when the
engine is running.
The engine coolant is used to heat
the air used for heating. The air
coming from the air vent will not be
warm until the engine coolant tem-
perature.
9-1
HEATER OR AIR CONDITIONER CONTROL
Change the switch and dial selections to match the season to make your driving pleasant.
Operation Panel
9-2
HEATER OR AIR CONDITIONER CONTROL
Temperature HOT Use maximum heating: Blows a warm air after passing the air through the heater core.
control dial
Adjust the temperature of the air:
COLD - HOT This changes the temperature of the air to match the temperature control dial setting.
Turn right: Increases temperature, Turn left: Lowers temperature
Dial
Vent Send air from the vent: Set the air outlet to the Vent position.
Vent & Foot Send air from the vent and foot vents: Set the air outlet to the Vent & Foot position.
Foot Send air from the foot vents: Set the air outlet to the Foot position.
Foot & Defrost 1 Send air from the foot and defrost vents: Set the air vents to the Foot & Defrost posi-
tion.
Mode dial Send air from the foot and defrost vents:
Foot & Defrost 2 Set the air vents to the Foot & Defrost position.
(This divides the air to blow more from the defrost vents than from the foot vents.)
Send air from the defrost vents:Set the air vents to the Defrost position.
Set the intake vents to outside air.
Defrost
Run the compressor.
The minimum air will blow even if the fan dial is set to OFF.
9-3
HEATER OR AIR CONDITIONER CONTROL
Air conditioner The light turns on/ This switches between the dehumidifier mode (light on) and heater mode (light off).
switch off each time this Light on: Compressor is operating normally
is pushed. Light off: Heater is operating (compressor is not operating)
Switch Alternates
between turning It switches between insider air recirculation and letting in the outside air.
Fresh/Recircula- on the inside air Inside air light: Set to inside air recirculation.
tion switch light and outside
air light each time Outside air light: Set to let in the outside air.
this is pushed.
NOTE:
Do not operate the dials or switches while driving.
9-4
HEATER OR AIR CONDITIONER CONTROL
Heating
Moving the mode dial to the Foot
position will blow warm air on the
feet.
The temperature control dial is
used to adjust the air temperature,
and the fan dial is used to adjust
the fan speed as desired.
When you want to heat up the cab
quickly or when you are in a dusty
location, push the Fresh/Recircula-
tion switch to select the inside air.
When the windshield fogs up eas- NOTE:
ily, set the air vents to Foot & Mode dial Foot & Defrost 1
Defrost. blows more air through the foot
vents than the defrost vents,
and Foot & Defrost 2 blows
more air through the defrost
vents than through the foot
vents.
9-5
HEATER OR AIR CONDITIONER CONTROL
Push the fresh/recirculation switch to illuminate the position light of the inside air recir-
culation mode.
The intake vent is fixed at inside air recirculation.
3 NOTE:
The air temperature from the vent becomes low when the outside air mode
is selected because the cold outside air is warmed. However, the air tem-
perature from the vent becomes high when the inside air recirculation
mode is selected because the warm inside air is warmed again.
If the air temperature in the cabin is cool after performing steps 1 to 3 above, perform the following step.
9-6
HEATER OR AIR CONDITIONER CONTROL
4 NOTE:
While parking the vehicle for a long period of time, the temperature of the
engine coolant tends to decrease. However, using the warm-up switch
allows sufficient performance of the heater.
For details on how to use the warm-up switch, refer to the “VEHICLE
OPERATION” chapter.
If it is still cold, even when the warm-up switch is turned on, operate the engine
throttle control knob to turn idle speed up with the warm-up switch in the ON posi-
tion.
5
NOTE:
The heater utilizes heat from the engine coolant. While idling, the engine coolant temperature gauge may indicate a
lower value because the temperature of engine coolant tends to decrease. However, performing the steps above will
allow sufficient performance of the heater.
9-7
HEATER OR AIR CONDITIONER CONTROL
Vent & Foot (Cool head, warm feet) Defrost Switching between inside and
outside air
Moving the mode dial to the Vent & Putting the mode dial in the Defrost
Foot eliminates the discomfort position will blow warm air from the Normally, the intake vents use out-
caused by the warm air making the defroster on the inside of the wind- side air, but when you want to
heat too hot, etc. shield. avoid dust, exhaust fumes, etc.,
push the Fresh/Recirculation
The temperature control dial is
switch to switch to inside air recir-
used to adjust the air temperature, culation.
and the fan dial is used to adjust
the fan speed as desired.
NOTE:
When the mode dial is moved to
the Defrost position, the com-
pressor begins to run and the
intake vents are set to outside WARNING
air. Note that the compressor
might not turn on due to certain Do not use inside air recircula-
conditions, such as the outside tion for a long time. Doing so
air temperature. will cause the air inside the
When the mode dial is moved to cab to become foul or the
the Defrost position, the mini- windshield to fog up, etc.
mum amount of air will blow
even if the fan dial is set to OFF.
9-8
HEATER OR AIR CONDITIONER CONTROL
9-9
VEHICLE OPERATION
VEHICLE WARNING
OPERATING PRECAUTIONS
Following a few precautions will help
OPERATION Never drive the vehicle with lengthen the life and reliability of
the engine stopped. your vehicle.
the clutch disengaged (not After starting, warm up the engine
applicable to automatic trans- until it runs smoothly.
mission). Do not race the engine during the
the transmission gear shift warm-up period.
lever in neutral. Avoid sudden starts and abrupt
These are very hazardous and stops.
can cause loss of control When you start a loaded vehicle,
resulting in death or serious use 1st gear. When you go uphill,
injury. This is because:
use an appropriate lower gear.
1.You cannot use the engine
Use the same gears going down a
brake.
2.When the engine is not run- grade as you used or would use
ning, the brake system will going up.
not function properly, and
this can result in a longer
stopping distance.
3.The power steering system
will not function, and much
greater effort is needed to
control the steering.
10 - 1
VEHICLE OPERATION
10 - 2
VEHICLE OPERATION
TOWING TRAILERS ning lights, brake lights, turn signals Do not exceed the GCWR rating or
and hazard lights are working. Con- transmission damage may occur.
Trailer brakes sult your authorized UD Trucks
dealer or the authorized dealer/man- Servicing after towing
Electric brakes and manual, auto- ufacturer of your trailer for instruc-
matic or surge-type trailer brakes are tions to connect the trailer lamps to If you tow a trailer for long distances,
safe if installed properly and the tow vehicle. your vehicle will require more fre-
adjusted to the manufacturer’s spec- quent service intervals. Refer to the
ifications. The trailer brakes must Safety chains “Vehicle Service and Maintenance”
meet local and Federal regulations. section for “Type 1” vehicle opera-
If you own a trailer with a hydraulic Always connect the trailer’s safety tion.
brake system, do not connect the chains to the frame or hook retainers
trailer’s hydraulic brake system of the vehicle hitch. Trailer towing safety tips
directly to your vehicle’s brake sys- To connect the trailer's safety chains,
tem. The vehicle’s brake system is cross the chains under the trailer General
only designed to carry the appropri- tongue and allow slack for turning Ensure that the trailer, safety
ate amount of brake fluid for the corners. If you use a rental trailer, chains and electrical connectors
vehicle alone. Connecting a hydrau- follow the instructions that the rental
are securely fastened.
lic trailer braking system could agency provides to you.
Make sure the truck receiver, draw
adversely affect your vehicle’s brak- bar, and coupler are properly con-
ing performance. Driving while you tow
nected and adjusted.
NOTE: When towing a trailer: Check side mirrors for proper visi-
The braking system of the tow Turn off and do not use the cruise bility, especially when towing a
vehicle is rated for operation at control. trailer wider than the truck.
the GVWR not GCWR. Consult your local motor vehicle When towing, operate the vehicle
speed regulations for towing a at lower speeds than you would
Trailer lamps trailer. when not towing a trailer. The like-
Trailer lamps are required on most Anticipate stops and brake gradu- lihood of trailer sway is greater at
towed vehicles. Make sure all run- ally. higher speeds.
10 - 3
VEHICLE OPERATION
When turning, make wide turns to or if they will not hold, chances are STARTING THE ENGINE
allow trailer tires to properly clear that they need adjustment.
any obstacles. Anticipate the need to stop; allow Before starting the engine, check to
Be prepared for trailer sway due to additional distance and time to be sure that:
buffeting when larger vehicles stop than normal. The MTM is shifted to the neu-
pass in either direction. Do not apply the trailer brakes for tral position. The engine can
extended periods of time as they only be started when the shift
Loading can overheat and lose their effec- lever is in the N (Neutral) posi-
Keep the center-of-gravity low for tiveness. tion.
best handling. For ATM, put the selector lever
Trailer loads should be evenly dis- Backing up (switch) into the P (Park) or N
tributed front to back and left to Practice backing up, particularly if (Neutral) position.
right. you are a novice. Turn the steering The transmission PTO switch
Never exceed truck, trailer, wheel to the right to move the (optional) is turned off.
receiver, ball, tongue, tire or cou- trailer’s rear end to the right. The parking brake is pulled to
pler loading recommendations. Sharp steering movements may the PARK position.
cause the trailer to jackknife or go The power steering fluid level
Braking out of control. is proper.
The trailer brakes must be The engine oil level and engine
inspected and serviced at intervals Tires coolant level are proper.
specified by the trailer manufac- All trailer tires should be of the Normal temperature conditions:
turer. This includes shoes, drums, same size and construction. Depress the clutch pedal (Not avail-
and trailer brake magnets. Select tires that meet the trailer able with automatic transmission)
Electric brakes also require peri- loading requirements. fully, and then turn the ignition key to
odic adjustment to keep the shoes Always check tow vehicle and the START position.
properly spaced. trailer tire pressure before towing.
If the brakes get hot when driving
10 - 4
VEHICLE OPERATION
10 - 5
VEHICLE OPERATION
10 - 6
VEHICLE OPERATION
10 - 7
VEHICLE OPERATION
10 - 8
VEHICLE OPERATION
NOTE:
For information regarding pre-
cautions when using the
warm-up switch, refer to the
"Engine warm-up switch" on
page 7-54.
10 - 9
VEHICLE OPERATION
DRIVING ON GRADES
1.When driving up a grade, operate WARNING WARNING
the vehicle in a lower transmission Do not rest your foot on the Operating the engine in the red
gear at the engine speed (about brake pedal or use the foot zone of the tachometer can
1,400 rpm) for which the engine brakes for extended periods. cause severe engine damage
develops its maximum torque. Such can cause the brake and serious injury.
Sustained high speed operation drums to overheat, the linings Do not downshift if the engine
may cause severe engine failure. to wear excessively and/or speed is in the red zone of the
2.When descending a grade, first cause a drop in braking pres- tachometer.
sure resulting in a reduction in
use engine braking by selecting
braking effectiveness and 4.Check the operation of the brakes
the same gear which was used or increased stopping distances. before you begin the descent of an
would be appropriate for going up
extended or steep grade.
the grade. Supplement the engine 3.When downshifting, wait until
braking with exhaust braking and engine speed corresponds to the
finally with service brakes, as nec- road speed of the next lower gear
essary, to maintain a safe vehicle before shifting. Do not allow the
speed. engine to overspeed. Do not oper-
ate the engine at speeds within the
tachometer red zone.
10 - 10
VEHICLE OPERATION
10 - 11
VEHICLE OPERATION
WARNING CAUTION
To avoid engine and clutch fail- Do not ride the clutch pedal.
ure which may result in serious “Riding the clutch” by resting
injury: your foot on the clutch pedal
Do not operate your vehicle while driving can lead to pre-
with a worn or damaged mature clutch failure.
clutch. Avoid shifting the transmis-
Do not operate the vehicle with sion into first gear while the
your foot resting on the clutch vehicle is moving. Shifting into
pedal. first gear while moving may
Do not use the clutch to hold damage the transmission.
your vehicle on a grade. Stop the vehicle completely
before shifting from forward to
To reduce the possibility of loss reverse or from reverse to for-
of vehicle control: ward.
