American Dryer Corp. UD-80 Owner`s manual

TO THE OWNER
This Owner’s Manual has been prepared to provide you with important operation, maintenance and safety information relating to your UD Trucks vehicle. We urge you and others operating the vehicle to carefully read this
manual and follow the recommendations for operation, maintenance,
and safety. Failure to follow these recommendations could result in
serious injury or death to those riding in this vehicle or bystanders.
This manual should be considered a permanent part of the vehicle and
must be kept with the vehicle at all times. This Owner’s Manual should
accompany the vehicle when sold to provide future owners and operators with important operation, safety and maintenance information.
The characteristics and functions of this vehicle make its driving and handling different from that of a car. Before operating your vehicle, familiarize
yourself and others operating the vehicle with these differences.
The Warranty and Service Booklet provided with each vehicle contains
important information about warranty and service matters. Keep it with your
vehicle at all times and present it to your authorized UD Trucks dealer or
other service facility when service is required.
When service or other assistance is required, consult your UD Trucks
dealer. If you have a problem that has not been handled to your satisfaction,
contact UD Trucks North America, Inc., 7900 National Service Road
Greensboro, NC 27409.
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 permitted 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
LABEL FOR U.S.
Make sure that the following clean
engine idling certified label is affixed
to the left side of the corner back
outer. By the CARB regulation listed
below, the label must be affixed
there to prove that the new vehicle
with diesel engine manufactured
from Jan., 2008 conforms to this regulation.
CARB §
1956.8. Exhaust
Emission Standard and
Test Procedure
(a) (b) Heavy-Duty Diesel
Engine Idling Requirements
ii
CALIFORNIA PROPOSITION 65
WARNING
WARNING
 Engine exhaust, some of its
constituents, and certain vehicle components contain or
emit chemicals known to the
State of California to cause
cancer and birth defects or
other reproductive harm. In
addition, certain fluids contained in vehicles and certain
products of component wear
contain or emit chemicals
known to the State of California
to cause cancer and birth
defects or other reproductive
harm.
FEDERAL HIGHWAY
ADMINISTRATION
REGULATION
Various regulations relating to vehicle performance, equipment, and
safety have been issued by the
Department of Transportation. These
regulations include, but are not limited to the Federal Motor Vehicle
Safety Standards and the Federal
Motor Carrier Safety Regulations.
Other federal, state and local regulations may also apply. Final stage
manufacturers and motor carriers
are responsible for knowing and
complying with all regulations that
may apply to the vehicle. A finished
vehicle may also require devices that
are not specified in the regulations.
Body builders, subsequent stage
manufacturers and carriers must
determine what safety devices are
necessary for the safe operation of
the vehicle.
WARNING
 Making modifications to vari-
ous parts, components and
systems of the vehicle, such
as brake and steering system
can adversely affect the quality, reliability and operation of
your vehicle and could result
in property damage, serious
injury or death. Such modifications must be avoided.
iii
iv
TABLE OF CONTENTS
INTRODUCTION AND SAFETY..................... 1-1
When Reading the Manual................................. 1-1
New Vehicles Break-in Period............................ 1-2
Keys ................................................................... 1-2
Fuel .................................................................... 1-3
Metric Mismatch ................................................. 1-3
Abbreviation ....................................................... 1-4
IDENTIFICATION............................................ 2-1
Vehicle Identification Number (VIN) ................... 2-1
Unit Identification................................................ 2-2
BEFORE DRIVING YOUR VEHICLE ............. 3-1
Overloading........................................................ 3-2
Towing Trailers ................................................... 3-3
Safety Reminders............................................... 3-6
Daily Maintenance.............................................. 3-6
EGR System Operation.....................................3-11
UD Trucks, US2010 Emissions solution............3-11
Handling of the exhaust emission
control system .................................................. 3-12
Vehicle Labels .................................................. 3-24
ENTERING AND LEAVING THE CAB ........... 4-1
DOORS AND WINDOWS ............................... 5-1
Door ................................................................... 5-1
Keyless Entry System ........................................ 5-2
Door Window (Power Window) .......................... 5-4
DRIVING POSITION........................................6-1
Seats .................................................................. 6-1
Seat Belts ........................................................... 6-5
Steering Wheel ................................................... 6-7
INSTRUMENTS AND CONTROLS .................7-1
Ignition Key Switch ............................................. 7-3
Meters and Gauges............................................ 7-5
Multi-display Monitor ........................................ 7-15
Warnings and Indicators................................... 7-26
Buzzers ............................................................ 7-30
Warnings .......................................................... 7-31
Warning and indicator lights ............................. 7-43
Switches and Buttons....................................... 7-53
DPF System ..................................................... 7-69
Levers and Control ........................................... 7-75
ACCESSORIES...............................................8-1
HEATER OR AIR CONDITIONER CONTROL .........9-1
Air Conditioner.................................................... 9-1
VEHICLE OPERATION .................................10-1
Operating Precautions...................................... 10-1
Break-in Precautions ........................................ 10-2
Vehicle Loading ................................................ 10-2
v
Towing Trailers ................................................. 10-3
Starting the Engine........................................... 10-4
Warming up Engine.......................................... 10-7
Stopping the Engine ......................................... 10-9
Driving on Grades .......................................... 10-10
Driving in Difficult Conditions ..........................10-11
Operating with Manual Transmission ..............10-11
Operating with Automatic Transmission......... 10-14
Brake Operation ............................................. 10-33
Parking your Vehicle ...................................... 10-35
After Parking Your Vehicle.............................. 10-36
In Cold Weather ............................................. 10-36
Idle Shutdown ................................................ 10-38
VEHICLE SERVICE AND MAINTENANCE...11-1
Clean Air Act .....................................................11-1
Maintenance Intervals .......................................11-3
Grease Lubrication Points...............................11-16
Before Performing Maintenance .....................11-19
Cab..................................................................11-20
Engine Cooling System...................................11-24
Engine Oil and Oil Filters ................................11-31
Fuel System ....................................................11-37
Air Cleaner Element ........................................11-44
Drive Belt.........................................................11-46
Aftertreatment DEF Filter ................................11-48
CCV Filter........................................................11-50
Transmission Gear Oil.....................................11-51
Differential Gear Oil.........................................11-59
vi
Steering System ............................................. 11-60
Service Brake System .................................... 11-62
Clutch ............................................................. 11-65
Suspension..................................................... 11-67
Windshield Washer Fluid................................ 11-68
Outside Mirrors............................................... 11-69
Emission Control Systems ............................. 11-70
Noise Control System..................................... 11-73
Battery ............................................................ 11-75
Lights.............................................................. 11-78
Fuses.............................................................. 11-80
Blower Motor Filters ....................................... 11-82
Wheels and Tires ........................................... 11-83
Appearance Care ........................................... 11-89
IN CASE OF EMERGENCY/
TROUBLESHOOTING............................................12-1
Engine Overheating.......................................... 12-1
Jump Starting ................................................... 12-3
Tire Change...................................................... 12-6
Towing .............................................................. 12-9
Troubleshooting.............................................. 12-13
SERVICE DATA.............................................13-1
Maintenance Standard ..................................... 13-1
Tightening Torque............................................. 13-3
Bulbs ................................................................ 13-5
Recommended Lubricants ............................... 13-5
Recommended SAE Viscosity Chart................ 13-6
Refill Capacities ............................................... 13-7
Conversion Factors .......................................... 13-8
REPORTING SAFETY DEFECTS ................ 14-1
INDEX............................................................ 15-1
vii
INTRODUCTION AND SAFETY
INTRODUCTION
AND SAFETY
WHEN READING THE MANUAL
In this manual, read very carefully those sections which have signs
“DANGER”, “WARNING”, “CAUTION” and “NOTE”. They are particularly
important.
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
CAUTION
Indicates a situation which, if not avoided, could result in
property damage to the vehicle.
NOTE
Indicates good practice.
If you see this symbol, it means “Do not do this” or
“Do not let this happen”.
UD Trucks Corporation offers a variety of options, components and features
on its vehicles. Therefore, the equipment described in this manual may or
may not be identified as standard or optional and may or may not be applicable to your particular vehicle. If you have any questions, consult your UD
Trucks dealer.
1-1
INTRODUCTION AND SAFETY
All information and specifications in
this manual are based on the product information in effect at the time of
printing. The right is reserved to discontinue models, change information, specifications or design without
notice and without incurring obligation.
We urge you to drive safely, use the
safety equipment provided with your
vehicle and observe traffic signs and
local laws.
Thank you for selecting a UD Trucks
product. We sincerely hope that your
UD Trucks experience is safe, satisfactory and pleasant.
NEW VEHICLES BREAK-IN
PERIOD
For extended service life and reliable
performance, your UD Trucks vehicle requires proper handling during
the first 600 miles (1,000 km) of
operation. Special instructions for
this break-in period are described in
the "BREAK-IN PRECAUTIONS" on
page 10-2. After this initial break-in
period, continued routine inspection
and maintenance as described in
this manual will help assure continued dependable operation of your
UD Trucks vehicle.
For details, refer to the “VEHICLE
SERVICE AND MAINTENANCE”
section.
KEYS
Duplicate keys are provided with
your UD Trucks vehicle. Each key
operates the door locks and ignition
key switch. Record the key number
stamped on your keys and store in a
safe place. Contact your UD Trucks
dealer if key replacement becomes
necessary. The key number will
enable the UD Trucks dealer to order
replacement keys.
See the “DOORS AND WINDOWS”
section for door operation and Keyless Entry System.
Key number plate
The key number is engraved on the
key number plate so that only the
owner will know the key number.
Remove this from the key you normally use and store it in a safe place
other than in the vehicle. (The key
number is not engraved on the key.)
1-2
INTRODUCTION AND SAFETY
FUEL
METRIC MISMATCH
Your UD Trucks vehicle is designed
to operate on diesel fuel only.
For details, refer to the "Fuel requirements" on page 11-38.
Your vehicle may utilize parts which
have either metric and/or SAE unit
dimensions. Any fasteners e.g. bolts
and nuts, used to replace old ones,
must have the same dimensions and
strength as those removed.
CAUTION
 Do
WARNING
 Do not leave children alone in
the vehicle. If you must leave
the car, be sure to remove the
ignition key to avoid an accident.
CAUTION
 Only use genuine part ignition
keys to prevent accidents.
NOTE:
 When leaving the car, be sure
to remove the key and lock the
doors. This will prevent theft.
1-3
not use fuel additives,
agents for removal of water
from the fuel, agents for
improvement of the fuel efficiency.
This can cause smoke generation or defects from defective
sliding of the sliding surfaces
lubricated by fuel system.
 Do not install devices for
improvement of the fuel efficiency inside the fuel tank.
Wear particles, fragments from
the installed devices (aftermarket parts) can cause
defects of the fuel system.
WARNING
 Mismatched
or
incorrect
thread fasteners can result in
thread stripping and/or assembly weakness leading to vehicle damage, malfunction or
possible serious injury.
INTRODUCTION AND SAFETY
ABBREVIATION
In this manual, the following abbreviations are used.
ATM: Automatic transmission
CAN: Controller Area Network
CCV: Closed Crankcase Ventilation
DEF: Diesel Exhaust Fluid
DPF: Diesel Particulate Filter
DTC: Diagnostic Trouble Code
EGR: Exhaust Gas Recirculation
MTM: Manual transmission
Multi-display meter: Combination
meter with multi-display function
OBD: On Board Diagnostic
SCR: Selective Catalytic Reduction
TCM: Transmission Control Module
1-4
IDENTIFICATION
IDENTIFICATION
VEHICLE IDENTIFICATION
NUMBER (VIN)
The vehicle identification number
(VIN) plate is located on the riser of
the driver’s side.
2-1
The meaning of each character in
the vehicle identification number is
given in the sample below.
IDENTIFICATION
Vehicle lines, series, Chassis, GVWR Class
Code
M1
M3
L1
L3
C1
C4
G1
G4
A1
A2
A4
A6
D1
D2
D4
D6
K1
K2
K5
K6
Information
UD1800 (MKA8F) with MLS63B transmission 4 x 2, Class 5
UD1800 (MKA8F) with 1000RDS transmission 4 x 2, Class 5
UD2000 (MKB8F) with MLS63B transmission 4 x 2, Class 5
UD2000 (MKB8F) with 1000RDS transmission 4 x 2, Class 5
UD2300DH (LKC8F) with MLS63B transmission 4 x 2, Class 6
UD2300DH (LKC8F) with 2200RDS transmission 4 x 2, Class 6
UD2300LP (LKC8F) with MLS63B transmission 4 x 2, Class 6
UD2300LP (LKC8F) with 2200RDS transmission 4 x 2, Class 6
UD2600 (PKA8F) with MLS63B transmission 4 x 2, Class 6
UD2600 (PKA8F) with MPS63B transmission 4 x 2, Class 6
UD2600 (PKA8F) with 2200RDS transmission 4 x 2, Class 6
UD2600 (PKA8F) with 3000RDS transmission 4 x 2, Class 6
UD2600LP (PKA8F) with MLS63B transmission 4 x 2, Class 6
UD2600LP (PKA8F) with MPS63B transmission 4 x 2, Class 6
UD2600LP (PKA8F) with 2200RDS transmission 4 x 2, Class 6
UD2600LP (PKA8F) with 3000RDS transmission 4 x 2, Class 6
UD3300 (PKC8F) with MLS63B transmission 4 x 2, Class 7
UD3300 (PKC8F) with MPS63B transmission 4 x 2, Class 7
UD3300 (PKC8F) with 2500RDS transmission 4 x 2, Class 7
UD3300 (PKC8F) with 3000RDS transmission 4 x 2, Class 7
UNIT IDENTIFICATION
The locations of the stamped chassis serial number, engine serial number, and each assembly and serial
number of transmission, differential
carrier, front axle and rear axle are
shown below:
Chassis serial number location
2-2
IDENTIFICATION
Engine serial number location
MTM (MPS63)
Transmission assembly and serial
number location
ATM (Allison 3000)
Differential carrier assembly and
serial number location
ATM (Allison 1000, 2200, 2500)
MTM (MLS63)
2-3
UD1800, UD2000 and UD2300LP
IDENTIFICATION
Rear axle assembly and serial
number location
UD2300DH
Front axle assembly and serial
number location
UD2600 and UD3300
2-4
BEFORE DRIVING YOUR VEHICLE
BEFORE
DRIVING YOUR
VEHICLE
WARNING
Be sure this vehicle includes required safety features. This vehicle
may be put to many uses, and UD Trucks Corporation cannot anticipate all of them. Always consult safety regulations in effect for location 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 retroreflective sheeting or other devices to insure the vehicle is clearly
visible. Be sure you have visibility devices in compliance with the regulations 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
Never load your vehicle in
excess of the Gross Vehicle
Weight Rating (GVWR) and the
Gross Axle Weight Ratings of
the front and rear axle (GAWR).
Overloading may cause loss of
vehicle control and result in serious injury or death. It may also
void the new vehicle warranty
and shorten vehicle life.
Model
Tire
GVWR
GAWR-Front
GAWR-Rear
UD1800
225/70R19.5 (F)
17,995 lb
(8,160 kg)
7,280 lb
(3,300 kg)
13,660 lb
(6,200 kg)
UD2000
225/70R19.5 (F)
19,500 lb
(8,845 kg)
UD2300 LP
245/70R19.5 (G)
UD2300 DH
9R22.5 (G)
7,280 lb
(3,300 kg)
8,375 lb
(3,800 kg)
8,375 lb
(3,800 kg)
13,660 lb
(6,200 kg)
15,430 lb
(7,000 kg)
16,535 lb
(7,500 kg)
UD2600
11R22.5 (G)
11,020 lb
(5,000 kg)
20,280 lb
(9,200 kg)
11,020 lb
(5,000 kg)
20,280 lb
(9,200 kg)
11,900 lb
(5,400 kg)
21,000 lb
(9,525 kg)
UD2600 LP
UD3300
255/70R22.5 (H)
11R22.5 (G)
23,000 lb
(10,435 kg)
25,995 lb
(11,790 kg)
32,900 lb
(14,925 kg)
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
WARNING
 Towing trailers beyond the maximum recom-
mended trailer weight which exceeds the limit of
the vehicle’s GCWR, GVWR, GAWR(s) or tire ratings could result in engine damage, transmission
damage, structural damage, loss of vehicle control, vehicle rollover and personal injury.
GVWR of the towing vehicle. The GCW must never
exceed the GCWR.
GVWR (Gross Vehicle Weight Rating) — is the maximum allowable weight of the fully loaded vehicle (including all options, equipment, passengers, and cargo).
CAUTION
 Exceeding the Tire Rating or Simplified Final-
Definitions:
GAWR (Gross Axle Weight Rating) — is the maximum
allowable weight that can be carried by a single axle
(front or rear). These numbers are shown on the Simplified 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.
GCWR (Gross Combined Weight Rating) — is the maximum allowable weight of the vehicle and the loaded
trailer — including all cargo and passengers — that the
vehicle can handle without risking damage (Important:
The towing vehicle's braking system is rated for operation at GVWR, not at GCWR). Separate functional
brakes should be used for safe control of towed vehicles
and for trailers where the GCW (Gross Combined
Weight) of the towing vehicle plus the trailer exceed the
3-3
stage Vehicle Certification Label vehicle weight
rating limits could result in substandard vehicle
handling or performance, engine, transmission
and/or structural damage, serious damage to the
vehicle, loss of control and personal injury.
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
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)**
4.33 / 4.56
34,000 (15,422)
26,000 (11,793)**
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
4.88
50,715 (23,000)
N/A
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)**
4.88
40,225 (18,246)
26,000 (11,793)**
UD2300LP
Engine Type
D (245hp)
UD2300DH
UD2600
E (280hp)
UD2600LP
D (245hp)
3-4
BEFORE DRIVING YOUR VEHICLE
Vehicle Model
UD2600LP
Engine Type
E (280hp)
D (245hp)
UD3300
E (280hp)
Rear Axle Ratio *
MTM
ATM
4.33
50,490 (22,900)
N/A
4.63
53,800 (24,400)
N/A
5.14
N/A
59,975 (27,200)**
5.86
N/A
64,385 (29,200)**
5.14
34,945 (15,850)
5.57
41,005 (18,600)
5.86
43,100 (19,550)
6.83
50,000 (22,680)
N/A
4.88
50,715 (23,000)
N/A
5.14
53,580 (24,300)
N/A
5.57
57,770 (26,200)
57,770 (26,200)**
5.86
58,430 (26,500)
58,430 (26,500)**
6.17
N/A
57,990 (26,300)**
6.50
N/A
55,565 (25,200)**
*Consult your authorized UD Trucks dealer for information on “Rear Axle Ratio”.
**GCWR rating limitations, as directed by AIlison Transmission.
N/A - not applicable, no approved GCWR.
3-5
33,000 (14,968)**
BEFORE DRIVING YOUR VEHICLE
SAFETY REMINDERS
DAILY MAINTENANCE
For your safety and that of others,
observe the following precautions:
 Never drive while under the influence of intoxicating beverages or
drugs which may affect your ability
to operate your vehicle safely.
 Drive defensively. Expect the
unexpected! Properly use the seat
belts and head restraints provided
with your vehicle.
 Observe posted speed limits and
other local laws. Never drive faster
than conditions allow.
 Know your vehicle and its operating characteristics.
 Maintain your vehicle according to
the schedules and instruction
described in this manual.
See the “VEHICLE SERVICE AND
MAINTENANCE”.
Daily maintenance should be performed by the driver before or after
the day’s operation in order to
assure safe driving and prevent
problems on the road.
For complete details, refer to the
“CHECK POINTS” (next page) and
“VEHICLE SERVICE AND MAINTENANCE” section in this manual.