Do not allow the vehicle to When shifting down or up, shift
coast with the clutch pedal the lever being careful not to
depressed or with the trans- pass the correct shift gate.
mission in neutral. When shifting from 6th to 5th
Do not operate the vehicle with gear, push the shift lever to the
the clutch partially engaged. right. If this is not done during
Always use 1st gear when shifting 6th to 5th, a misdown-
starting to move the vehicle. shift to 3rd gear may occur,
resulting in engine overspeed-
ing and possible engine or
clutch damage.
10 - 12
VEHICLE OPERATION
Double-clutch operation
Use the following double-clutch technique when shifting:
1.Fully depress the clutch pedal to 3.Release the clutch pedal. When 6.Release the clutch pedal. When
disengage the clutch. downshifting, raise the engine downshifting, wait until engine
2.With the clutch pedal fully speed using the accelerator pedal. speed corresponds to the road
depressed, shift the gear shift lever 4.Fully depress the clutch pedal speed of the next lower gear
to the neutral position. again. before shifting. Do not overspeed
5.While holding the pedal down, shift the engine.
to the next gear.
10 - 13
VEHICLE OPERATION
2500 series
10 - 14
VEHICLE OPERATION
started when the shift lever is in lever will move). At this time the NOTE:
the P (Park) or N (Neutral) posi- SHIFT LIMIT warning light comes When shifting from Neutral to
tion. on. If this occurs, stop the vehicle, any other range, approximately
When shifting from Park to any and shift first to P (Park) or N 1 second is required for the
other range, depress the brake (Neutral). Then depress the brake transmission clutch to connect.
pedal while shifting. pedal and shift to the desired driv- If the accelerator pedal is
Shifting is not done if the engine ing range. depressed during this time,
speed is high (1,000 rpm or more). (N): Neutral Position — excessive stress is placed on
This position is used when starting the transmission. Wait until the
Use P (Park) for the following. the engine, for warming up the clutch has connected and then
to turn on or turn off the engine gradually depress the accelera-
engine, and when stopped. The
tor pedal.
to check vehicle accessories engine can only be started when
to operate the engine in idle for the shift lever is in the P (Park) or (D): Driving Position —
longer than five minutes N (Neutral) position. This is the position used during
for stationary operation of the When shifting from Neutral to a normal driving.
power takeoff (if your vehicle is driving range, depress the brake Gears will change from 1 - 5 when
equipped with a PTO) pedal while shifting. At this time the overdrive (O/D) switch is on,
This position places the transmission the SHIFT LIMIT warning light illu- and from 1st to 4th when it is off.
in N (Neutral) and engages the park minates. If this occurs, return the
pawl. shift lever to the P (Park) or N
(R): Reverse Position — (Neutral) position, then depress
This position is used when moving
the brake pedal and shift to the
the vehicle backwards. You must desired driving range.
first stop the vehicle before shifting
Shifting will not be done if the
from a forward gear to Reverse, or
engine speed is high (1,000 rpm or
from Reverse to a forward gear.
more).
This range cannot be shifted to
while driving (although the shift
10 - 15
VEHICLE OPERATION
10 - 16
VEHICLE OPERATION
WARNING WARNING
CAUTION
D (Drive) and other forward If you just downshift or just
ranges may not be obtained use service brakes when going Do not idle in R (Reverse) or D
due to an active inhibitor. The downhill, you can lose control (Drive) for more than 5 min-
range selected may not be and cause injury and/or prop- utes. Doing so may cause
obtained, resulting in unex- erty damage. To avoid loss of transmission overheating and
pected vehicle motion. Always control, use a combination of damage. Always use P (Park)
apply the service brakes when downshifting, braking, and or N (Neutral) if you need to
selecting D (Drive) or other for- other retarding devices. idle over 5 minutes.
ward ranges. Downshifting to a lower trans-
The transmission incorpo- mission range increases <Operating with automatic
rates a hold feature to prohibit engine braking and helps you transmission>
upshifting above the range to maintain control. The trans-
Check before engine start
selected during normal driv- mission has a feature to pre-
ing. For downhill operation, vent automatic upshifting Always use the right foot to oper-
select a lower transmission above the lower range ate the accelerator pedal and the
range. If the engine-governed selected. However, during brake pedal in order to prevent
speed is exceeded in the held downhill operation, if engine depressing either by accident.
range, however, the transmis- governed speed is exceeded in Shift lock system
sion may upshift to the next the lower range, the transmis-
<Model without P position
higher range. To avoid loss of sion may upshift to the next (2500 series)>
vehicle control, use the vehicle higher range. This will reduce
When shifting the selector lever for
brakes to prevent exceeding braking and could cause a loss
engine governed speed in the of control. Apply the vehicle the first time after turning the igni-
held range. brakes or other retarding tion key to the ON position, the
device to prevent exceeding selector lever cannot be shifted
engine governed speed in the from N to another position if the
lower range selected. brake pedal is not depressed.
Moreover, when the shift lever is
10 - 17
VEHICLE OPERATION
left engaged in the N position for If the selector lever cannot be <Model with P position
about 5 minutes even after shifting shifted from N to another position (1000 and 2200 series)>
the selector lever for the second even when the brake pedal is The selector lever cannot be
time, it cannot be shifted from the depressed, press the shift lock shifted from the P position if the
N position. In this case, depress release button. While pressing the brake pedal is not depressed.
the brake pedal and operate the button, the selector lever can be When the ignition key is in the
selector lever. shifted. ACC or LOCK position, the selec-
When the ignition key is in the tor lever cannot be shifted from the
ACC or LOCK position, the selec- P position even if the brake pedal
tor lever cannot be shifted from N is depressed.
to another position even if the When the selector lever is in any
brake pedal is depressed. position other than the P position
When the selector lever is in any ・The key cannot be removed from
position other than the N position the ignition key switch. Place the
selector lever in the P position
・The key cannot be removed from
and then remove the key.
the ignition key switch. Place
・The ignition key cannot be turned
the selector lever to the N
from ACC to the LOCK position.
position and then remove the key. NOTE: When shifting the selector lever
・The ignition key cannot be turned If this situation occurs, contact
from P to another position,
from ACC to the LOCK position. your nearest UD Trucks dealer
When shifting the selector lever for inspection. depress the brake pedal first and
from N to another position, then operate the lever. If the lever
depress the brake pedal first and is operated first, it does not move
then operate the lever. If the lever so that the shift lock mechanism is
is operated first, it does not move not released.
so that the shift lock mechanism is If the selector lever cannot be
not released. shifted from the P position even
when the brake pedal is
10 - 18
VEHICLE OPERATION
depressed, press the shift lock Release the parking brake. Lift When parking, first stop the vehi-
release button. While pressing the your foot off of the brake pedal. cle, then shift to P (Park) or N
button, the selector lever can be When traveling forward, accelera- (Neutral). Then slowly release the
shifted. tion begins from 1st gear. Accord- brake pedal and check that the
NOTE: ing to the engine load and speed, lock has been engaged. Then
If this situation occurs, contact the transmission will automatically firmly set the parking brake.
your nearest UD Trucks dealer shift from 1st gear, to 2nd, to 3rd... Each time you park the vehicle or
for inspection. up to the maximum gear for the leave the operator’s station with
selected range. the engine running, do the follow-
Engine start NOTE: ing.
Check that the parking brake has The engine protection function 1.Bring the vehicle to a complete
been pulled up. may provide torque derating to stop using the service brake.
Check that the shift lever is in the prevent the engine from being 2.Ensure that the engine is at low
P (Park) or N (Neutral) position, damaged, in this case, also shift idle rpm.
then start the engine. (The engine shock might occur. 3.Put the transmission in P (Park)
will not start if the lever is in or N (Neutral).
Stopping and parking
another position.) Check that the 4.Engage the P (Park) range by
When stopping temporarily, leave
warning light turns off after the slowly releasing the service
the shift lever in the D (Drive) posi-
engine has started. brake.
tion. Be sure to keep the brake
5.Apply the emergency brake and/
Starting to move the vehicle pedal depressed with the right
or parking brake, if present, and
Depress the brake pedal with your foot. In this way, there is no need
make sure it is properly
right foot. Select a gear range. To to return the shift lever to N (Neu-
engaged.
move the vehicle forward, select D tral).
6.If the operator’s station will be
(Drive), to move backwards select When stopping for 5 minutes or
unoccupied with the engine run-
R (Reverse). longer, shift to the N (Neutral) or P
ning, chock the wheels and take
The gear will not shift if the engine (Park) position.
any other steps necessary to
speed is high.
keep the vehicle from moving.
10 - 19
VEHICLE OPERATION
10 - 20
VEHICLE OPERATION
Using the engine to slow the vehicle ing to accelerate. This will avoid an
To use the engine as a braking force, unexpected downshift during accel- WARNING
shift the selector to the next lower eration. To avoid injury or property
range. If the vehicle is exceeding the Rocking out damage caused by sudden
maximum speed for a lower gear, If the vehicle is stuck in deep sand, movement of the vehicle, do
use the service brakes to slow the snow, or mud, it may be possible to not make shifts from N (Neu-
vehicle to an acceptable speed rock it out. Shift to D (Drive) and tral) to a forward range or R
where the transmission may be apply steady, light throttle (never full (Reverse) when the accelerator
downshifted safely. throttle). When the vehicle has pedal is depressed. The vehi-
Parking brake (2500 series) rocked forward as far as it will go, cle will lurch forward or rear-
There is no park position in the apply and hold the vehicle service ward and the transmission can
transmission shift pattern. Therefore, brakes. Allow the engine to return to be damaged. Avoid this condi-
always put the selector in neutral idle; then select R (Reverse). tion by making shifts from N
and apply the parking brake to hold Release the brakes and apply a (Neutral) to a forward range or
the vehicle when it is unattended. steady, light throttle and allow the R (Reverse) only when the
Driving on ice or snow vehicle to rock in R (Reverse) as far throttle is closed.
as it will go. Again, apply and hold
Here is where all of your ability as a
the service brakes and allow the
professional driver comes into focus
engine to return to idle. This proce-
regardless of what transmission you
dure may be repeated in D (Drive)
have. If possible, reduce your speed
and R (Reverse) if each directional
and select a lower range before you
shift continues to move the vehicle a
lose traction. Select the range that
greater distance. Never make N
will not exceed the speed you expect
(Neutral)-to-D (Drive) or directional
to maintain. Accelerate or decelerate
shift changes when the engine rpm
very gradually to prevent losing trac-
is above idle.
tion. It is very important to slow grad-
ually when a lower range is selected.
It is important that you reach the
lower range selected before attempt-
10 - 21
VEHICLE OPERATION
10 - 22
VEHICLE OPERATION
Turn the PTO switch on. <PTO operation> The transmission operates in either
Set the engine speed at idle. converter mode or torque converter
CAUTION
Place shift selector lever in D clutch mode. In converter mode, the
(Drive). Do not exceed the engagement torque converter (lockup) clutch is
Shift the PTO power shift clutch and operational speed limits not engaged and the PTO is driven
imposed on the driven equip- through the torque converter, pro-
lever to Drive.
ment during the operation of ducing a torque at the PTO drive
Bring the engine up to speed. the PTO. Exceeding the speed gear that is always greater than the
Shift to N (Neutral). limits produces high hydraulic input torque. In torque converter
pressure in the PTO that can clutch mode, the torque converter
Disengage the PTO drivetrain as fol- damage the PTO components. (lockup) clutch is engaged, the PTO
lows. Consult the vehicle manufac- drivetrain is driven at a speed pro-
Stop the vehicle. turer’s literature for these
speed limits. portional to the engine speed.