If a problem with any part of the vehicle is noticed during daily inspection,
it should be repaired immediately.
Consult your authorized UD Trucks
dealer or qualified service facility for
repairs.
WARNING
 Repair any malfunction before
operating your vehicle. Failure
to do so can increase the risk
of serious injury, death or
property damage.
objects embedded in tread
grooves.
 Inspect disc wheels for damage.
 Check that wheel nuts are properly
installed and tightened.
 Drain condensate from air reservoir.
 Check if water has accumulated in
the primary fuel filter.
 Check whether a red signal shows
on air cleaner service indicator for
clogging of the air cleaner.
 Check that all light lenses are
undamaged and clean.
 Check levels of engine oil and
power steering fluid.
With the cab tilted
 Check drive belts for proper ten-
sion and for damage.
 Examine all oil and fluid reservoirs
for leaks.
Inside the cab
Outside the vehicle
 Check tire air pressure.
 Examine all tires for cracks, dam-
age, abnormal wear, and foreign
 Check
that mirrors are intact,
adjusted, and clean.
 Check that doors are securely
closed and locked.
3-6
BEFORE DRIVING YOUR VEHICLE
 Check that seat belts are intact,
 Check the horn for proper opera-
undamaged and properly adjusted.
 Check that head restraints are
intact and properly adjusted.
tion.
 Check the operation of windshield
wipers and washer and the condition of the wiper blades.
 Check that each gauge on the
instrument panel is functioning
properly. Be sure that no buzzers
With engine started
Refer to “INSTRUMENTS
CONTROLS”.
AND
are sounding and no warning
lights, warnings are on except for
the PARKING BRAKE warning
light.
 Check that all lights and turn signals function properly.
Check points
Items
 Drive belt
 Engine oil leakage and
engine oil level
Check points
Check for belt tension, wear or cracks. If required, have the belt replaced
by your authorized UD Trucks dealer or qualified service facility.
Always replace the two belts as a set.
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.
Check for leakage from engine. Also check for traces of water on the road
directly under the engine. If leakage is noticed, check the coolant level.
Check that the ENGINE COOLANT LEVEL warning light remains off while
engine coolant level
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.
tor
 Coolant leakage and
 Water hoses and clamps
 Primary fuel filter
3-7
Check all radiator and heater hose clamps for tightness. Inspect all hoses;
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 accumulated in the fuel filter, it has also accumulated in the fuel tank. Drain
water from fuel tank when the fuel filter is drained.
Reference
page
11-46
11-33
11-25
11-44
–
11-41
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items
Check points
Check the amount of fuel using the fuel gauge. It is advisable to keep the
fuel tank full.
Check the amount of fuel using the DEF gauge. It is advisable to keep the
 DEF quantity
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
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.
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.
 Service brake operation
Then, release the pedal to ensure the sound is accompanied by discharging air. Next, drive the vehicle at low speeds and check for braking performance.
 Fuel quantity
Reference
page
7-12
7-10
–
–
11-86
–
11-83
7-8,
10-33
3-8
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items
Check points
Open the drain cocks and drain condensation completely from air reservoir. Close the drain cocks completely.
 Draining water condensaIf a large quantity of water accumulates, the air dryer may be faulty and
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
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
headlights, turn signal lights, etc. operate properly. Clean dirty light lenses.
 Horn
Operate the horn button to ensure the horn sounds.
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.
warning and warning light
Also check the indicator light for proper operation in response to the operation 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.
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
Reference
page
11-63
7-76
7-57
7-68
7-1
7-55
BEFORE DRIVING YOUR VEHICLE
(Cont’d)
Items
Check points
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
 Heater defroster
 Seat belt
 Door lock
 Cab tilt lock mechanism
if dirty.
Operate the car heater to check the condition of hot-air discharge from the
defroster. This check should be carefully performed especially in rainy
weather.
Fasten the seat belt to check for proper operation of the buckle. Also
check the belt for damage.
Check door locks for proper operation.
Check the condition and operation of the cab tilt lock mechanism.
Reference
page
11-69
9-8
6-5
5-1
11-21
3 - 10
BEFORE DRIVING YOUR VEHICLE
EGR SYSTEM OPERATION
UD TRUCKS, US2010
EMISSIONS SOLUTION
WARNING
 Do not carelessly touch the
EGR system components (EGR
valves, EGR adapter, EGR piping, EGR cooler, coolant piping, etc.) when the engine is
hot, such as during operation
and immediately after driving.
These components are hot and
touching them could cause
burns, therefore touching them
is very dangerous.
CAUTION
 Do not rest your feet, etc., on
the EGR system components.
Doing so could damage the
EGR system components.
 Overheating of the engine could
damage the EGR system components, so have them inspected and
serviced by the nearest authorized UD Trucks dealer.
3 - 11
When a certain amount of soot accumulates in the aftertreatment DPF,
the DPF automatically goes into the
regeneration mode to burn the collected soot. To obtain the expected
DPF performance, please observe
the following precautions. The frequency of the occurrence of the
aftertreatment DPF regeneration
mode differs according to how you
drive the vehicle.
The exhaust aftertreatment system
virtually eliminates exhaust smoke.
White exhaust vapor (water condensation) may be visible during a cold
start. If black exhaust smoke visible
during engine operation, this indicates a problem with the exhaust
aftertreatment system. Take the
vehicle to an authorized UD Trucks
dealer immediately.
Vehicles equipped with a 2010 emission compliant engine have an
exhaust aftertreatment system which
includes an aftertreatment Selective
Catalytic Reduction (SCR) system
and a Catalyzed aftertreatment Diesel Particulate Filter (DPF). The
Aftertreatment DPF takes the place
of the standard muffler, and it
reduces soot and particulate emissions into the atmosphere.
Soot and other particulate matter are
collected by a filter where it is eventually oxidized.
Vehicles equipped with an aftertreatment DPF require the use of UDXtra
(or VDS-4) specification high perfor-
BEFORE DRIVING YOUR VEHICLE
mance diesel engine oil and Ultra
Low Sulfur Diesel (ULSD) fuel.
HANDLING OF THE EXHAUST
EMISSION CONTROL
SYSTEM
 The following must be observed to
prevent malfunctioning of this system.
 The exhaust emission control sys-
tem reduces PM (Particulate Matter) 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 (regenerate) the collected soot. The frequency 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
Precautions on handling the DPF
When a certain amount of soot that
is included in the exhaust gas accumulates in the aftertreatment DPF,
the DPF automatically burns (regenerates) the collected soot.
This prevents the excessive accumulation of soot and keeps the
cleaning function of the DPF in good
condition.
The DPF automatically burns
(regenerates) the collected soot.
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 flammable materials such as dried
grass or paper waste.
3 - 13
BEFORE DRIVING YOUR VEHICLE
 If there are flammable materi-
als around the vehicle, a fire
may occur. This could cause
burns from the heated exhaust
gas.
NOTE:
 Depending on the driving condi-
tions, the burning (DPF regeneration) of the soot collected in
the DPF may not be completed.
When both the DPF clogging
warning light and the indicator
light that is built in the manual
forced
regeneration
switch
blink, press the exhaust gas
cleaning device switch to manually clean the soot.
 While operating the aftertreatment DPF, the engine speed at
idle may increase under the following conditions. This is due to
a temperature increase of the
exhaust gas in order to burn
(regenerate) the collected soot.
This does not indicate a malfunction.
・The engine exhaust gas
temperature is low for a long
period of time. (For example, the
engine idles too long.)
If a gear is engaged to drive the
vehicle, the operation of the
device will stop. However, if the
processing time is not sufficient
to satisfy a specified duration,
the operation of the device will
resume after stopping the vehicle.
・The
cleaning
mode
automatically turns on while
driving.
When the DPF clogging warning
light blinks, perform the DPF regeneration manually.
When both the DPF clogging warning light that is located in the combination meter and the indicator light
that is built in the manual forced
regeneration switch blink, immediately perform manual cleaning of the
aftertreatment DPF to burn (regenerate) the soot that has collected.
WARNING
 Do not perform manual clean-
ing in a location with poor ventilation. Exhaust gas may
cause carbon monoxide poisoning
especially
in
an
enclosed location, such as in a
garage, indoors, etc.
 Do not perform manual cleaning in a location where there
are flammable materials such
as dried grass or paper waste.
The temperature of the exhaust
gas and the area around the
exhaust pipe and muffler
become high during cleaning.
Therefore, if there are flammable materials nearby, a fire may
occur.
In addition, never allow your
body to contact exhaust gas
and the area around the
exhaust pipe and muffler.
Doing so may cause burn injuries.
If the vehicle is stopped over a
road surface that is painted,
the road surface may be discolored.
3 - 14
BEFORE DRIVING YOUR VEHICLE
CAUTION
 If driving is continued, clog-
ging in the DPF or a system
malfunction may occur.
NOTE:
 The
engine speed increases
while performing manual DPF
regeneration. This is due to a
temperature increase of the
exhaust gas in order to burn
(regenerate) the collected soot.
This does not indicate a malfunction.
 While performing manual aftertreatment DPF regeneration, the
aftertreatment
hydrocarbon
doser system supports the manual DPF regeneration by injecting fuel in the exhaust pipe.
3 - 15
Handling of the aftertreatment
diesel exhaust fluid (DEF) dosing
system
The DEF dosing system (DEF
pump, DEF dosing valve) continues to operate for approximately
120 seconds after the ignition key
is turned to OFF position. Therefore, wait for at least 120 seconds
before disconnecting the battery
cable or electrical system connectors when servicing the vehicle,
etc.
Handling of the muffler
 The muffler that is equipped with
the aftertreatment DPF for the PM
reduction device needs to be
cleaned regularly to maintain its
performance (either 155,000 miles
[250,000 km] or 4,500 hours,
whichever comes first). This is
because unburnable ash that is
different from burnable soot will
accumulate in the DPF.
For details about cleaning of the
muffler equipped with the DPF,
contact your nearest authorized
UD dealer.
 For the muffler that is equipped
with the SCR catalyst system, no
inspections and maintenance are
basically required.
 If they must be replaced by necessity because they are damaged,
use UD Trucks genuine parts.
BEFORE DRIVING YOUR VEHICLE
Do not touch the water that comes
from the muffler.
The muffler has the following characteristics.
NOTE:
WARNING
 Do not touch the water that
comes from the muffler. The
action of the oxidizing catalyst
contained in the catalyst integrated muffler makes the water
slightly acidic. If it gets on the
skin, etc., flush well with water
to wash it off.
Do not kick or strike the muffler.
CAUTION
 The muffler contains a cata-
lyst, so do not kick or strike
the muffler. Doing so could
damage the catalyst inside.
 The
aftertreatment
system
cleans and discharges the
exhaust gas, so the exhaust gas
smells differently than that of
conventional diesel vehicles.
 Some white smoke might come
from the exhaust pipe when the
engine is started, but this is just
steam and is not a problem.
 White smoke may be emitted
from the area around the muffler
during the soot burning (DPF
regeneration) process. This is
due to the emission of water
vapor from the area around the
muffler, and it does not indicate
a malfunction.
 When manual DPF regeneration
is performed while driving in
rain or after washing the vehicle,
water vapor may be observed
around the muffler. This does
not indicate a malfunction.
Do not modify the tailpipe.
CAUTION
 Changing the orientation or
length of the tailpipe could
degrade the exhaust gas
cleaning effect, so do not modify the tailpipe. When the construction of the body requires
that the tailpipe be modified,
contact the nearest authorized
UD Trucks dealer for advice.
3 - 16
BEFORE DRIVING YOUR VEHICLE
Handling of the diesel exhaust
fluid (DEF)
 Do not drive the vehicle when
the DEF tank is empty. This will
not only worsen exhaust gas
emissions but will prevent the
engine from being started
again. Always fill the tank
ahead of time to leave plenty of
leeway for driving.
Fill the tank with the specified
amount of DEF.
Only add DEF to the DEF tank that is specified by UD Trucks and
meets the ISO22241-1 specification.
13.2 gal (50 liter) tank
CAUTION
 If something other than the
5.3 gal (20 liter) tank
3 - 17
specified substance (diesel,
kerosene, etc.) is mistakenly
added to the DEF tank, it could
cause a fire, so have it
inspected and serviced by the
nearest authorized UD Trucks
dealer.
NOTE:
 Spilled
DEF
should
been
cleaned up in accordance with
local regulation.
Only use DEF that satisfies the
ISO22241-1 specification.
 Only use DEF specified by UD
Trucks
that
satisfies
the
ISO22241-1 specification.
 The specified DEF is colorless and
odorless (urea 32.5%, water
67.5%) and begins to freeze at
12.2°F (–11°C). When the ambient 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.
BEFORE DRIVING YOUR VEHICLE
Precautions for handling of the DEF
<Handling Precautions>
 Handle in accordance with good
industrial hygiene and safety practices.
 Only use DEF specified by UD
Trucks
that
satisfies
the
ISO22241-1 specification.
 Use the UD Trucks genuine part
5.3 qt (5 liter) portable tank or a
special container recommended by
the DEF dealer to hold the DEF.
General containers, containers
that have been used for other
applications, and dirty containers
will not maintain the quality of the
DEF, so absolutely do not use
them.
<Temporary Measures>
DEF is a very safe liquid, but it might
cause a very slight irritation for some
people. If it is spilled on the body,
wash it off with water, and if it is
drunk mistakenly, drink 1 or 2 cups
of milk. if milk is not available, drink
water. In all case, consult physician.
<When Fires or Leaks Occur>
 DEF is nonflammable, but quickly
move it to a safe location if there is
a fire.
 If DEF is spilled, wash it away with
water. It can be disposed of without a problem by first diluting it
with a large amount of water and
then pouring it into the sewage
system. It must be treated as
industrial waste in areas with nitrogen restrictions.
not lose water due to evaporation,
etc., so as long as the container is
sealed, there is no particular concern
about an expiration date.
Fuel for the vehicle equipped with
the aftertreatment DPF
Do not use any fuel other than the
specified fuel.
CAUTION
 Use ultra low sulfur diesel
(ULSD) fuel only. Use of any
other fuel may adversely affect
the engine, exhaust gas cleaning device, etc., resulting in
aftertreatment DPF clogging
and so on.
Refer to "Fuel requirements"
on page 11-38.
<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 deterioration, etc., of DEF as long as it does
3 - 18
BEFORE DRIVING YOUR VEHICLE
Engine oil for the vehicle
equipped with the aftertreatment
DPF
Do not use any engine oil other
than the recommended oil.
CAUTION
 To obtain the expected mainte-
nance life of the aftertreatment
DPF, it is necessary to use the
recommended engine oil.
Refer to "Engine oil recommendations" on page 11-31.
3 - 19
BEFORE DRIVING YOUR VEHICLE
DPF Regeneration system
3 - 20
BEFORE DRIVING YOUR VEHICLE
The status of DPF soot accumulation: Level 0
The status of DPF soot accumulation: Level 1
When the Level 0 indication is
shown, the manual DPF regeneration is not required. However, the
optional manual DPF regeneration is
available.
When the DPF clogging warning
light blinks, immediately perform the
manual DPF regeneration (before
the driving distance reaches 125
miles [200 km]).
NOTE:
Operation procedure
 Press the mode select switch
1. Stop the vehicle at a safe place,
apply the parking brake firmly
and put the shift lever in the N
(neutral) position. For automatic
transmission with the P (Park)
position, put the selector lever
into the P (Park) position.
(located on the left side knob in
the combination meter) to check
the DPF soot accumulation level
that will be shown with the DPF
soot level gauge.
 The DPF clogging warning light
may blink when soot does not
accumulate in the DPF. This may
occur in order to maintain the
performance of the muffler.
3 - 21
WARNING
 Make sure that there are no
flammable materials around or
under the exhaust system
components.
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 regeneration switch to activate the aftertreatment DPF regeneration.
DPF regenerating warning and
message are displayed.
Idling speed will increase and the
exhaust brake will be activated.
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.
5. Wait approximately 25 minutes.
(when it is operated after the
engine has already warmed up.)
When the DPF regenerating
warning is no longer displayed on
the multi-display monitor, regeneration is completed.
CAUTION
 Do not continue driving the
vehicle while at level 1. The
system restricts engine torque
and reduces engine output,
depending on the amount of
soot accumulation.
The status of DPF soot accumulation: Level 2
When the engine control warning
light and the DPF system warning
(Amber) and message are indicated,
the system restricts engine torque
and reduces engine output.
Immediately contact your nearest
UD Trucks dealer for inspection.
CAUTION
 The DPF may be damaged if
the vehicle is continuously
driven while at level 2.
Immediately contact your nearest UD Trucks dealer for
inspection.
The status of DPF soot accumulation: Level 3
If the DPF system warning (Red) is
illuminated, the system will reduce
torque to a specified value within
approximately 10 seconds and a
buzzer will sound. In this case, the
acceleration pedal cannot be oper-
3 - 22
BEFORE DRIVING YOUR VEHICLE
ated and the engine is forced to run
at the idling speed.
Vehicle
speed
is
gradually
decreased to protect the engine,
which will be shut down (automatically stopped) when the vehicle is
stopping or completely stops.
Contact your nearest UD trucks
dealer immediately.
CAUTION
 When the DPF system warning
(red) appears, immediately
stop the vehicle in a safe location and contact your nearest
UD trucks dealer.
Handling of the diesel particulate
filter (DPF)
The following phenomena does not
indicate trouble.
The idle speed varies and the
exhaust brake operates the same
time.
 When the vehicle is stopped for a
traffic signal or other reason the
engine shifts to idle running. (Automatic DPF regeneration is in progress.)
 When the engine is idled continuously for a long time. (The idle
speed increases from time to time
to prevent the emission of white
smoke.)
White smoke may sometimes be
emitted.
 White smoke may be emitted from
the end of the exhaust muffler.
・This is due to the emission of
water vapor.
・This will not occur when the
engine exhaust gas temperature
increases to a sufficient level.
3 - 23
 White smoke may be emitted from
the surface of the exhaust muffler
if the aftertreatment DPF regeneration is operated manually in the
rain.
・This is due to the fact that water
adhering on the surface of the
exhaust muffler evaporates.
 If any fuels other than the specified
one are used, the emission of
white smoke may continue.
Always use ultra-low sulfur diesel
(ULSD) fuel (S15) because any
other fuel may adversely affect or
damage the engine and the DPF.
The exhaust gas odor will not be
same as that of previous diesel
vehicles.
 The odor is different because the
exhaust gas is passed through a
catalytic converter and cleaned.
Regularly clean the aftertreatment diesel particulate filter (DPF)
 The DPF should be cleaned every
155,000 miles (250,000 km) or
4,500 hours, which occurs first as
BEFORE DRIVING YOUR VEHICLE
necessary to ensure proper performance.
 If the DPF Maintenance warning is
illuminated, the vehicle should be
taken to the nearest UD Trucks
dealer as soon as possible.
Always use genuine engine oil.
 Always use the specified engine oil
to maintain the performance of the
DPF.
VEHICLE LABELS
Products safety labels are affixed to
your UD Trucks vehicle at the factory.
Labels with DANGER, WARNING or
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 authorized UD Trucks dealer or UD Trucks
North America, Inc. for replacement
labels.
Use ultra-low sulfur diesel (ULSD)
fuel only
 Failure to use ultra-low sulfur die-
sel fuel in this vehicle may damage
the emission related parts, violate
the EPA and CARB regulations
and possibly void the UD Trucks
vehicle warranty as listed in the
Warranty & Service Booklet.
3 - 24
ENTERING AND LEAVING THE CAB
ENTERING AND
LEAVING THE
CAB
Driver’s side
1. Open door and firmly grasp the
rear handle behind the door
opening with your right hand.
WARNING
 Be careful when entering or
leaving cab so you don’t slip
or fall.