Idle the engine. The PTO drive is normally in contin-
Some vehicles creep in range
Set the brake. at low vehicle speeds while uous converter mode operation
Place the shift selector in a drive maintaining a specified engine when the transmission is in P (Park)
range. speed for PTO operation (e.g., and R (Reverse). Torque converter
Stop the PTO-driven equipment. paint stripers and feed lot clutch operation in N (Neutral) is
trucks). For PTO operation at available for some applications. If
Disengage the power takeoff.
low speeds, do not use the the PTO is used with the transmis-
Return the transmission shift brakes to limit vehicle speed sion in D (Drive) or another forward
selector to N (Neutral). while using the throttle to
range, transmission shifts (both con-
Turn the PTO switch to off. maintain an engine speed
above idle when the transmis- verter/torque converter clutch mode
<PTO Engagement—Clutch Driven> sion is in range. Such opera- shifts and shifts between gears) are
The PTO will engage only when the tion will cause the based on the automatic shift
PTO switch is on, the throttle posi- transmission to overheat. sequence of the transmission shift
tion is low, and engine speed and Extended operation at elevated controls. PTO drive gear speed will
output speed are within the limits temperatures will result in be affected each time a shift occurs.
specified by body builders. transmission damage. With the vehicle stopped and the
engine at idle, PTO output speed is
10 - 23
VEHICLE OPERATION
dependent upon the transmission <PTO overspeed protection> ALLISON 3000 automatic
gear selection. transmission (Optional for
If the transmission is in D (Drive) UD2600 and UD3000)
CAUTION
or R (Reverse), the PTO output
speed is zero. Do not exceed the engagement
The Allison automatic transmissions
have 6 forward and 1 reverse gear
If the transmission is in N (Neutral) and operational speed limits
ranges.
or P (Park), the PTO output will imposed on the driven equip-
rotate slowly. ment during the operation of
the PTO. Exceeding the speed Selector switch
In some vehicles, the transmission The Range selector switch is used to
will shift into N (Neutral) regardless limits produces high hydraulic
pressure in the PTO-driven shift the gear to the desired driving
of the shift selector position under range from among 6 forward ranges
the following conditions. components that can damage
the PTO-driven components. and the reverse range. When the
the PTO is enabled switch is pushed, the selected range
the transmission output speed is
Consult the vehicle manufac-
turer’s literature for these is displayed on the left side of the
near zero digital display of the selector. With
speed limits.
the throttle position is near zero the or switch, the range can
When the PTO is disengaged
To reselect a range, the operator due to overspeed, the PTO will be selected. While driving forward,
must shift into N (Neutral), then shift be automatically re-engaged at
to the desired range. each time the switch is pushed
user specified speed, which is
typically relatively low. The once, the selector range is shifted
resultant re-engagement shock downward by one gear, and each
could cause damage to a high- time the switch is pushed once,
inertia PTO system. the selector range is shifted upward
by one gear. The selected range is
displayed on the left side of the digi-
tal display of the selector, and the
range in operation on the right side.
10 - 24
VEHICLE OPERATION
Digital display
Range Automatic transmis-
operation Selection Range in sion range
range operation
R R R R
N N N N
D 6 1 to 6 1 to 6
Once 5 1 to 5 1 to 5
Twice 4 1 to 4 1 to 4
3 times 3 1 to 3 1 to 3
4 times 2 1 to 2 1 to 2
5 times 1 1 1
10 - 25
VEHICLE OPERATION
10 - 26
VEHICLE OPERATION
Do not make shifts from N The transmission incorpo- Downshifting to a lower trans-
(Neutral) to a forward range or rates a hold feature to prohibit mission range increases
from N (Neutral) to R (Reverse) upshifting above the range engine braking and helps you
to avoid sudden movement of selected during normal driv- to maintain control. The trans-
the vehicle. ing. For downhill operation, mission has a feature to pre-
Do not make shifts from a for- select a lower transmission vent automatic upshifting
ward range to N (Neutral). range. If the engine-governed above the lower range
Selecting N (Neutral) does not speed is exceeded in the held selected. However, during
apply vehicle brakes unless an range, however, the transmis- downhill operation, if engine
auxiliary system to apply the sion may upshift to the next governed speed is exceeded in
parking brake is installed. higher range. To avoid loss of the lower range, the transmis-
vehicle control, use the vehicle sion may upshift to the next
brakes to prevent exceeding higher range. This will reduce
WARNING engine governed speed in the braking and could cause a loss
held range. of control. Apply the vehicle
D (Drive) and other forward brakes or other retarding
ranges may not be obtained device to prevent exceeding
due to an active inhibitor. The WARNING engine governed speed in the
range selected may not be lower range selected.
obtained, resulting in unex- If you just downshift or just
pected vehicle motion. Always use service brakes when going
apply the service brakes when downhill, you can lose control
selecting D (Drive) or other for- and cause injury and/or prop-
ward ranges. erty damage. To avoid loss of
control, use a combination of
downshifting, braking, and
other retarding devices.
10 - 27
VEHICLE OPERATION
10 - 28
VEHICLE OPERATION
Keeping the brake pedal ing to the engine load and speed,
depressed with the right foot, push the transmission will automatically
the switch and select the range. To shift from 1st gear, to 2nd, to 3rd...
move the vehicle forward, select D up to the maximum gear for the
(Drive), to move backwards select selected range.
R (Reverse). NOTE:
Shifting with the power mode
switch can be done only during
the engine running.
The engine protection function
NOTE: may provide torque derating to
After the engine is started, warm prevent the engine from being
up the engine. When the fluid damaged, in this case, also shift
temperature is low during win- shock might occur.
tertime, only “N”, “R” and the
lowest speed gear of “D” can be CAUTION
used.
When the engine can be started If the engine speed is high, the If the phenomenon in which
in any range other than “N”, gear is not engaged. Then, turn upshifts and downshifts are
there is something wrong. Con- repeated (shift hunting) occurs
the engine throttle control knob to
tact the nearest authorized UD while driving, shift to a lower
Trucks dealer. the AUTO position to lower the speed gear range using the
Avoid attempting to start your speed.
To start the vehicle on a level
switch.
vehicle by pushing or towing.
ground, select the “D” range.
Starting to move the vehicle Release the parking brake. Lift
With the power mode switch, your foot off of the brake pedal.
select normal or power mode. When traveling forward, accelera-
tion begins from 1st gear. Accord-
10 - 29
VEHICLE OPERATION
10 - 30
VEHICLE OPERATION
10 - 31
VEHICLE OPERATION
10 - 32
VEHICLE OPERATION
10 - 33
VEHICLE OPERATION
(ABS) Anti-lock Brake System faces. may lock the driving wheel, and
Also, in deep snow, on gravel the vehicle can become unstable.
The ABS, when it activates, properly
roads, or when tire chains are In this case, release the clutch,
controls the slippage of wheels and
effectively utilizes frictions between installed, if the ABS activates, the and apply the brake.
tires and road surfaces. It is a device stopping distance may be slightly When decelerating on slippery or
that enhances safety, but it does not longer than the models without uneven road surface with the auxil-
enable you to drive beyond the limi- ABS. iary brake (exhaust brake) applied,
tations. Follow the precautions Always take into account the road if wheel slippage occurs, the auxil-
below, and always drive safely. conditions, tire conditions, etc., iary brake may be automatically
maintain a safe distance from the released and the indicator light
Confirm that the warning light illu- vehicle in front of you, and drive at goes out. This is a normal opera-
minates when the ignition key is safe speeds. tion of ABS, and it is not a malfunc-
turned to the ON position and that The ABS helps to prevent the tion. Pay attention to the road
it goes out after about 3.0 sec- wheel slippage when the brake is conditions and the distance
onds. applied, and it does not function for between vehicles, and always
The motor operating sound may the slippage when the accelerator drive safely.
be temporarily heard from the pedal is applied or when turning.
frame side when the vehicle speed Also, even if the ABS activates, on
reaches 4 mph (7 km/h) each time a frozen and very slippery road, CAUTION
after the engine is started. This is the steering wheel operation can When installing an electronic
the sound of the ABS operation be difficult due to the loss of con- device such as radio or com-
check, and it is not a malfunction. trol.Always drive at safe speeds, munication equipment, be
When the ABS is in operation, the and avoid abrupt braking or steer- careful not to affect the func-
operating sound is intermittently ing operations as much as possi- tion of the ABS. Contact an
heard. This is not a malfunction. ble. authorized UD Trucks dealer if
The stopping distance on slippery When driving with the transmission you have any unclear points.
road surfaces will be longer than in a lower gear position on a frozen
on normal, dry, paved road sur- and slippery road, engine braking
10 - 34
VEHICLE OPERATION
10 - 35
VEHICLE OPERATION
10 - 36
VEHICLE OPERATION
engine impossible. At the end of maintained in the fully-charged may be faulty and should be
each daily operation, drain water condition. repaired.
from the fuel filter.
Always fill the fuel tank up to its
specified level to prevent conden- WARNING WARNING
sation. Do not attempt to jump start a Failure to drain water could
vehicle having a frozen bat- cause freezing in the air lines
Oil tery; the battery may rupture or and result in serious injury due
The lubricating oil thickens as it explode. If a frozen battery is to insufficient braking power.
suspected or if ice can be seen
gets colder, slowing engine crank-
in each cell, do not attempt to
ing speed. Be sure to use proper start the vehicle with jumper
lubricating oil in order to offer less cables.
resistance to the cranking effort of
the engine. Anti-freeze
See the "Oil viscosity and relation
between viscosity and tempera- Check the UDXtra Long Life Diesel
ture:" on page 11-32. Engine Antifreeze/Coolant to
assure proper winter protection.
Battery For details, see the "ENGINE
COOLING SYSTEM" on page 11-
If the battery is not fully charged,
24.
the battery electrolyte may freeze
and the resultant expansion may Draining air reservoir
damage the battery.
To maintain maximum efficiency, At the end of each daily operation,
the battery should be checked reg- always drain water from the air
ularly, at least once a month, and reservoir. If a large quantity of
water accumulates, the air dryer
10 - 37
VEHICLE OPERATION
10 - 38
VEHICLE OPERATION
10 - 39
VEHICLE SERVICE AND MAINTENANCE
11 - 1
VEHICLE SERVICE AND MAINTENANCE
without diagnosing and responding paragraphs 1 through 4 of this sec- tion that they cannot reasonably
appropriately to the DTCs, regard- tion. The records shall include at access.
less of whether the systems are minimum the mileage and/or hours
installed to satisfy requirements in at time of rebuild, a listing of work C.Parties may keep records of their
§ 86.004-25 or for other reasons performed on the engine and rebuilding practices for an engine
family rather than on each individ-
and regardless of form or inter- emissions-related control compo-
ual engine rebuilt in cases where
face. Diagnostic systems must be nents including a listing of parts those rebuild practices are fol-
free of all such DTCs when the and components used, engine lowed routinely.
rebuilt engine is returned to ser- parameter adjustments, emis-
vice. Such signals may not be ren- sions-related DTCs or signals D.Records must be kept for a mini-
dered inoperative during the responded to and reset, and work mum of two years after the engine
rebuilding process. performed under paragraph 4 of is rebuilt.
this section.
4.When conducting a rebuild with-
out removing the engine from the A.Parties may keep records in what-
vehicle, or during the installation of ever format or system they choose
a rebuilt engine, all critical emis- as long as the records are under-
sions-related components listed in standable to an EPA enforcement
officer or can be otherwise pro-
§ 86.004-25 (b) not otherwise
vided to an EPA enforcement offi-
addressed by paragraphs 1 cer in an understandable format
through 3 of this section must be when requested.
checked and cleaned, adjusted,
repaired, or replaced as neces- B.Parties are not required to keep
sary, following manufacturer rec- records of information that is not
ommended practices. reasonably available through nor-
mal business practices including
5.Records shall be kept by parties information on activities not con-
conducting activities included in ducted by themselves or informa-
11 - 2
VEHICLE SERVICE AND MAINTENANCE
MAINTENANCE INTERVALS
Abbreviations:
A = Check and adjust if I = Inspect, clean and correct or T = Tighten to specified torque
necessary replace as necessary L = Lubricate
R = Replace or change
NOTE:
It is the owner’s responsibility to see that the vehicle receives proper care and maintenance.
The maintenance or lubrication services shown below are to be performed at the indicated intervals (miles
or months, whichever occurs first).
Items indicated by “♦” should be performed only by your authorized UD Trucks dealer or qualified service
facility. For other items, the maintenance procedures are given in this chapter.
Items marked with “*” are related to the EMISSION CONTROL SYSTEM MAINTENANCE.
Under the following severe operating conditions, more frequent servicing will be required.
– Operation in heavy dust conditions
– Operation at extremely low or high ambient air temperature
– Extended high-speed operation with vehicle fully-loaded to its GVWR
– Extended low-speed operation
– Frequent stop-and-go operation
Any replacement parts used for required maintenance service or repairs should be genuine UD Trucks
parts or equivalent in quality and design to genuine UD Trucks parts.