 Always keep your shoe soles
and hands clean. Keep the cab
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
times with at least 2 feet and 1
hand or 2 hands and 1 foot
firmly placed during all phases
of entering or leaving the cab.
4-1
3. Bring your right foot up to the 2nd
step.
2. Firmly grasp either the lower or
upper handle on the front of the
door opening with your left hand
and place your left foot on the 1st
step.
ENTERING AND LEAVING THE CAB
4. Bring your left foot up to the 2nd
step next to your right foot.
If you grasped the lower handle
with your left hand then move
your left hand to the upper handle.
5. Step to the cab floor with your left
foot.
6. Bring your right foot to the cab
floor.
7. Position yourself in the driver’s
seat and release your left hand
from the front upper handle.
8. Close door.
9. To leave the cab, open the door
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
DOORS AND
WINDOWS
WARNING
 Before starting to drive, be
sure cab doors are securely
closed and locked.
 Before opening cab door, look
for bystanders and approaching vehicles.
5-1
Using seat belts and keeping the
doors closed and locked provides
greater safety in the event of an accident. It will also help keep children
and other from unintentionally opening the doors and will help keep out
intruders.
DOOR
Operation from outside of vehicle
Opening door
When opening the door from the
outside, pull the outside handle
while pressing the push button.
NOTE:
 Lock the door from the inside by
pushing the door lock knob in.
To lock the door from the outside, use the ignition key or
push the inside lock knob in and
close the door while pushing in
the outside handle push button.
You may want to consider carrying a duplicate ignition key in
your billfold in the event you
lock your ignition key in the cab.
Locking and unlocking
<Power door lock >
The power door lock system allows
you to lock or unlock all doors simultaneously.
Turning the driver side door key will
lock or unlock both doors.
DOORS AND WINDOWS
Locking and unlocking
The power door lock system allows
you to lock or unlock all doors simultaneously.
Pushing the driver side lock knob will
lock both doors. Pulling the lock
knob will unlock both doors.
KEYLESS ENTRY SYSTEM
The keyless entry system enables
you to lock/unlock all doors away
from the vehicle (approximately 3.3
to 9.9 ft [1 to 3 m]) using the remote
control.
Operation from inside of vehicle
Opening door
When opening the door from the
inside, pull the inside handle
toward you while pushing the door
outward
5-2
DOORS AND WINDOWS
NOTE:
 As many as 4 remote controls
can be used. Contact an authorized UD Trucks dealer for purchasing or how to start using
additional remote controls.
How to use remote control
Door lock button (LOCK):
All doors will be locked by pushing
the button, and the hazard lights will
blink once.
After locking the doors using the
remote control, operate the door
handle to confirm the door has been
securely locked.
Door unlock button (UNLOCK):
All doors will be unlocked by pushing
the button, and the hazard lights will
blink twice. All doors will be locked
automatically unless any door is
opened within approximately 30 seconds after pressing the UNLOCK
button.
The remote control will not function
under the following conditions.
 Any door is not completely closed.
 The remote control is too far away
from the vehicle.
5-3
 The battery of the remote control is
completely discharged.
 The ignition key is in the ON or
ACC position.
NOTE:
 The
operating range of the
remote control depends upon
the conditions around the vehicle. Make sure that the remote
control is within 9.9 ft (3 m) from
the door to make it surely function.
 Though the remote control is
waterproof, it can be damaged
when it gets wet. If the remote
control gets wet, immediately
wipe it off.
Contact an authorized UD
Trucks
dealer if the remote
control was washed in a washing machine or if it was soaked
in water for a long time.
 Do not drop or strike the remote
control.
 Do not leave the remote control
for a long time in a hot area.
 In case the remote control does
not function when pushing a
button, the battery may be discharged. Contact an authorized
UD Trucks dealer for battery
replacement. (The battery used
is a CR1620 lithium battery.)
DOORS AND WINDOWS
DOOR WINDOW (POWER
WINDOW)
 When children are riding in the
vehicle, for safety reasons, use
the power window lock switch
to lock the windows.
Open/Close switch
This switch is used to open and
close the door windows on the driver
and passenger’s side. It can be
operated when the ignition key
switch is in the ON position.
<Opening and closing the driver’s
side>
Passenger’s side
The driver’s side door window switch
is used to open or close the window
manually when pushed or pulled.
The window stops in its current position when the switch is released.
WARNING
 When closing the windows,
Driver’s side
make sure that no one has
their head or hands extended
outside the window before
operating the switch. Not
doing so could result in someone 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
<Opening and closing the
passenger’s side>
A passenger’s side door window
switch is provided in both the driver
and passenger’s side doors. The
window moves while the switch is
being pushed and stops when it is
released.
Window lock switch
When this switch is pushed, the passenger’s side door window cannot
be opened or closed even when the
open/close switch is operated. To
open or close the window, release
the window lock.
5-5
DRIVING POSITION
DRIVING
POSITION
SEATS
Front seat base adjustment
Fore and aft adjustment
WARNING
 To prevent loss of vehicle con-
trol, never adjust the driver’s
seat while driving.
The driver’s seat can be adjusted
forward and backward by pulling up
on the slide lever located on the front
of the seat base and sliding the seat
to the desired position. Lock the seat
in place by releasing the lever. To
assure that the seat is properly
locked in place, attempt to slide the
seat fore and aft with the slide lever
released.
The front of the driver’s seat can be
raised by pulling up the lever at the
left side of the seat base.
To lower the seat downward, pull the
lever and push down on the seat.
Rear seat base adjustment
6-1
DRIVING POSITION
The rear of the driver’s seat can be
raised by pulling up the lever at the
left side of the seat base.
To lower the seat downward, pull the
lever and push down on the seat.
Lumbar support adjustment
Riding comfort adjustment
<Up-down air suspension>
Reclining adjustment
This improves riding comfort by
automatically adjusting the up-down
movements of the vehicle body.
<Seat with fore-aft suspension>
Driver’s seat
Turn the knob on the outside of the
seat toward the front so that the center portion of the seatback will come
out slightly to support the lumbar
portion of the body. This may be useful in reducing fatigue during long
distance driving. The support is
adjustable continuously within the
adjusting range.
6-2
 Riding comfort in the fore-and-aft
direction is automatically adjusted.
 Operate the lever on the front side
of the seat to lock the fore-aft suspension of the seat.
Passenger seat
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
DRIVING POSITION
force to the seatback. To return the
seatback to the upright position lift
up the lever while leaning forward.
Forward and backward
adjustment of cushion
Headrest adjustment (Passenger
seat)
Adjust the cushion to the desired
position while pushing the lever to
the right. It is possible to adjust in
two stages in the forward direction
from the standard position.
The height of the headrest can be
adjusted manually. Adjust the headrest height while pressing the lock
knob.
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 comfort.
6-3
DRIVING POSITION
To make fully flat / lift up the seat
cushion
 In addition to being used as a reg-
ular assistant seat, the seatback
can be folded forward (made fully
flat) to form part of the bed. The
seat cushion can also be lifted up
to form a work space for changing
clothes, etc., or space for storage.
lock to keep the cushion in the
down position.
 The cushion is locked when the
seatback is folded forward. Pull the
reclining lever and lift up the seatback. Trying to forcefully pull up
the seatback could result in an
injury or it could damage the seat.
CAUTION
 Make sure that the seat cush-
 To lift up the seat cushion, hold the
front edge of the cushion and raise
it until the lock engages.
 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
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.
Doing so could result in an
injury or it could damage the
seat.
 Do not rest on or put your
weight on the headrest or head
of the seatback when the seatback is folded forward. Doing
so could result in an injury or it
could damage the seat.
 When lowering the seat cover
with items placed in the space
made by lifting the seat cover,
carefully lower the seat to
make sure that it does not
strike any of the stored items.
DRIVING POSITION
SEAT BELTS
WARNING
 Seat belts should be worn at
all times. Before fastening a
front seat belt, always adjust
the driver’s seat to the position
in which you will drive. Seat
belts should be worn across
the hips and adjusted snugly.
Never adjust a seat belt across
the abdomen.
 Never attempt to fasten seat
belts while the vehicle is in
motion.
 Never let a passenger hold a
child on his or her lap while
the vehicle is moving.
The passenger cannot protect
the child from injury in a collision. Children should be
seated in appropriate child
restraints.
 Do not wear a twisted or loose
belt.
 Never use the same belt for
<Driver and passenger seat belts>
more than one person.
 Replace damaged or inoperative belts.
 Replace belts which were in
use during an accident unless
the accident was minor.
 Do not modify the seat belts.
The driver and passenger seat belts
are equipped with an ELR (Emergency Locking Retractor). These
belts are flexible under normal conditions; however, they automatically
lock in an emergency. Belt length
adjustment is not necessary.
NOTE:
 Slowly pull out the seat belt. If
pulled abruptly, it may lock.
 Slowly rewind the belt while
holding the tongue.
To fasten the belt, position the seat
and fit the seat belt snugly without
twisting. Insert the open end of the
tongue into the buckle until it snaps
and engages.
To unfasten the seat belt, push the
release button and disengage the
belt tongue from the buckle.
If the driver tries to drive without
wearing the seat belt, the warning
light will illuminate to warn the driver.
If the tongue of the driver’s side seat
belt is not completely locked into the
buckle, the warning light will illuminate when the ignition switch is
turned to ON or START.
6-5
DRIVING POSITION
Seat belt warning light
To loosen the seat belt, raise the
front end of the adjuster and pull the
belt.
NOTE:
 When the seat belt is not in use,
insert the
buckle.
tongue
into
the
<Important child restraint
precautions>
 U.S. law requires you to use safety
<Center seat belt (Optional)>
To tighten the seat belt, pull the
loose end toward the belt anchorage
until it fits snugly.
6-6
restraints for children who are riding in this vehicle. Many states
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 requirements regarding the safety of children in your vehicle.
 Choose a child restraint system
that complies with federal standards and fits your vehicle. Install
and use it in accordance with the
manufacturer's instructions.
 Children who are too large for child
restraint systems should be seated
and restrained by the seat belts
provided.
<Pregnant woman restraint>
 Pregnant women should check
with their doctors before using seat
belts. In you are in an accident and
wearing a seat belt, significant
pressure can be exerted on the
abdominal area.
 Pregnant woman should place the
lap belt as low as possible, over
the hips and not over the waist.
DRIVING POSITION
Seat belt maintenance
1.Clean the seat belt webbing only
with mild soap or detergent. Avoid
direct sunlight when wiping and
drying the webbing.
2.Do not bleach or dye the seat belts
that may significantly weaken the
webbing.
3.Periodically check the seat belts,
metal parts, buckles, tongues and
anchors for damage and proper
function. Replace the belt assembly if damaged or not functional.
WARNING
 If foreign material gets into the
buckle or it becomes dirty, the
seat belt might not fasten or
unfasten smoothly.
Protect the buckles from foreign material or dirt.
STEERING WHEEL
The steering wheel telescopes 2.95
inches (75 mm) and tilt angle 9.5°.
Position the driver’s seat before
adjusting the steering wheel. Loosen
the lock lever and adjust the steering
wheel to the desired position. After
adjustment, securely tighten the lock
lever.
WARNING
To prevent loss of vehicle control, Do not adjust steering
wheel while driving. Tighten lock
lever securely after adjustment.
6-7
INSTRUMENTS AND CONTROLS
INSTRUMENTS AND CONTROLS
7-1
INSTRUMENTS AND CONTROLS
1. Lighting, Dimmer, Passing, Turn signal, Accelerate and resume switch,
Set and coast button
2. Combination meter with multi-display
function
3. Horn
4. Windshield wiper, Washer,
Hazard warning flasher and
Exhaust brake switch
5. Multi-display select switch
6. Air suspension dump switch (UD2600
and UD3300 equipped with air
suspension)
7. Power mode switch (Allison 1000,
2000 and 2500 series)
8. Cruise Control main switch
9. Mirror heater switch (Optional)
10. Heater or Air conditioner control
11.
12.
13.
14.
15.
16.
Overhead box
Room light
Cigarette lighter
Power socket
Fuse lid
Transmission PTO switch
(Optional)
17. Engine throttle control knob
18. Ashtray
19. Power window switch
20. Front lid knob
21. Clutch pedal
22. Ignition key switch
23. Brake pedal
24.
25.
26.
27.
28.
29.
30.
31.
Accelerator pedal
Transmission gear shift lever
Parking brake valve
Cup holder
Engine warm-up switch
Manual forced regeneration switch
Power mirror switch (Optional)
Automatic transmission
selector lever (Allison 1000, 2000
and 2500 series)
32. Automatic transmission
selector switch (Allison 3000 series)
33. Ashtray
34. Power window switch
7-2
INSTRUMENTS AND CONTROLS
IGNITION KEY SWITCH
The ignition key switch, located on
the right side of the steering column,
has four positions:
LOCK (OFF): This is the position
that turns off the power to the
engine. It is also the position
in which the key can be
inserted and removed and in
which the steering wheel can
be locked. Turning the steering wheel after removing the
key will automatically lock the
steering wheel in the fixed
position to prevent theft.
ACC: This is the position used to
stop the engine. It is also the
position that is used to listen
7-3
to the radio, etc., when
parked, etc., while the engine
is stopped.
ON: This is the position used when
the engine is running. Absolutely do not turn the ignition
key to any other position while
driving.
In addition, if the ambient air
temperature is low when starting the engine, it provides
power to the intake air heater
and air dryer heater.
START: This is the position used to
start the engine. The ignition
key automatically returns to
the
ON
position
when
released.
Absolutely do not turn the ignition key to the START position
after the engine has started.
WARNING
 Absolutely do not move the
vehicle with the ignition key
switch removed or with it in
the LOCK position. The steering wheel could lock and prevent steering.
 Do not turn the ignition key to
any position other than the ON
position while driving.
If turned to the ACC position,
the engine will stop, which will
make it very difficult to turn the
steering wheel and operate the
clutch pedal, and the brakes
will not work as well as normal.
And if turned to the LOCK
position, the steering wheel
could lock and prevent steering, which is dangerous.
INSTRUMENTS AND CONTROLS
CAUTION
Engine stop
 To avoid damage to the start-
ing system, do not turn the
ignition key to the START position during engine operation.
 If the engine should turn over
in the reverse direction, operate the ignition key to stop the
engine. When the engine has
turned over in the reverse
direction, the engine sound
will change and exhaust
smoke will be emitted from the
air intake pipe.
NOTE:
 If the ignition key is difficult to
turn when inserting it and turning 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.
Stop the engine using the ignition
key switch. When it is turned from
ON to LOCK (OFF), the engine will
stop.
Also when the ignition key is turned
from ON to ACC, the engine will
stop.
7-4
INSTRUMENTS AND CONTROLS
METERS AND GAUGES
NOTE:
 The meter indicators might move slightly when the
ignition key is turned to ON position. This is done
to detect the zero position of the meter indicators
and this is not a malfunction.
9. Multi-display monitor
Fuel gauge
10. Illumination control rheoSpeedometer
stat and odo/trip changeTurn signal indicator lights
over switch
Tachometer
Air pressure gauge (Front) 11. Indicator and warning
lights
DEF gauge
Indicator and warning
12. Air pressure gauge
(Rear)
lights
8. Mode select switch
1.
2.
3.
4.
5.
6.
7.
7-5
INSTRUMENTS AND CONTROLS
Speedometer
The needle indicates the vehicle
speed in miles and kilometers per
hour on the speedometer. Observe
the speed limit and make an effort to
drive safely.
TRIP A is displayed, this will be
reset.)
Odometer
(Integrating distance meter)
NOTE:
The odometer indicates in mile the
total distance the vehicle has been
driven.
 The distance after refueling the
vehicle also can be measured in
TRIP B while measuring the distance from the vehicle start
point in TRIP A.
 This switch is combined with
the illumination control rheostat.
It adjusts the brightness of the
instrument cluster. It can be
used when the lighting switch is
set to the 1st or 2nd position.
NOTE:
Odo/trip change-over switch
Pushing the reset knob (less than 1
second) changes the odometer and
trip meter displays as follows:
ODO  TRIP A  TRIP B  ODO
 ...
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
 The
maximum
display
is
1,999,999 miles.
 Pushing the odo/trip switch
when the ignition key is in OFF
position, odometer and TRIP A/
B are displayed for about 45
seconds.
7-6
INSTRUMENTS AND CONTROLS
Trip meter
(Individual trip distance meter)
The trip meter indicates the distance
of individual trips in miles. (The figure shown at right is in 0.1 mile unit.)
The trip meter can register two different trip distances; TRIP A and TRIP
B.
The trip meter A and B displays up to
9999.9 miles. When the distance
surpasses this amount, it returns to
“0”.
and another trip meter continue
measuring.
Hour/Trip hour meter
 Indicates the operating time of the
engine.
 The trip hour meter will be reset to
0 when the mode select switch is
pressed more than 1 second.
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
Tachometer
The needle of the tachometer indicates the engine speed in revolutions per minute.
 The green zone is a guide for economical driving. Drive in the green
zone as much as possible to conserve fuel.
 The red zone shows the overrun
operation zone. Be careful that the
indicator does not enter the red
zone.
Red zone is more than 2,600 rpm.
 When the engine rpm exceeds the
allowable maximum rpm, a warning message will be displayed to
warn the driver.
INSTRUMENTS AND CONTROLS
Air pressure gauge
CAUTION
 Please do not exceed the maxi-
mum allowable rpm. Driving
beyond this range overstresses the engine components and could cause the
engine to malfunction.
This gauge shows the air pressure in
the air reservoir.
If the indicator shows the standard
air pressure while driving, this is normal.
Normal air pressure is:
102 - 121 psi (706 - 834 kPa)
(7.2 - 8.5 kgf/cm2)
WARNING
 If the air pressure gauge indi-
cator is in the red zone and
either the warning light illuminates or the warning buzzer
sounds, stop driving the vehicle. Not doing so could lead to
the brakes not working.
 Do not drive until the air pressure gauge indicator shows
the normal air pressure.
7-8
INSTRUMENTS AND CONTROLS
Engine Coolant Temperature
(ECT) gauge
This gauge indicates the engine
coolant temperature (ECT).
 If the coolant temperature signifi-
cantly increases, an overheat
warning with a 2-phase indication
(amber: moderate, red: severe) will
appear.
WARNING
 If the cap is removed without
allowing the pressure inside
the cooling system to drop,
you could be burned by hot
steam or hot water, so be very
careful when opening the cap.
CAUTION
 Do
 When the gauge indicates nothing,
the ECT is very cold.
When
the
gauge
indicates
between 1 to 8 point, the ETC is
normal.
 When the ECT becomes high
while another screen is displayed
on the multi-display, a beep will
sound twice and the display will
automatically change to the ECT
gauge (except when other warnings are displayed).
7-9
 it is recommended to idle the
engine until the ECT drops, then
stop the engine and check the
engine coolant level (ECL), and
then inspect the cooling system for
leaks.
not suddenly stop the
engine when it has overheated.
Doing so could cause the
engine to seize up.
Keep the engine idling until the
engine coolant temperature
(ECT) drops before turning off
the engine.
INSTRUMENTS AND CONTROLS
Diesel exhaust fluid (DEF) gauge
Low level
DEF empty
The DEF gauge indicates the
approximate amount of DEF in the
aftertreatment DEF tank.
 When the ignition key is turned
OFF position, the indicator returns
to E.
 F denotes FULL, and E denotes
EMPTY. Add DEF before the indicator reaches E.
 When the level in the aftertreat-
 If the level of DEF becomes empty,
ment DEF tank is low, a warning
message will be displayed and a
warning light will illuminate to warn
the driver.
the DEF warning light blinks. The
25% of engine torque reduction is
simultaneously performed.