11 - 3
VEHICLE SERVICE AND MAINTENANCE
Engine
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72 Months Reference
Items
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120 (every) page
FUEL SYSTEM
♦Low and High idle speed A -
*Fuel filters (Main and primary fuel filter) Once for every 2 engine oil and filter replacements - 11-39
Fuel hose and pipe
(Fuel filter to supply pump, Fuel tank to A R R:36 11-43
fuel filter, Engine to fuel tank)
LUBRICATION
*Engine oil and oil filter: Type 1 R 12
(With UDXtra Engine oil) Type 2 R 12
*Engine oil and oil filter: Type 1 R 6 11-33
(With Non-UDXtra Engine oil) Type 2 R 6
(Refer to note 1.)
Type 1/Type 2: For type of operation details refer to page 11-33
11 - 4
VEHICLE SERVICE AND MAINTENANCE
Engine (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72 Months Reference
Items
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120 (every) page
COOLING SYSTEM
*Cooling fan I 12 11-27
Initial inspection at first 6,000 miles (10,000 km)
*Drive belts 11-46
R 12
Engine coolant R: Every 320,000 miles (500,000 km) 48 11-28
*Radiator and heater hoses and clamps A 12 11-24
INTAKE AND EXHAUST SYSTEM
*Air cleaner element R 12 11-44
Intake air hose and clamps R 24 11-75
*Charge air cooler body I 6 11-27
♦*Charge air cooler hoses I 24
♦ Turbocharger rotor operation I 24
Exhaust pipe and muffler attachment A 12 11-75
loose and damage
♦*DPF I: Every 155,000 miles (250,000 km) or 4,500 hours - 11-70
♦*CCV filter R: Every 62,000 miles (100,000 km) 12 11-50
♦*DEF filter R: Every 150,000 miles (240,000 km) or 7,000 hours - 11-48
♦*DPF sensor hose R: Every 36 months 36
♦*DPF regeneration system I: Every 12 months 12 11-71
11 - 5
VEHICLE SERVICE AND MAINTENANCE
Engine (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72 Months Reference
Items
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120 (every) page
ELECTRICAL EQUIPMENT
Starter bearing grease I 12
♦ Starter brush I 24
♦ Alternator assy R: Every 218,000 miles (350,000 km) -
11 - 6
VEHICLE SERVICE AND MAINTENANCE
Chassis
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72
Items Reference page
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120
Months (every) 1 2 4 6 8 10 12
CLUTCH
Clutch fluid I R 11-66
Clutch pedal play I 11-65
♦ Clutch disc I
♦ Clutch piping I
MANUAL TRANSMISSION
♦ Breather I
Manual transmission gear oil R R 11-56
AUTOMATIC TRANSMISSION (UD1800 thru UD3300)
Automatic transmission fluid & filter Refer to 11-12
PROPELLER SHAFT
Sliding shaft I
♦ Universal joint I
♦ Center bearing I
11 - 7
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72
Items Reference page
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120
Months (every) 1 2 4 6 8 10 12
STEERING SYSTEM
♦ Gear box T
Power steering fluid and filter R I R 11-62
Steering wheel free play I 11-60
♦ Steering linkage T
♦ Power steering rubber hose R: Every 24 months
AXLE AND WHEEL
♦ Front axle (I-beam) I
♦ Clearance between front axle and I
knuckle
♦ Kingpin cotter pin T
♦ Wheel alignment I
♦ Rear axle housing I
♦ Breather I
♦ Front wheel bearing (Refer to note 1.) I
♦ Front wheel bearing grease R
♦ Rear wheel bearing (Refer to note 1.) I
♦ Rear wheel bearing grease R
Wheel nut (Refer to note 2.) I 11-86
NOTE: 1. If the mileage is 2,500 miles (4,000 km) or less in 6 months just before the 6 month inspection, the inspection
can be skipped.
2. Perform maintenance after the first 1,000 miles (1,600 km) of operation. This maintenance procedure also
applies whenever a tire is replaced.
11 - 8
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72
Items Reference page
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120
Months (every) 1 2 4 6 8 10 12
AIR-OVER-HYDRAULIC BRAKE SYSTEM (UD1800 thru UD2600)
♦ Service brake valve I
Air dryer I 11-64
♦ Air dryer repair kit R: Every 12 months
♦ Air compressor and air pressure governor (air I
dryer integrated model)
♦ Brake piping I
♦ Brake hose R: Every 12 months
♦ Air booster repair kit R: Every 12 months
Brake fluid I R 11-62
♦ Wheel cylinder repair kit R: Every 12 months
♦ Brake lining clearance (Refer to note 1.) I: Every 2,500 miles (4,000 km) or 1 month
♦ Brake lining I
♦ Brake drum I
♦ Parking brake system (note 2.) I
♦ Parking brake chamber diaphragm (note 2.) R: Every 24 months
NOTE: 1. During periods of severe service operation or frequent stop-and-go operation, more frequent inspections
of the brake system should be performed.
2. Spring-activated rear wheel parking brake.
11 - 9
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72
Items Reference page
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120
Months (every) 1 2 4 6 8 10 12
AIR BRAKE SYSTEM (UD3300)
♦ Service brake valve I
Air dryer I 11-64
♦ Air dryer repair kit R: Every 12 months
♦ Air compressor and air pressure governor I
♦ Brake piping I
♦ Brake hose R: Every 12 months
♦ Rear and front brake chamber diaphragm R: Every 24 months
♦ Brake chamber push rod stroke (Refer to I: Every 2,500 miles (4,000 km) or 1 month
note 1.)
♦ Rear brake chamber spring cylinder (Refer R: Every 36 months
to note 2.)
♦ Brake lining I
♦ Brake drum I
♦ Parking brake system I
NOTE: 1. During periods of severe service operation or stop-and-go high volume operation, more frequent inspections of the brake
system should be performed. Always maintain correct push rod stroke and brake adjustment to ensure correct braking.
2. Non-disassembling
11 - 10
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72
Items Reference page
Kilometers x1,000 5 10 15 16 20 25 30 32 40 48 60 80 120
Months (every) 1 2 4 6 8 10 12
SUSPENSION
Leaf spring I 11-67
Shock absorber I 11-68
♦ U-bolt and nut T I
Air bellows (Air suspension) I I I 11-68
Leveling valve (Air suspension) I I I 11-68
Air leakage (Air suspension) I I I 11-68
♦ Looseness and damage (Air suspen- I I I 11-68
sion)
Shock absorber (Air suspension) I
ELECTRICAL SYSTEM
Battery electrolyte level I 11-76
Battery terminal I 11-77
Specific gravity of battery electrolyte I 11-77
OTHERS
♦ Acoustical shielding I
Grease lubrication L: Every 5,000 miles (8,000 km) or 1 month 11-16
11 - 11
VEHICLE SERVICE AND MAINTENANCE
Change the automatic transmission fluid and filter at the intervals specified in the following chart.
UD1800 thru UD3300 (Allison 1000, 2200 and 2500 series)
Filters (#2)
Vocation Fluid* (#1)
Control Main** Internal Lube/Auxiliary
Change fluid when indi- Change filter when indi-
Change filter when indicated
cated by controller or 48 cated by controller or 48
General or severe Overhaul by controller or 48 months,
months, whichever months, whichever
whichever comes first.
comes first. comes first.
* Allison Prognostics must only be used with Allison approved TES 295 fluid.
** Allison Prognostics must only be used with Allison P/N 29539579 control main spin-on filter.
Control Main Spin-on Filters Only - Initial 10,000 miles (16,000 km) or 400 hours, whichever comes first.
The ATM maintenance indicator will be illuminated, denoting a required change of the transmission fluid, when the
remaining fluid life reaches approximately 2 percent (the parameter begins at 100 percent moving downward
towards the lowest threshold). The ATM maintenance indicator will be lit steadily upon each initialization of the TCM,
and will remain on steady for approximately two minutes after the initial selection of a drive range, until service is
performed and the indicator is reset.
Failure to perform maintenance and reset the ATM maintenance indicator within the next 100 hours of transmission
operation will result in the illumination of the ATM system light (in addition to the ATM maintenance light). Any time
this light is illuminated.
11 - 12
VEHICLE SERVICE AND MAINTENANCE
11 - 13
VEHICLE SERVICE AND MAINTENANCE
11 - 14
VEHICLE SERVICE AND MAINTENANCE
11 - 15
VEHICLE SERVICE AND MAINTENANCE
2 Rear spring pin & shackle pin 3RL 10 Door hinge 2RL
Cab mounting front torsion bar contact Rear brake camshaft and slack adjuster
6 seat 1RL 14 2RL
(UD3300)
NLGI No. 1 1, 6, 8, 10
11 - 16
VEHICLE SERVICE AND MAINTENANCE
UD2300
11 - 17
VEHICLE SERVICE AND MAINTENANCE
UD3300
UD3300
11 - 18
VEHICLE SERVICE AND MAINTENANCE
BEFORE PERFORMING Shift the transmission to the NEU- Used oil, coolant, fuel, etc.
MAINTENANCE TRAL position (Manual transmis- It is illegal and harmful to the envi-
sion) or P (Park) or N (Neutral) ronment to dispose of used oil or
position (Automatic transmission). coolant, fuel, etc., by pouring it on
WARNING Apply the parking brake and chock the ground, into sewers, or into bod-
the wheels. ies of water. Only use authorized
Incomplete or improper ser- recycling facilities that may be pro-
Allow the engine to cool before
vice or repair could cause vided by the local government or a
vehicle malfunction resulting attempting to service the vehicle. service facility. If any doubt, contact
in serious injury or vehicle Whenever possible, perform local government authorities or your
damage. inspections with the engine off and authorized UD Trucks dealer or qual-
If you must work under the cooled. ified service facility.
vehicle while it is jacked up,
use safety stands and wheel WARNING
chocks.
When you must inspect or ser-
Use care when inspecting, servicing vice a part or system with the
or repairing the vehicle. Heed the engine running:
warnings and follow the instructions Remove neckties, rings,
given on the labels and in this man- watches, other jewelry and
ual. loose articles.
If you have any questions, contact Keep articles, hands, clothes,
your authorized UD Trucks dealer or hair and tools away from the
qualified service facility before pro- drive belts and fan.
ceeding. Assure that the service or Avoid shorting the battery ter-
repair has been completed properly. minals.
Before performing any service or Be sure that sufficient ventila-
maintenance on your UD Trucks tion is available.
vehicle; Avoid contact with hot sur-
Park the vehicle on a level ground. faces.
11 - 19
VEHICLE SERVICE AND MAINTENANCE
CAUTION
Crush hazard. Turn off wipers
before servicing.
Before opening the front lid,
set the wiper arms to their nor-
mal positions. If the front lid is
opened with the wiper arms 3.When opening the front lid, be sure
tilted forward, the front lid will to set the lever into the hole that is
contact the wiper arms. This indicated with the mark located on
could damage the wiper arms the front lid.
and front lid. 2.Disengage the front lid hook. Push
Before driving, make sure the up the front lid and secure it with
front lid is securely locked. the rod.
11 - 20
VEHICLE SERVICE AND MAINTENANCE
11 - 21
VEHICLE SERVICE AND MAINTENANCE
WARNING
Do not stand in front of or
under the cab while tilting or
lowering the cab. Put the
safety pin into the pin hole
immediately after tilting to
avoid accidental lowering of
the cab. 4.Tilt the cab all the way forward until
the tilt strut is straight and insert
1.Remove the lock pin from the tilt 3.While holding the grip (located on the safety pin into the pin hole on
lock lever. the lower left side of the cab) on the side of the tilt strut.
the cab, pull the sub hook lever out
all the way. When the sub hook
lever is fully extended, the cab will
float up. If the cab does not float
up, push the cab body up manu-
ally.
11 - 22
VEHICLE SERVICE AND MAINTENANCE
11 - 23
VEHICLE SERVICE AND MAINTENANCE
11 - 24
VEHICLE SERVICE AND MAINTENANCE
11 - 25
VEHICLE SERVICE AND MAINTENANCE
11 - 26
VEHICLE SERVICE AND MAINTENANCE
CAUTION When mud, debris, etc., becomes Cooling fan and fan shroud
attached to the front of the core, the
passage of cooling air is impaired, so Check the cooling fan and fan
Do not direct pressurized air to
it is recommended that this material shroud for proper installation, cracks
the front surface of the radiator
should be removed completely by or damage. Replace or repair faulty
(that is, with the air hose
washing with a non corrosive deter- parts or damage.
pointed toward the engine).