7 - 10
INSTRUMENTS AND CONTROLS
DEF empty + 1 hour
True empty & Speed limit
CAUTION
 1 hour after the DEF becomes
nearly empty, the engine control
warning light illuminates, the 40%
of engine torque reduction is performed.
7 - 11
 Furthermore,
if the warning
changes to the engine control
warning,
vehicle
speed
is
restricted to 5 mph (8 km/h).
 Once
the DEF Trigger is
achieved, the vehicle will be
limited to 5 mph (8 km/h) after
refuel up to the measurable
amount, or keeping zero vehicle speed for 20 minutes with
engine off or idle.
INSTRUMENTS AND CONTROLS
Fuel gauge
Engine oil pressure gauge
The fuel gauge indicates the approximate amount of fuel in the fuel tank.
 When the ignition key is turned
OFF position, the indicator returns
to E.
 F denotes FULL, and E denotes
EMPTY. Add fuel before the indicator reaches E.
 If regenerate the DPF when the
fuel gauge indicates less than E,
engine system malfunction might
be detected.
In this case, refill the fuel and
regenerate DPF again, and then
confirm that this malfunction is
solved.
This gauge shows the engine oil
pressure.
 The range of 29 to 67 psi (200 to
460 kPa) (2.0 to 4.7 kgf/cm2) is
shown while the engine is running.
The pressure could exceed the
standard pressure when the oil is
cold, but it will return to the standard pressure when the engine
warms up.
 If the engine oil pressure drops
below the specified pressure, the
engine oil pressure warning with a
2-phase indication (amber: moderate, red: severe) will be displayed
to notify the driver.
 For more information regarding the
warning, refer to “Warnings”.
7 - 12
INSTRUMENTS AND CONTROLS
Voltmeter
NOTE:
Engine oil temperature gauge
This meter operates when the ignition key is in the ON position, and it
shows the battery voltage when the
engine is stopped and the generator
charge voltage when the engine is
running.
 The normal value is 12V when the
engine is stopped and 14V when it
is running.
 When charging is not possible
while the engine is running, the
charge warning is displayed to
notify the driver of the malfunction.
 For more information regarding the
warning, refer to “Warnings”.
 This will not decline below the
This gauge shows the engine oil
temperature.
 The range of 194 to 257 °F (90 to
125 °C) is shown while the engine
is running.
 If the engine oil temperature
exceeds the specified temperature, the engine oil temperature
warning a 2-phase indication
(amber: moderate, red: severe) will
be displayed to notify the driver.
 For more information regarding the
warning, refer to “Warnings”.
7 - 13
battery voltage while driving
even if charging is insufficient
or inoperable. Always be conscious of the meter indicator
and check the state of charging.
INSTRUMENTS AND CONTROLS
DPF Soot level gauge
DPF ash level gauge
 Indicates the soot accumulation
 Indicates the ash accumulation
level in the diesel particulate filter
(DPF).
 For details on the diesel particulate
filter (DPF), refer to the “DPF system” section in “INSTRUMENTS
AND CONTROLS”.
 For details on how to display the
gauge, refer to the “Multi-display
monitor” section.
level in the diesel particulate filter
(DPF).
 For details on the DPF ash level
gauge, refer to the “Regular maintenance for the DPF system” section in “VEHICLE SERVICE AND
MAINTENANCE”.
 For details on how to display the
gauge, refer to the “Multi-display
monitor” section.
7 - 14
INSTRUMENTS AND CONTROLS
MULTI-DISPLAY MONITOR
MTM specification vehicles
The multi-display monitor shows
several kinds of information in each
display area.
 MTM specification vehicles:
The left area of the monitor dis
plays a calendar and the time.
ATM specification vehicles:
The left area of the monitor displays ATM select positions, overdrive off (Allison 1000, 2200, 2500
series) and power mode (Allison
3000 series).
 The center area of the monitor displays warnings and icons.
 The right area of the monitor displays warning messages that operate simultaneously with icons and
several multi-gauges.
 The ODO area displays the ODO
meter and other operational messages.
7 - 15
ATM specification vehicles
The multi-display monitor displays
the following information: engine
coolant temperature gauge, calendar, engine oil pressure and temperature gauges, voltmeter, DPF soot
and ash level gauges, operation control display, several maintenance
and inspection items. Furthermore,
other setting items such as date and
language are displayed. If necessary, the multi-display warns the
driver with display items that include
warnings and warning messages.
INSTRUMENTS AND CONTROLS
The screens of the multi-display monitor can be toggled as follows.
7 - 16
INSTRUMENTS AND CONTROLS
Changing the screen of the multidisplay monitor
 The initial screen is displayed
when the ignition key is turned to
the ON position.
 The initial screen changes to the
next screen after 2 seconds.
 After the initial screen display dis-
appears, a warning cannot be displayed on the screen for 10
seconds in order to display the
gauge.
7 - 17
Normal mode
While setting
Briefly press the
button (less than 1
second)
Press and hold the
button (more than 1
second)
Briefly press the
button (less than 1
second)
The value is
increased by 1
MODE
Mode change
Go to settings
SELECT
Change in order
Go to settings
The digit shifts up
RETURN
Change subscreens in reverse
order
Go to settings
The digit shifts
down
Press and hold the
button (more than 1
second)
The value is continuously increased
The screen returns to
normal
The screen returns to
normal
INSTRUMENTS AND CONTROLS
NOTE:
 Inputting and modifying an item
cannot be done while a warning
is displayed.
To input or modify an item while
the warning is displayed, press
the mode select switch for less
than 1 second so that the warning display can be temporarily
cancelled.
The screen will return to the
warning display approximately
60 seconds after the mode
select switch is pressed.
 Setting is not available while
driving the vehicle.
Park the vehicle in a safe location, and then perform settings
such as calendar change or data
input.
EACH SCREEN DISPLAY AND
VALUE INPUT METHOD
<Clock/Calendar display (ATM
specification vehicles)>
<Engine coolant temperature gauge
display>
<Engine oil pressure, Engine oil
temperature gauge display>
<DPF soot level gauge display>
7 - 18
INSTRUMENTS AND CONTROLS
<Voltmeter display>
<Trip management display>
 To change the display to the dis-
tance setting screen, push the
mode select switch or the select
switch for more than 1 second or
turn the return switch for more than
7 - 19
1 second while the operation control screen is displayed. A cursor
will be displayed on the thousands
digit.
 Press the mode select switch to
change a number.
 Press and hold the mode switch to
continuously increase a number.
 Turn the select switch or return
switch to move the cursor.
・The distance can be set by 1 mile
within the range of 0 to 5,000
miles.
・The remaining driving distance is
decreased by 1 mile.
 Set the distance to “0” to reset the
operation control function.
 When the remaining driving distance reaches 50%, 10% or 0% of
the set distance, a notice will
appear on the screen and blink 14
times.
While the monitor displays a
screen other than the operation
control screen, an operation control notice will interrupt the screen
and blink for 14 seconds.
 If the monitor is displaying a warn-
ing indicator, the operation control
notice will not interrupt the warning
indicator display. However, when
the mode switch is pressed to
change the display or the warning
indicator display is cancelled, the
operation control notice will interrupt and blink for 14 seconds.
If the ignition key is turned to the
OFF position while the notice
appears and blinks, the notice will
resume the next time the ignition
key is turned to the ON position.
NOTE:
 Whenever the select switch or
the return switch is turned for
more than 1 second while operating, the display will return to
the normal screen.
 The cursor returns to the thousands digit after the ones digit.
 The indicated remaining driving
distance may be different from
the one that is displayed on trip
meter A or B.
 Setting is not available while
driving the vehicle.
Park the vehicle in a safe loca-
INSTRUMENTS AND CONTROLS
tion, and then input the distance.
<Hour meter display>
The hour meter indicates the total
running time of the engine at a designated engine speed. This helps
determine maintenance and inspection intervals.
 When the mode switch is pressed
for more than 1 second while the
hour meter is displayed, the trip
hour meter is reset to “0.0”.
NOTE:
 The trip hour meter indicates
000.0 while resetting.
 The trip hour meter does not
count while resetting.
<Maintenance and inspection display>
 When turning the select switch (for
 The
hour meter continuously
counts and displays up to 199999
hours.
The minimum unit is 1 hour.
 The trip hour meter displays up to
999.9 hours, and then returns to
0.0 hours.
The minimum unit is 0.1 hour (6
minutes).
<DPF ash level gauge display>
less than 1 second) while the
maintenance and inspection display appears, the ash level gauge
is displayed. Then, when turning
the switch more (for less than 1
second), the general maintenance
and inspection screen is displayed.
 For details on the DPF ash level
gauge, refer to the "Regular maintenance for the DPF" on page 1170.
7 - 20
INSTRUMENTS AND CONTROLS
<Several maintenance and inspection screen displays>
Differential oil
Engine belt
Tire
Coolant
Engine oil
Transmission oil
7 - 21
INSTRUMENTS AND CONTROLS
Air cleaner element
Air dryer
User setting 2
Fuel filter
User setting 1
User setting 3
 To change the display to the input
screen of the periodic replacement
intervals, push the mode select
switch or the select switch for more
7 - 22
INSTRUMENTS AND CONTROLS
than 1 second or turn the return
switch for more than 1 second
while the maintenance and inspection screen is displayed. A cursor
will be displayed on the year position.
 When the mode select switch is
pressed, the number is changed.
・The date can be set as follows.
Year: 2008 to 2038
Month: January to December
Day: 1 to 31
・The distance can be set by 1
mile within the range of 1 to 6
digits (from 0 to 999,999 miles).
・The remaining driving distance
is decreased by 1 mile.
 When the mode select switch is
pressed and held, the number is
continuously increased.
 When the select switch or the
return switch is turned, the cursor
is moved.
・The cursor returns to the distance
position after the date position.
 When the remaining driving distance reaches “0” (the vehicle has
7 - 23
been driven for the set distance) or
the set date comes, a warning and
an item to be replaced are displayed while the parking brake is
applied.
 To reset the maintenance and
inspection display, set the distance
to “0” or set the date to the present
or the past date.