Doing so will force insects, dirt gent and water solution. (Refer to
and other debris into the radia- instructions on the detergent con-
tor core and possibly cause tainer.)
engine overheating.
Deformed fins also can impair cool-
ing, and should be repaired.
Clean charge air cooler body Clean the inside by blowing with air
when changing charge air cooler
hoses.
CAUTION
Precautions when washing near
the alternator.
Using a moist alternator brush
may shorten the life of the
alternator. Use an alternator
that has been sufficiently dried
by using an item such as an
air-blower.
The charge air cooler is used to cool
the overheated intake air charged by NOTE:
the turbocharger, and is installed at Do not use water to clean the
the front of the radiator. inside of the charge air cooler
body. Using water will impair
cooling due to corrosion.
11 - 27
VEHICLE SERVICE AND MAINTENANCE
Changing coolant
WARNING
To prevent hand injury, never WARNING
get your hand near the fan
when the engine is running. If To avoid serious injury from hot
vehicle has an automatic fan coolant or steam release:
clutch, the fan may slow when Do not open the radiator filler
the coolant is cool, but it can cap and drain cocks while the
still cause hand injury. engine cooling system is hot;
wait until it cools.
Be extremely careful when
CAUTION opening the radiator filler cap.
Place a thick cloth on the cap
Do not modify the crankshaft and slowly loosen to allow a
or fan pulleys to increase the reduction in pressure in the
rated speed of the engine or cooling system.
fan. Doing so may cause the Be careful not to spill coolant
cooling fan blades to break over the hot exhaust system
possibly resulting in injury. which can cause fire, serious
Also, such modification consti- injury and/or property damage.
tutes tampering with the noise
control system. Every 4 years or 320,000 miles
(500,000 km) the UDXtra Long Life
Diesel Engine Antifreeze/Coolant or
its equivalent in the cooling system
should be drained and thoroughly
flushed.
11 - 28
VEHICLE SERVICE AND MAINTENANCE
WARNING
Never drink Long Life Coolant,
as it is toxic.
If you drink it by mistake,
immediately induce vomiting
and then consult with your
doctor.
If the coolant gets into the eye,
immediately rinse it away with
fresh water and take medical
treatment promptly.
Unless the cooling system is treated Wash the coolant off with
with corrosion preventive, rust and clean water and then with soap
scale will eventually clog up pas- immediately when the coolant
sages in the radiator and water jack- gets on to your skin or cloth.
ets. This condition is aggravated in Tighten the coolant container
some localities by formation of insol- cap and store it out of the
reach of children.
uble salts from the water used.
11 - 29
VEHICLE SERVICE AND MAINTENANCE
4.Drain all coolant solution from the Start the engine and run it at a
system into the containers. moderate speed in the same man-
For Allison 3000 series specifica- ner as described in step 6.
tion vehicles, drain coolant from 9.Stop the engine. Open the drain
two drain cocks: one is located on cocks and drain the rinsing water.
the oil cooler coolant hose and the 10.Repeat the rinsing procedure 2 or
other is located under the radiator. 3 times until the discharged rinsing
5.Shut the drain cocks. Fill the cool- water appears clean.
ing system with a proper mixture of 11.Close the drain cocks.
water and a good quality cooling To fill up the cooling system (With
Allison 3000 series specification system detergent. (Refer to the coolant)
vehicles additional instructions on the Use the following refill procedure to
detergent container) remove air from the system and pro-
3.Open the radiator drain cock and vide proper engine coolant level.
6.Start the engine and run it at a high
the cylinder block drain cock. 1.Fill the radiator slowly with the
idling speed until the indicator
NOTE: points to the middle region of the proper coolant solution up to the
The radiator drain cock has a engine coolant temperature filler opening. Add coolant solution
specified turning direction and gauge. Maintaining the above up to the MAX level of the coolant
must be turned to the position engine coolant temperature with reservoir tank. Capacities are
directly below the mark when shown below.
the thermostat open, run the
draining water.
Drain water by turning the radia- engine and allow the detergent to
tor drain cock round approxi- circulate throughout the cooling
mately 7 to 8 times. system for at least 15 minutes.
Be careful not turn the radiator 7.Stop the engine. Open the drain
drain cock round more than 9 cocks and completely drain the
times. Doing so may cause the detergent from the system.
drain cock to fall off. 8.Shut the drain cocks and fill the
cooling system with plain water.
11 - 30
VEHICLE SERVICE AND MAINTENANCE
US 4.Check the engine coolant level in ENGINE OIL AND OIL FILTERS
mea- Liters the coolant reservoir tank. If the
sure
level is between the MIN and MAX Engine oil recommendations
With manual transmission 6.9 gal 26
lines, it is normal. If it is below the
Except for To extend the lubrication perfor-
With auto- Allison 6.6 gal 25 MIN level, add coolant solution up
mance of your engine “UDXtra
matic trans- 3000 series to the MAX level.
mission Allison
Engine oil” or equivalent is available,
5.If the added coolant solution is
3000 series 7.9 gal 30 which has been specifically tested
more than 16.9 US fl oz (500 milli and approved for UD Trucks
Then properly close the radiator liter), check and correct for any engines.
filler cap and the reservoir tank sign of leakage, then repeat steps Please contact an authorized UD
cap. 1 to 4. Trucks dealer for further details
2.Operate the engine at a slightly 6.Check the drain cock for leaks. about “UDXtra Engine oil”.
higher than normal idling speed Please consult the following instruc-
with the throttle control knob until tions to select and use the proper
lubricant from a reliable supplier to
the engine coolant temperature
enhance trouble-free operation and
indicator points the middle region service life of the engine.
of the gauge. Run the engine an
additional 10 minutes to allow the Oil grade: VDS-4
air to escape from the engine cool- Oil quality
ing system. UD TRUCKS North America recog-
3.Stop the engine. After the engine nizes engine oils that meet or
has completely cooled down, exceed the standards given by
remove the radiator filler cap and American Petroleum Institute (API)
check the engine coolant level in for the oil classifications listed in this
the radiator. If low, add coolant to manual.
the radiator filler opening. Only oils licensed to carry the API
Reinstall the radiator filler cap. symbol should be used. Lubricants
meeting API standards have pro-
11 - 31
VEHICLE SERVICE AND MAINTENANCE
vided maximum engine life when is not fully defined until both the API
used together with the recom- quality classification and the viscos-
mended oil and oil filter change inter- ity grade are specified.
vals. Choose the viscosity grade for the
UDXtra (or VDS-4) diesel engine oil typical ambient air temperature
is mandatory for use in all 2010 (AAT) for the application.
emission compliant engine. Multi grade oils have a broad range
UDXtra (or VDS-4) oils exceed the that suit operation in changing tem-
API CJ-4. perature.
For a complete list of approved oils, The standard oil weight for UD
see your UD TRUCKS dealer. TRUCKS engines is 10W/30.
Also, refer to Technical Bulletin EN- UD TRUCKS recommends the vis-
42, Approved Oils, UDNA. cosities shown in the viscosity/ tem- CAUTION
NOTE: perature table for UD TRUCKS
engines. Use of diesel fuel other than
UD Trucks recommends using ULSD (Ultra Low Sulfur Diesel
the engine oil designated above NOTE: fuel) and engines oils other
for the proper function of the Select the oil viscosity accord- than UDXtra (or VDS-4), will
DPF system, and also use ultra ing to the next diagram, basing adversely affect performance,
low sulfur diesel fuel (0.0015% your selection on the maximum efficiency and durability of the
[15 ppm] by weight) only and and the minimum ambient air Aftertreatment DPF system
low-ash fuel must be less than temperatures. and the engine may not run at
1% in weight. all.
Manufacture’s warranties can
Oil viscosity and relation between
viscosity and temperature: also be rendered void due to
The viscosity grade defines the usage of improper fuel.
thickness of the oil. The oil must be Unapproved fuel additives
thin enough at low temperatures for (including engine oil) are NOT
easy cold starts and thick enough to permitted.
protect at high temperatures. An oil
11 - 32
VEHICLE SERVICE AND MAINTENANCE
11 - 33
VEHICLE SERVICE AND MAINTENANCE
11 - 34
VEHICLE SERVICE AND MAINTENANCE
11 - 35
VEHICLE SERVICE AND MAINTENANCE
Oil filter To replace the filter 2.The oil will drain within approxi-
mately 5 minutes and the cartridge
can then be removed.
CAUTION CAUTION 3.Tighten the drain plug.
Do not handle hot oil filter Just after driving, the engine Tightening torque:
without hand protection. Fail- oil is still hot and can burn 9.4 to 16.7 ft·lbf (12.8 to 22.6 N·m)
ure to do so may result in burn you. Before changing or (1.3 to 2.3 kgf·m)
injury. checking the oil, let it cool 4.Place a new cartridge, turn it 3/4 to
down until you can touch the 1 time after the seal contacts.
oil without getting burned.
NOTE: NOTE:
Use genuine UD Trucks filter or Make sure the oil drain plug is
equivalent in quality and design. As oil is full in the cartridge after an tightened to the listed specifica-
Use of an inferior filter could engine stops, it is needed to drain tion prior to the installation of
diminish operation of the engine the oil. The following is an outline of the new cartridge.
and emission controls. the procedure.
Always replace the oil filter at 5.Add approximately of engine oil
the same time that the engine oil 1.Remove the air draining plug, and
loosen the drain plug until it spins and install the filler cap tightly.
is replaced.
free. US Liter
measure
With oil filter 18.4 qt 17.4
Without 18.0 qt 17.0
oil filter
11 - 36
VEHICLE SERVICE AND MAINTENANCE
11 - 37
VEHICLE SERVICE AND MAINTENANCE
11 - 38
VEHICLE SERVICE AND MAINTENANCE
11 - 39
VEHICLE SERVICE AND MAINTENANCE
11 - 40
VEHICLE SERVICE AND MAINTENANCE
11 - 41
VEHICLE SERVICE AND MAINTENANCE
11 - 42
VEHICLE SERVICE AND MAINTENANCE
Purging air from fuel system 2.Put the hose in the air purge plug Fuel hose and clamp
and loose the plug. Let the other
If air gets into the fuel system, it will Check the fuel rubber hose and
side of the hose get into the tray.
cause inconsistent fuel injection and clamp of the fuel system for loose-
possible engine malfunction. It is (loosen until you can see an o- ness cracks or damage. Replace
therefore necessary that any air be rings on the plug). faulty parts if necessary.
bled off which may have found its 3.Push the priming pump then the
way into the fuel system while fuel is pumped up from the tank
changing fuel filters, or when the fuel and get into the filter. WARNING
lines have been otherwise discon- 4.Keep pushing the priming pump Keep flames and heat away
nected. until clear fuel with no air is exiting from the fuel system since the
the air purge plug. fuel is flammable.
To purge air from the fuel system
5.After the air has been removed, Any of these can result in seri-
tighten the air purge plug securely ous injury and/or property
by hand. damage due to fire.
Wipe off any leaked fuel, as it
could cause a fire.
Fuel tubing
Check the fuel tubing for fractures,
damage or improper installation.
Replace faulty parts if necessary.
Whenever the fuel tubing is discon-
1.Prepare a tray for drained fuel nected, be sure to purge air from the
fuel system.
(approx. 2.1 qt [2.0 liter]) and a
hose (inner diameter 0.2 in [5 mm],
length 3.3 ft [1 m]).
11 - 43
VEHICLE SERVICE AND MAINTENANCE
11 - 44
VEHICLE SERVICE AND MAINTENANCE
11 - 45
VEHICLE SERVICE AND MAINTENANCE
WARNING
Do not check or adjust drive
belt, unless engine is off and
the transmission is in N (Neu-
tral).
11 - 46
VEHICLE SERVICE AND MAINTENANCE
11 - 47
VEHICLE SERVICE AND MAINTENANCE
11 - 48
VEHICLE SERVICE AND MAINTENANCE
Replacement procedure
1.Switch off the engine.
NOTE:
4.Remove the equalizing element. 6.Clean the sealing surface of the
Wait at least two minutes before
removing DEF hoses to allow housing with water only.
the automatic draining of the
DEF system and to depressurise
the DEF system.
11 - 49
VEHICLE SERVICE AND MAINTENANCE
11 - 50
VEHICLE SERVICE AND MAINTENANCE
11 - 51
VEHICLE SERVICE AND MAINTENANCE
3.Reinsert the plug and tighten the To check the automatic transmis-
plug. sion fluid level (Allison 1000, 2200
and 2500 series)
Tightening torque:
UD1800 thru UD3300 Check the fluid while the vehicle is
MLS63 on level ground and the parking
72 to 89 ft·lbf (98 to 120 N·m) brake applied. Start the engine and
(10 to 12 kgf·m) run for at least one minute at 900
UD2600 and UD3300 to 1,000 rpm to clear the system of
MLS63 air. Shift the transmission to Drive,
72 to 94 ft·lbf (98 to 130 N·m) Reverse, and then to Neutral to fill
(10 to 13 kgf·m) the clutch cavities and fluid pas-
MPS63 sages.
CAUTION 87 to 101 ft·lbf (118 to 137 N·m) Always clean around the end of
(12 to 14 kgf·m)
To prevent dirt and debris from the filler tube before removing the
entering the transmission, dipstick. Dirt or foreign matter must
clean the filler plug, transmis- not be permitted to enter the fluid
sion housing, and surrounding system. It can cause valves to
area before checking. stick, cause undue wear of trans-
If the transmission oil level is mission parts, or clog passages.
low, the transmission will not Check the fluid level by one of the
operate normally and could following procedures and report
malfunction. Check to deter- any abnormal fluid level to your
mine the cause of low oil level.
maintenance personnel.
Correct the condition before
operating the vehicle.
11 - 52
VEHICLE SERVICE AND MAINTENANCE
11 - 53
VEHICLE SERVICE AND MAINTENANCE
To check the automatic transmis- fluid level is within the COLD band
sion fluid level (Allison 3000 series) range. If the fluid level is not within
Inspection with the fluid dipstick the range, refill fluid.
Check the fluid while the vehicle is <HOT CHECK>
on level ground and the parking After warming up the engine and
brake applied. Start the engine and driving for about 10 to 15 minutes,
run for at least one minute at 900 pull the fluid dipstick out of the filler
to 1,000 rpm to clear the system of tube, wipe fluid off the dipstick sur-
air. face, and then insert the dipstick
Idle the engine. back in the original position.
With the engine at idle, depress Pull out the fluid dipstick again to
the brake pedal and shift the range inspect the fluid level. Check (at
to D (Drive) or R (Reverse) to fill least twice) to make sure that the
the whole hydraulic circuit with fluid level is within the HOT band
fluid. range.
Shift the range to N (Neutral). If the fluid level is within the HOT
With the engine at idle and the band range, the inspection is com-
range in the N (Neutral) position, pleted. If the fluid level is not within
inspect the fluid level. the range, refill fluid.
<COLD CHECK>
Pull the fluid dipstick out of the filler
tube, wipe fluid off the dipstick sur-
face, and then insert the dipstick
back in the original position.
Pull out the fluid dipstick again to
inspect the fluid level. Check (at
least twice) to make sure that the
11 - 54
VEHICLE SERVICE AND MAINTENANCE
11 - 55
VEHICLE SERVICE AND MAINTENANCE
“E L” Engine speed (rpm) too low 1.Place a container under the drain
“E H” Engine speed (rpm) too high
plug. Remove the drain plug and
completely drain the transmission
“S N” N (Neutral) must be selected oil.
“O L” “ -- ” “T L” Sump fluid temperature too low
*
: The display is a flashing numeral, counting down from 8 to 1 until the
waiting period is complete.
11 - 56
VEHICLE SERVICE AND MAINTENANCE
2.After draining, replace the gasket Oil refill capacity (Approximately) Automatic transmission fluid
of the drain plug with a new one. Oil capacities filter (Allison 1000, 2200 and 2500
PTO US qt (liters)
Reinsert the plug and tighten the series)
plug. Without 7.2 (6.8)
MLS63
Tightening torque: With 7.8 (7.3)
UD1800 thru UD3300 WARNING
Without 8.3 (7.8)
MLS63 MPS63
With 8.8 (8.3) Do not handle hot filter without
72 to 89 ft·lbf (98 to 120 N·m) hand protection. Failure to do
(10 to 12 kgf·m) 4.Visually check the oil level and add so may result in burn injury.
UD2600 and UD3300 oil, if necessary, until it reaches the
MLS63 bottom of the filler plug hole. To replace the filter
72 to 94 ft·lbf (98 to 130 N·m) 1.Drain the fluid when the transmis-
(10 to 13 kgf·m) Automatic transmission fluid sion is at normal operating sump
MPS63
change temperature 160 to 200°F (71 to
87 to 101 ft·lbf (118 to 137 N·m)
(12 to 14 kgf·m) Have the automatic transmission 93°C). Hot fluid flows quicker and
fluid changed by an authorized UD drains more completely.
NOTE: Trucks dealer or other qualified ser-
The drain plug contains a mag- vice facility. Use only the transmis-
net. Remove any iron filings on sion fluid listed in the
the plug before reinstalling the "RECOMMENDED LUBRI-
plug. CANTS"on page 13-5.
11 - 57
VEHICLE SERVICE AND MAINTENANCE
2.Remove the drain plug from the oil CAUTION Allison 3000 series
pan and allow the fluid to drain into A disassembled type of filter is used
a suitable container. Turning the filter more than and incorporated in the oil pan.
3.Using a filter wrench, remove the ONE FULL TURN after gasket
control-main filter by rotating it contact will damage the filter.
counterclockwise.
4.Remove the magnet from the filter 10.Reinstall the drain plug and seal-
attachment tube or from the top of ing washer.
the filter element. Tightening torque:
5.Clean any metal debris from the 22 to 30 ft·lbf (30 to 40 N·m) (3.1
magnet. Report any metal pieces to 4.1 kgf·m)
11.After refill, check the fluid level
larger than dust to your mainte-
and add the proper fluid, if neces-
nance personnel.
sary.
6.Reinstall the magnet onto the filter
For the fluid check procedure, 1.Clean the periphery of the filter
attachment tube.
refer to "To check the automatic cover to prevent dust from entering
7.Lubricate the O-ring on the control-
transmission fluid level (Allison at the time of removal of the filter.
main filter with transmission fluid.
1000, 2200 and 2500 series)"on 2.Remove the mounting bolts of the
8.Install, by hand, the control-main
page 11-52. filter cover and pull out the cover
filter until the O-ring on the control-
12.Start the engine. Check the filter and filter downward.
main filter touches the converter
and seal for leaks. 3.Replace the filter, O-ring and seal
housing.
with new ones and install to the
9.Turn the filter ONE FULL TURN
cover. When installing, apply a
ONLY by hand, after O-ring con-
light coating of clean oil to the
tact.
entire perimeter of O-ring and seal.
4. Install the cover and filter com-
bined in one unit into the transmis-
sion body.
11 - 58
VEHICLE SERVICE AND MAINTENANCE
WARNING
Check and/or change the dif-
ferential gear oil only after the
rear axle cools to avoid possi-
ble burn injuries.
11 - 59
VEHICLE SERVICE AND MAINTENANCE
UD2600 and
13.8 qt 13
UD3300
2.After draining, replace the gasket
of the drain plug with a new one.
Install the plug and tighten the
plug.
11 - 60
VEHICLE SERVICE AND MAINTENANCE
11 - 61
VEHICLE SERVICE AND MAINTENANCE
11 - 62
VEHICLE SERVICE AND MAINTENANCE
11 - 63
VEHICLE SERVICE AND MAINTENANCE
11 - 64
VEHICLE SERVICE AND MAINTENANCE
CLUTCH Adjusting clutch pedal free play To adjust the outer lever assembly
After adjusting the clutch master cyl-
To adjust the clutch master cylinder
Clutch pedal free play inder, adjust the clutch booster outer
First adjust the master cylinder lever assembly located at the left
To check clutch pedal free play, located on the clutch pedal. side of the transmission.
depress the clutch pedal by hand 1.Loosen the lock nut on the push 1.Remove the return spring.
until resistance is felt. The play, the rod. 2.Loosen the push rod lock nut.
distance from the point where the 2.Turn the push rod until it touches 3.Adjust the play of the outer lever to
clutch pedal normally rests and the piston and there is no play.
where resistance is felt should be 0.177 to 0.217 inches (approx. 4.5
Under this condition, return the to 5.5 mm) by turning the push rod.
1.18 to 1.97 inches (30 to 50 mm). If push rod 4/5 turn and make sure
the play is less than 1.18 inches (30
the free play is approximately 0.04
mm) or more than 1.97 inches (50
mm), then adjust the clutch pedal inches (1 mm).
free play. 3.Tighten the lock nut while holding
the push rod stationary with a
wrench.
MLS63
11 - 65
VEHICLE SERVICE AND MAINTENANCE
MPS63 MLS63
11 - 66
VEHICLE SERVICE AND MAINTENANCE
11 - 67
VEHICLE SERVICE AND MAINTENANCE
Air spring WINDSHIELD WASHER FLUID 2.If it is low, add more washer fluid
via reservoir cap opening
Check the air bellows for damage,
air leakage, looseness and leveling
valve for proper functioning. WARNING
Periodically have the U-bolt nut
retightened by an authorized UD Do not use cooling system
Trucks dealer or qualified service solution in the windshield
facility. washer reservoir. When
sprayed on the windshield,
Tightening torque: cooling system solution can
U- bolt nut significantly diminish visibility.
406 - 455 ft·lbf
(550 - 617 N·m) (56 - 63 kgf·m) Open the front lid, and check the NOTE:
fluid level in the windshield washer Do not overfill the windshield
Shock absorber reservoir daily. If low, add an appro- washer reservoir.
Check the shock absorber for proper priate washer fluid solution. Also,
installation, damage or leakage. If check that fluid is properly sprayed
leakage is present, have the shock onto the windshield.
absorber checked or replaced by an In cold weather, use a windshield
authorized UD Trucks dealer or qual- washer anti-freeze with water at the
ified service facility. proper mixture ratio. Follow the anti-
freeze manufacturer’s instructions
for the mixture ratio.
Replenishing washer fluid
The windshield washer reservoir
located behind the front lid.
11 - 68
VEHICLE SERVICE AND MAINTENANCE
CAUTION
Do not yank the heater har-
ness by hand or hang on the
Check the outside mirrors daily for For vehicles equipped with power heater harness. The heater
damage, position and visibility. Also mirror, refer to the "Power mirror harness may be broken.
check that the mirror mounting bolts switch (Optional)"on page 7-68.
are properly tightened.
11 - 69
VEHICLE SERVICE AND MAINTENANCE
EMISSIONS CONTROL Exhaust Aftertreatment System Regular maintenance for the DPF
SYSTEMS Maintenance
The vehicle must be taken to an The muffler that is equipped with
authorized UD Trucks dealer to the DPF needs to be cleaned regu-
To maintain efficient emissions con- remove the ash from the Aftertreat- larly to maintain its performance
trol systems operation, have the ment Diesel Particulate Filter and (either every 155,000 miles
emission control system mainte- clean the Aftertreatment Hydrocar- [250,000 km] or 4,500 hours). This
nance in the VEHICLE SERVICE bon Doser. is because unburnable ash will
AND MAINTENANCE performed at
the intervals indicated. Emissions Maintenance accumulate in the filter during
Emissions Maintenance Interval – regeneration; otherwise, the soot
EPA / CARB defines this as the accumulated in the DPF can be
CAUTION burned to regenerate the filter.
adjustment, cleaning, repair, or
Do not modify, alter, discon- replacement shall be recommended For details on the cleaning infor-
nect or remove any part of the at intervals no less than described mation about the muffler that is
vehicle which could affect, below. equipped with the DPF, contact
directly or indirectly, vehicle Injector tips (cleaning only), crank- your nearest UD trucks dealer.
emissions. case ventilation The DPF ash level gauge that is
Do not operate your vehicle if valve, EGR filters and coolers: displayed on the multi-display
you notice engine misfire, a Medium Heavy Duty:
monitor indicates the amount of
significant loss of performance Miles: 50,000
Hours: 1500 ash accumulation.
or other improper operation.
Consult your UD Trucks dealer
or other qualified service facil- Injectors, Turbocharger, ECM, sen-
ity for service. sors, actuators, EGR components
(except filter and coolers), Aftertreat-
ment DPF plus related components,
this includes ash cleaning
Medium Heavy Duty:
Miles: 150,000
Hours: 4500
11 - 70
VEHICLE SERVICE AND MAINTENANCE
CAUTION
The muffler that is equipped
with the DPF for the PM reduc-
tion device needs to be
cleaned regularly (either every
155,000 miles [250,000 km] or
4,500 hours) even if the DPF
ash level gauge does not reach
“H”.
If not, poor fuel economy and
DPF ash level gauge DPF maintenance warning
engine output decrease may
occur.
The DPF ash level gauge indicates
the accumulation level of the ash
in the filter. NOTE:
For details on how to display the Ash is mainly generated from
meter, refer to the “Multi-display the elements included in engine
oil additives. Always use the
monitor” section in “INSTRUMENT
specified engine oil to minimize
AND CONTROLS”. ash generation.
When the level reaches “H”, it indi- The soot collected in the DPF
cates that the filter should be that is built in the muffler for the
cleaned. The system simultane- PM reduction device is burned
ously indicates the DPF mainte- to be regenerated. However, ash
nance warning, warning message is unburnable during regenera-
and comment to alert the driver of tion and accumulates in the fil-
cleaning the DPF. ter. Thus, the filter must be
cleaned regularly.
To keep the DPF efficiency, it
recommend that the manual
11 - 71
VEHICLE SERVICE AND MAINTENANCE
11 - 72
VEHICLE SERVICE AND MAINTENANCE
NOISE CONTROL SYSTEM Tampering with Noise Control device or element of design has
System Prohibited been removed or rendered inopera-
To assure noise control system Federal law prohibits the following tive by any person.
integrity, the maintenance services acts or the causing thereof: Among those acts presumed to con-
shown in the following chart must be stitute tampering are the acts listed
performed at the intervals indicated. (1) The removal or rendering inoper- below.
When inspecting the exhaust system ative by any person other than for
purposes of maintenance, repair, or
confirm that all components are
replacement, of any device or ele- WARNING
intact and securely fitted. Also check
all exhaust system components for ment of design incorporated into any
new vehicle for the purpose of noise To avoid serious injury from
holes, leaks and corrosion. Do not hot engine and exhaust sys-
perform any prohibited act to the control prior to its sale or delivery to
the ultimate purchaser or while it is in tem, perform maintenance
noise control system as described in after engine has cooled.
use, or
the following chart.
(2) the use of the vehicle after such
11 - 73
VEHICLE SERVICE AND MAINTENANCE
Noise Control System Maintenance may be equipped with the following maintenance at the intervals shown
Schedule items. in the following maintenance chart.
In order to comply with federal noise To avoid or minimize the degradation
regulation, the UD Trucks vehicle of noise emission level, it is essential
to perform proper inspection and
Abbreviations:
A = Check and adjust if T = Tighten to specified torque R = Replace or change
necessary
First Every
Miles x 1,000 3 6 9 10 12 15 18 20 24 30 36 50 72 Months
Items
Kilometersx1,000 5 10 15 16 20 25 30 32 40 48 60 80 120 (every)
11 - 74
VEHICLE SERVICE AND MAINTENANCE
Exhaust system
Check the complete exhaust system.
Check for damage, missing or mis-
positioned parts, loose connections,
open seams, holes, loose fasteners,
or deformed or plugged outlets.
Replace or tighten if necessary.
Inspect for leaks at various joint con-
nections and tighten clamp. Make
visual inspection for crack or holes in
DPF cleaner and tail pipe. Always
replace with UD Trucks recom-
mended parts. Tail pipe elbow or off-
set tail pipe orientation must not be
11 - 75
VEHICLE SERVICE AND MAINTENANCE
11 - 76
VEHICLE SERVICE AND MAINTENANCE
11 - 77
VEHICLE SERVICE AND MAINTENANCE
3.After tightly connecting the cables, LIGHTS removal. During this operation, do
apply a thin coat of grease to the Occasionally it may become neces- not touch the bulb with bare hands.
terminals to prevent corrosion. sary to replace a burned out bulb on
your vehicle. When replacing bulbs
with a lens, take care not to over-
tighten lens screws. Overtightening
the screws could damage the lens.
NOTE:
Use the same number and watt-
age as originally installed.
Refer to "BULBS"on page 13-5.
Headlights
NOTE:
Your vehicle is equipped with halo- When the headlight is changed,
Always dispose of automotive batter- gen headlights. the light axis must be adjusted.
ies in a responsible manner. Follow To replace a burned out headlight If you inevitably replaced it,
your local authorized standard for bulb: bring the vehicle for inspection
disposal. Call your local authorized immediately at the nearest
recycling center to find out more 1.Turn the ignition key and lighting authorized UD Trucks dealer.
about recycling automotive batteries. switch to OFF.
2.Tilt the cab.
3.Turn the bulb cover toward OPEN
and remove it.
4.Disconnect the harness connector.
5.While pressing on the set spring,
bring it to the center to take it out.
6.Insert a new bulb into the socket.
Install it in the reverse order of
11 - 78
VEHICLE SERVICE AND MAINTENANCE
Front turn signal light 3.Turn the socket counterclockwise Rear combination light
to remove it and replace the bulb
1.Remove the fixing clips (2 loca-
with new one.
tions) from the rubber and turn
over the rubber.
11 - 79
VEHICLE SERVICE AND MAINTENANCE
11 - 80
VEHICLE SERVICE AND MAINTENANCE
CAUTION
Never connect add-on electri-
cal accessories (or electrical
circuits) to engine control
fuses or circuits. Doing so
could cause fuses to burn out,
thereby causing a possible
loss of engine and ABS func-
tion.
Inside fusible link box To replace a blown fuse
1.Use the fuse puller to remove the 2.Install a new fuse with the same
blown fuse. current rating as that specified for
WARNING the circuit.
When replacing a fuse, never A new fuse that burns out immedi-
use a fuse with a higher cur- ately could indicate other problems
rent rating than that specified in the electrical system. If this
for the circuit. Heat produced occurs, have the electrical circuits
by currents in excess of circuit checked by an authorized UD Trucks
capacity can cause fire. dealer or other qualified service facil-
ity.
11 - 81
VEHICLE SERVICE AND MAINTENANCE
BLOWER MOTOR FILTERS Outside air intake filter the handle into the hole of the
Air filters for a heater or an air condi- case.
<Method for removal>
tioner are installed behind the front
1.Hold the upper and lower centers
lid at the right side of the cab front. Inside air intake filter
of the filter with left hand and bend
the filter toward you. 1.Pull the upper and lower two filters
The air filters for outside air intake
2.Hold the handle at the right end of toward you.
and inside air intake may cause
the filter with right hand and pull it 2.After cleaning, insert the filter into
clogging due to dirt or dust. Clean
toward you. the filter slot of the case until it is
them.
locked.
The installation and removal of the
air filter is a cartridge type.
Clean the air filter with water or air.
<Installation method>
1.Hold the handle at the left of the fil- NOTE:
ter and insert the tab around the Clogging of the air filter lowers
handle into the hole of the case. air flow, resulting in poor perfor-
2.Hold the upper and lower centers mance of the heater and the air
conditioner.
of the filter and bend the filter
Clean the air filter every 6
toward you. months or when performance of
3.Hold the handle at the right end of the heater or the air conditions
the filter and insert the tab around is poor.
11 - 82
VEHICLE SERVICE AND MAINTENANCE
11 - 83
VEHICLE SERVICE AND MAINTENANCE
Load specification
TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES
(The pressure is minimum for the load.)
Current SI units Current SI units Current SI units Current SI units Current SI units Current SI units Current SI units
Tire size
designation kPa 660 670 690 720 760 790 830
psi 90 (95) 95 (95) 100 (100) 105 (105) 110 (110) 115 (115) 120 (120)
1,550 kg
Dual – – – – – – – – – – – – –
225/ (3,415 lb)
70R
19.5 (F) 1,650 kg
Single – – – – – – – – – – – – –
(3,640 lb)
2,650 kg
Dual – – – – – – – – – – – – –
(5,840 lb)
11R
22.5 (G)
2,800 kg
Single – – – – – – – – – – – – –
(6,175 lb)
Radial Tires
1,950 kg
Dual – – – – – – – – – – – – –
245/ (4,300 lb)
70R
19.5 (G) 2,060 kg
Single – – – – – – – – – – – – –
(4,540 lb)
2,120 kg
Dual – – – – – – – – – – – – – (4,675 lb)
9R
22.5 (G)
2,240 kg
Single – – – – – – – – – – – – – (4,940 lb)
2,300 kg
Dual – – – – – – – – – – – – –
255/ (5,070 lb)
70R
22.5 (H) 2,500 kg
Single – – – – – – – – – – – – – (5,510 lb)
11 - 84
VEHICLE SERVICE AND MAINTENANCE
Checking the tire pressure and tire valves when damaged or leaking. 3.Check the tires for uneven or
condition Replace missing valve caps. unusual tread wear. Consult the
1.Check the pressure of each tire 2.Check the tire sidewall and tread table below to determine the cause
with a tire gauge daily. For accu- for cuts, cracks and damage daily. of uneven or unusual wear and
rate measurement, check the tires Remove any foreign objects such corrective action to be taken. Cor-
when they are cool. Be sure to as metal, glass and stones rect the cause of the wear and, if
inflate tires to proper pressure wedged in the tread grooves and necessary, replace the tire.
according to the load and inflation check for tire damage.
pressure table. Check tire valves Repair or replace as necessary.
regularly for air leaks. Replace
11 - 85
VEHICLE SERVICE AND MAINTENANCE
Each tire has six wear indicators. Checking and retightening the
Check the tread grooves of each tire WARNING wheel nuts
daily. Replace a tire when any of the Loose wheel stud nuts may cause
Do not operate your vehicle:
tread indicators become visible. shimmy and vibration which can
With tires inflated in excess of
cause damage to the wheel bear-
the recommendations of the
ings. Retorque the wheel stud nuts
tire or wheel manufacturer.
at the first 1,000 miles (1,600 km) of
With cut, cracked or damaged
operation. Thereafter, check the nuts
tires.
for tightness every 6,000 miles
When any of the tire tread wear
(10,000 km) or two months of opera-
indicators are visible.
tion, whichever occurs first and, if
necessary, retorque to specification.
Improperly inflated and dam-
aged tires, and tires with uneven Using a torque wrench, alternately
or excessive wear may cause tighten wheel nuts. Do not exceed
blowouts, loss of vehicle con- wheel nut torque specification. Over-
trol and reduced braking effec- tightening the wheel nuts will elon-
WARNING tiveness. Inspect tires carefully gate the bolts, deform the wheels
and make any necessary repairs and prevent tightening to the speci-
Be sure to confirm that the or replacements. fied torque.
wheel has not been damaged Tightening torque:
or deformed before putting a <Front wheel alignment> UD1800 and UD2000
new tire on it. Follow industry If abnormal tire wear or ride and han- 273 - 310 ft·lbf (370 - 420 N·m)
and government safety regula- dling characteristics such as vehicle (38 - 43 kgf·m)
tions when assembling and lead or wander are experienced with UD2300, UD2600 and UD3300
inflating new tires. Failure to properly inflated tires, the front wheel 398 - 435 ft·lbf (540 - 590 N·m)
do so could result in serious alignment should be checked. (55 - 60 kgf·m)
injury or death.
11 - 86
VEHICLE SERVICE AND MAINTENANCE
NOTE: After rotating the position of the When tire tread pattern is identical
The wheel nuts on the right side tires, drive the vehicle a dis- all the way around:
of the vehicle have right-handed tance of 30 to 60 miles (50 to 100
threading; the left side wheel km) to settle the wheel disc with
nuts have left-handed threading. hub, and then retighten the
wheel nuts to the specified
Re-tightening procedures for rear torque.
dual nuts The wheel must not be over-
loaded. Pay attention to the total
vehicle load, the weight distribu-
tion related to individual axle
loading and the matching of tire
pressures in the case of dual
wheels.
When tire tread pattern differs
Tire wear differs depending on between front and rear:
where the tire is mounted. Rotate the
tire position to allow more even wear
and extend tire life.
1.Loosen the outer wheel nuts. Tire rotation is recommended every
2.Tighten the inner wheel nuts. 6,000 miles (10,000 km). Shown are
3.Tighten the outer wheel nuts. two types of rotation patterns. Use
the one best suited to your needs.
After rotation, adjust individual tire
Tire position rotation pressure as specified in the "Load
NOTE: specification"on page 11-84. Tighten
wheel stud nuts to the required
For removal and mounting of
torque specification and after 1,000
tires, refer to "TIRE CHANGE"on
miles (1,600 km), retorque again to
page 12-6.
specification.
11 - 87
VEHICLE SERVICE AND MAINTENANCE
11 - 88
VEHICLE SERVICE AND MAINTENANCE
11 - 89
VEHICLE SERVICE AND MAINTENANCE
11 - 90
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 1
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 2
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 3
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 4
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
<To jump start a vehicle> 5.Start the engine of the vehicle with 6.After your engine is started,
the good battery. After increasing remove the jumper cables in the
1.Position the vehicles so that the to a moderate engine speed, start reverse order of connection.
jumper cables can be attached. Do the vehicle with the discharged 7.Charge the discharged battery at
not allow the vehicles to come into battery. an authorized UD Trucks dealer or
contact with one another. other qualified service facility.
2.Turn off the ignitions of both vehi-
cles and apply the parking brakes.
3.Connect one end of one jumper
cable to the red positive (+) termi-
nal of the discharged battery and
the other end to the red positive
terminal of the good battery.
4.Connect one end of the second
jumper cable to the grounded
black negative (–) terminal of the
good battery. Connect the other
end of the second cable to the
frame of the vehicle with the dis-
charged battery at a location as
distant from the battery as possi-
ble. Confirm that the cables are
routed such that they will not come
into contact with fans, belts, or
other moving parts when the
engines are started.
12 - 5
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 6
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 7
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 8
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
WARNING
When towing your vehicle,
observe all state and local laws
and regulations.
NOTE:
Turn signals do not work when
the hazard warning flasher
(UD2300) NOTE: switch is operating.
When replacing both dual
wheels, make sure that the inner Towing the vehicle
wheel nuts are securely tight- If there is a need to tow your vehicle:
ened before installing the out- 1.Unload your vehicle.
side wheel. 2.Turn the ignition key to the OFF
When installing the outside position.
wheel, place its air valve 180° 3.Release the parking brake.
apart from the inside wheel. 4.Shift the transmission to the NEU-
After changing the wheels, drive TRAL position.
the vehicle a distance of 30 to 60 5.Use a qualified towing service with
miles (50 to 100 km) to settle the
a suitable lift and towing equip-
wheel disc with hub, and then
retighten the wheel nuts to the ment.
specified torque. 6.When possible, tow the vehicle
from the front.
12 - 9
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
12 - 10
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
NOTE:
If the air pressure drops to CAUTION
approximately 40 psi (275 kPa)
Do not apply excessive force
(2.8 kgf/cm2) in both front and to the clevis. Doing so may
rear brake system, the parking damage the wheel cylinder.
brake will automatically be
applied.
[UD2300 and UD2600]
[UD1800 and UD2000] Manual Release Procedure
Manual Release Procedure 1.Block the wheels to prevent the
vehicle from moving. UD2600
1.Block the wheels to prevent the
vehicle from moving. 2.Loosen the lock nut. (See figure
2.Loosen the lock nuts. (See figure below.) [UD3300]
below.) 3.Turn the release nut to extend the Manual Release Procedure
3.Turn the turnbuckle to extend the push rod until the brake shoes are
push rod until the brake shoes are released from the drum.
released from the drum.
12 - 11
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
CAUTION
The release nut is secured on
the release bolt with the knock
pin. Do not remove the knock
pin for securing. If it is
removed, the spring brake can-
not be released.
12 - 12
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
TROUBLESHOOTING
The information in the following charts may be helpful in identifying the cause and corrective action to be taken when
a problem arises.
Warm-up
Problem Possible Cause Cause Correction
Low idling speed Adjust with throttle control knob
Engine stops immediately No fuel Add fuel
after starting Fuel filter clogged Replace fuel filter element
Air cleaner clogged Replace air cleaner element
12 - 13
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation
Problem Possible Cause Cause Correction
Release parking brake completely if problem per-
Parking brake is not completely released sists, consult an authorized UD Trucks dealer or
other qualified service facility
Fuel filter clogged Replace fuel filter element
Air cleaner clogged Replace air cleaner element
Engine lacks power Have brakes checked and adjusted by an autho-
Brakes are dragging rized UD Trucks dealer or other qualified service
facility
Have clutch checked and adjusted by an autho-
Clutch slipping rized UD Trucks dealer or other qualified service
facility
Replace at an authorized UD Trucks dealer or
Fan clutch malfunctioning
other qualified service facility
Radiator front is clogged with insects and debris Clean
Radiator is clogged with scale Clean
Engine overheats
Insufficient coolant solution Add coolant solution
Drive belt loose Adjust belt tension or replace belts
Check at an authorized UD Trucks dealer or other
Defective thermostat
qualified service facility
12 - 14
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem Possible Cause Cause Correction
Check fuel system and tighten connections if
Fuel leaks
loose
Air cleaner clogged Replace air cleaner element
Tire air pressure low Adjust to proper pressure
Excessive fuel consumption Have brakes checked and adjusted by an autho-
Brakes are dragging rized UD Trucks dealer or other qualified service
facility
Have clutch checked and adjusted by an autho-
Clutch slipping rized UD Trucks dealer or other qualified service
facility
Improper grade or viscosity engine oil used Replace with proper engine oil
Excessive engine oil con- Too much engine oil Adjust engine oil level properly
sumption Check lubrication system and tighten connections
Oil leaks
as necessary
Steering wheel does not Insufficient lubrication of steering system Lubricate steering system
return smoothly
Tire air pressure low Adjust the air pressure
Steering wheel is heavy
Lack of power steering fluid Add fluid up to normal level
Wheel nuts loose Tighten to specified torque
Tire air pressure low or uneven Adjust to normal air pressure
Tires partially worn Replace tires
Excessive steering wheel
vibration Check and adjust at an authorized UD Trucks
Improperly adjusted wheel balance
dealer or other qualified service facility
Check and adjust at an authorized UD Trucks
Excessive steering wheel play
dealer or other qualified service facility
12 - 15
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem Possible Cause Cause Correction
Bolts and nuts connecting propeller shafts loose Tighten
Check at an authorized UD Trucks dealer or other
Excessive propeller shaft deflection
qualified service facility
Vehicle vibrates excessively Check and adjust at an authorized UD Trucks
Wheel balance out of adjustment
dealer or other qualified service facility
Replace at an authorized UD Trucks dealer or
Loose propeller shaft universal joints
other qualified service facility
Bleed air from brake system at an authorized UD
Air in brake system Trucks dealer or other qualified brake service
facility
Worn linings Adjust or replace at an authorized UD Trucks
Poor braking action Incorrect shoe clearance dealer or other qualified brake service facility
Tighten loose connections. If still leaking, check
Brake system leaks air or fluid and repair at an authorized UD Trucks dealer or
other qualified brake service facility
Uneven tire pressure Adjust air pressure
Brakes on one side operate Tires partially worn Replace tires
more than on other
Adjust at an authorized UD Trucks dealer or other
Incorrect shoe clearance
qualified brake service facility
Adjust at an authorized UD Trucks dealer or other
Incorrect shoe clearance
qualified brake service facility
Brakes drag
Wheel cylinder returns improperly. Broken return Check at an authorized UD Trucks dealer or other
spring qualified brake service facility
12 - 16
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem Possible Cause Cause Correction
Tighten loose connections. If still leaking, check
Loss of brake fluid Brake system leaks fluid and adjust at an authorized UD Trucks dealer or
other qualified brake service facility
Battery terminals disconnected, loose, or corroded Connect securely and remove corrosion
Insufficient battery fluid Add fluid
Battery runs down Battery life has expired Replace battery
Loose or slipping drive belt Adjust belt tension or replace belts
Light or electrical device left on Turn off switch
Other
Problem Possible Cause Cause Correction
Bulb burned out Replace bulb
Lights do not come on Fuse blown Replace fuse
Loose connection at system ground Clean and tighten ground terminal
12 - 17
SERVICE DATA
SERVICE DATA
MAINTENANCE STANDARD
Items Maintenance Standard Remarks
Intake 0.012 - 0.016 in (0.30 - 0.40 mm)
Valve clearance While cold
Exhaust 0.018 - 0.020in (0.45 - 0.50 mm)
Auto adjusting Fan belt deflection
Engine Drive belt tension
See page 11-47. Air conditioner belt tension
Engine low idling speed 550 rpm
Engine high idling speed 2,750 rpm
0.39 - 1.57 in (10 - 40 mm) UD1800, UD2000 and UD2300
Steering wheel free play
1.18 - 1.97 in (30 - 50 mm) UD2600 and UD3300
0 - 0.08 in (0 - 2 mm) UD1800, UD2000 and UD2300
Toe-in
0 in (0 mm) UD2600 and UD3300
Wheel alignment 1.5° UD1800, UD2000 and UD2300
Chassis Camber
1° UD2600 and UD3300
Caster 3°20′
Brake pedal play 0.12 - 0.28 in (3 - 7 mm)
Clearance between service brake
Auto adjusting
drum and lining
13 - 1
SERVICE DATA
WARNING
Automatic brake slack adjusters should not be manually adjusted in an effort to correct excessive push-
rod chamber stroke.
This condition indicates that a problem exists with the automatic brake slack adjuster, the installation of
the adjuster, or with the related foundation brake components, which manual adjustment will not cor-
rect. The manual adjustment of automatic brake slack adjusters is a dangerous practice that could have
serious consequences, because it gives the vehicle operator a false sense of security about the brake
effectiveness, which may likely go out of adjustment again.
13 - 2
SERVICE DATA
13 - 3
SERVICE DATA
13 - 4
SERVICE DATA
Remarks:
(1) UDXtra Long Life Diesel Engine Antifreeze/Coolant
13 - 5
SERVICE DATA
Synthetic Lubrication
Synthetic oils are offered by some oil suppliers as an
alternative to the traditional, petroleum based oils for
engines. These oils may be used in UD TRUCKS
engines, provided UDXtra and VDS-4 they meet the
quality levels specified in “Oil Quality”.
The use of synthetic oils does not permit the extension of
the recommended oil change intervals. It is the contami-
nation rate, i.e., soot, and the depletion of additives,
rather than base oil quality that determines the useful
engine oil life and therefore the oil change intervals.
13 - 6
SERVICE DATA
NOTE:
Quantities listed are approximate. When filling,
observe the specified level.
13 - 7
SERVICE DATA
CONVERSION FACTORS
Length
1 inch (in) = 25.40 millimeters (mm)
Pressure
1 kilopascal (kPa)
= 0.1450 pound/square-inch (psi)
= 0.01020 kilogram/square-centimeter (kgf/cm2)
Torque
1 newton-meter (N·m)
= 0.7375 feet-pound (ft·lbf)
= 0.1020 kilogram-meter (kgf·m)
Weight
1 pound (lb) = 0.4536 kilogram (kg)
Volume
1 US pint (US pt) = 0.4732 liter
1 US quart (US qt) = 0.9463 liter
1 US gallon (US gal) = 3.785 liter
Temperature
degrees Fahrenheit (°F)
= 1.8 x degrees Celsius (°C) + 32
13 - 8
REPORTING SAFETY DEFECTS
REPORTING SAFETY
DEFECTS
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying UD
Trucks North America, Inc. 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 UD Trucks North America, Inc.
14 - 1
A-C
15 - 1
D-F
15 - 2
G-M
15 - 3
N-T
15 - 4
U-W
15 - 5
W-W
Windshield
Washer fluid ............... 11-68,13-7
Washer reservoir................ 11-68
Wiper, washer and
exhaust brake switch ...........7-55
15 - 6