NOTE:
 Whenever the select switch or
the return switch is turned for
more than 1 second while operating, the display will return to
the normal screen.
 The number of the set distance
for replacement may be different
from the one that is displayed
on the trip meter A or B.
 Setting is not available while
driving the vehicle.
Park the vehicle in a safe location, and then input the replacement interval.
<Settings display>
 The remaining driving distance is
preliminarily set to 600 miles in the
user setting 1 as a factory default
setting.
Contact the nearest authorized UD
Trucks dealer for the 600 miles
inspection.
INSTRUMENTS AND CONTROLS
than 1 second in the clock setting
mode, the minutes of the clock will
change to "00" and the display will
return to the normal screen.
・When the minutes are in the 00 to
29 range, the minutes will be reset
to “00”.
・When the minutes in the 30 to 59
range, the hour will advance by 1
hour and the minutes will be reset
to “00”.
<Calendar and clock display>
 To set the calendar and clock dis-
play, press the mode select switch
or the select switch for more than 1
second or turn the return switch for
more than 1 second while the calendar and clock display is shown.
A cursor will be displayed and blink
on the year position.
Clock display: AM 12:00 - 11:59
PM 12:00 - 11:59
 Press the mode select switch while
the cursor blinks to change the
number.
 Press and hold the mode select
switch to continuously increase the
number.
 Turn the select switch or return
switch to move the cursor.
 When the odo/trip switch located
on the right side is pressed for less
7 - 24
INSTRUMENTS AND CONTROLS
CAUTION
 When setting the clock on the
calendar and clock display,
always place the shift lever
(MTM) or selector (ATM) in the
neutral position. The combination meter is equipped with the
shift recognition function that
automatically recognizes the
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
correctly.
NOTE:
 Whenever the select switch or
the return switch is turned for
more than 1 second while operating, the display will return to
the normal screen.
 The cursor returns to the year
position after the minute position.
 Setting is not available while
driving the vehicle.
Park the vehicle in a safe loca7 - 25
tion, and then input the time and
date.
<Language setting screen>
while operating, the display will
return to the normal screen.
 Language can be selected from
English, Chinese and Japanese.
NOTE:
 Setting is not available while
driving the vehicle.
Park the vehicle in a safe location, and then select a language.
 To select language, push the mode
switch or the select switch for more
than 1 second or turn the return
switch for more than 1 second
while the language setting screen
is displayed. Press the mode
switch to select a language. The
selected language will blink.
 When the mode switch or the
select switch is pressed for more
than 1 second or the return switch
is turned for more than 1 second
INSTRUMENTS AND CONTROLS
WARNINGS AND INDICATORS
Mark
Multi-display
Mark
Display
Color
Message
Engine overheat
Red or
Amber Reduce coolant
temp
DEF level low
Re-Fill DEF Tank
DEF tank near empty
Amber Engine is derated
Re-Fill DEF tank
DEF tank is empty
Before Re-Fueling
Re-Fill DEF tank
Red Reduce engine
revolution
Red
Red or
Amber
Red or
Amber
Charging system
error
Check generator belt
Contact Dealer
Engine oil pressure
is low
Contact Dealer (or
Check at Dealer)
Engine oil temp too
high
Reduce engine oil
temperature
Name
Overheat warning
Page
7-9
12-1
DEF low level
warning (Low level)
DEF low level
warning
(Near empty)
7-10
DEF low level
warning
(True empty))
Engine overrun
warning
7-31
Charge warning
7-32
Engine oil pressure
warning
7-32
Engine oil temperature warning
7-37
Display
Message
Engine system
Red or malfunction
Amber Contact Dealer (or
Check at Dealer)
Communication line
error
Check at Dealer
Amber DEF tank is empty
Vehicle speed
limited
Re-Fill DEF tank
Insufficient DEF
quality or failure
Contact Dealer
Insufficient DEF
quality or failure
Amber Engine is derated
Contact Dealer
Insufficient DEF
quality or failure
Vehicle speed
limited
Contact Dealer
Color
Name
Page
Engine system
warning
7-38
Engine communication malfunction
warning
7-40
DEF low level
warning (True empty 7-10
& Speed limit)
DEF insufficient
quality warning
(Initial detected)
DEF insufficient
quality warning
(1 hour after)
7-34
DEF insufficient
quality warning
(4 hours after)
7 - 26
INSTRUMENTS AND CONTROLS
Mark
Display
Message
Insufficient DEF
quality or failure
Contact Dealer
Insufficient DEF
quality or failure
Amber Engine is derated
Contact Dealer
Insufficient DEF
quality or failure
Vehicle speed
limited
Contact Dealer
Engine system
Amber malfunction
Check at Dealer
Vehicle electrical
Red or sys. malfunction
Amber Contact Dealer (or
Check at Dealer)
Communication line
Amber error
Check at Dealer
Color
Name
7 - 27
Mark
SCR system tampering warning
(Initial detected)
SCR system tampering warning
(1 hour after)
7-35
SCR system tampering warning
(4 hours after)
SCR system fault
warning
7-37
Vehicle electrical
system malfunction
warning
7-39
Vehicle electrical
system communication malfunction
warning
7-40
Communication line Meter communicaAmber error
tion malfunction
warning
Check at Dealer
Maintenance and
Amber “Item to be replaced” inspection screen
display
Amber PTO is in operation
Page
Transmission PTO
indicator
7-39
7-23
7-64
Display
Message
Starter overheat
Amber
Waiting time
PTO is operation
Amber Engine start is not
possible
Transmission oil
temp too high
Red
Reduce oil
temperature
ATM system error
Red
Check at Dealer
Engine system
Red or malfunction
Amber Contact Dealer (or
Check at Dealer)
Color
Name
Starter overheat
warning
10-4
PTO engine start
interrupt warning
10-4
ATM fluid
temperature warning 7-41
ATM system
warning
7-42
DPF system warning
3-22
7-74
regenerating
Amber DPF is regenerating DPF
warning
Amber Regeneration
system is disabled
DPF maintenance
Amber
Check at Dealer
IDLE Amber Auto engine shut
STOP
down
O/D Amber
OFF
POWER
Amber
-
Page
3-21
7-72
DPF regeneration
restriction warning
7-72
DPF maintenance
warning
3-23
11-71
Idle shutdown
information
ATM O/D OFF
indicator light
ATM Power mode
indicator light
10-38
7-52
7-52
INSTRUMENTS AND CONTROLS
Warning and indicator lights
No
Tell mark
Name
Name
Page
No
Name
Page
4
Seat belt warning
light
6-6
15
Spare
5
Spare
16
Spare
6
Spare
17
Exhaust gas high
temperature
indicator light
7-50
7
Spare
18
Spare
8
Spare
19
Engine coolant
7-45
level warning light
9
DEF low level
warning light
7-10
20
Tilt lock warning
light
7-48
10
Engine control
warning light
7-43
21
Cruise control “ON”
indicator light
7-60
11
Spare
22
Cruise control
“SET” indicator
light
7-60
12
Spare
23
Parking brake
warning light
7-47
13
DPF clogging
warning light
3-21
7-70
24
Brake warning light
7-47
14
Intake air heater
indicator light
7-51
25
ABS warning light
7-44
No
Tell mark
Page
1
Left turn signal
and hazard indicator light
2
HIGH beam indicator light
7-52
3
Right turn signal
and hazard indicator light
7-51
7-51
Tell mark
7 - 28
INSTRUMENTS AND CONTROLS
No
Tell mark
Name
Page
26
Spare
27
Exhaust brake
indicator light
28
Spare
29
ATM shift limit
warning light
7-49
30
ATM maintenance
information light
7-50
31
Spare
32
Spare
33
Spare
34
Spare
35
Spare
36
Spare
7 - 29
7-51
No
Tell mark
Name
Page
7-43
37
Spare
38
Spare
39
Spare
40
Spare
41
Air pressure
warning light
INSTRUMENTS AND CONTROLS
BUZZERS
Buzzer list in cabin
No.
1
2
Warning item
Portion
Pattern
Low air pressure
Remarks
Warning light and
synchronizing
Brake
In cabin
Continuous sound
3
ATM fluid temperature
4
Tilt lock
5
6
7
Engine system
Engine oil pressure
Overheat
8
Engine coolant level
9
10
Engine oil temperature
DPF system
11
Multiple inputs
Intermittent sound 1
(short intermittent sound)
12
ATM reverse
Intermittent sound 2
(normal intermittent sound)
13
Interrupting buzzer on engine
coolant temperature gauge
Intermittent sound 3
(intermittent sound twice)
Warning message and
synchronizing
Warning light and
synchronizing
Warning message and
synchronizing
Continuous sound
In combination
meter
Warning light and
synchronizing
Warning message and
synchronizing
Select position “R” and
synchronizing
Display switching
timing
When multiple warnings occur at the same time.
When two warnings from No.5 to 10 occur at the same time, it changes to intermittent sound No.11.
If the No.12 or No.13 warning occurs while the meter buzzer is sounding, the intermittent buzzer of No.12 or
No.13 is given priority.
7 - 30
INSTRUMENTS AND CONTROLS
WARNINGS
Engine overrun warning
When necessary, the multi-display
displays warnings while also displaying a warning message and comments in order to warn the driver, or
warning lights are illuminated.
When the engine rpm exceeds the
maximum allowable rpm, the warning and warning message display
will turn on to warn the driver.
 The basic pattern for the warning
display contents is given below.
NOTE:
 The multi-display also displays
warning messages, comments,
a calendar, clock, trip management, inspection and servicing
message display, range select
position
(ATM specification
vehicles) in addition to warning
displays.
7 - 31
 The tachometer’s red zone shows
the overrun speed range, so make
sure that the indicator does not
enter the red zone.
CAUTION
 Please do not exceed the maxi-
mum allowable rpm. Driving
beyond this range overstresses the engine components and could cause the
engine to malfunction.
INSTRUMENTS AND CONTROLS
Engine oil pressure warning
Charge warning
If a problem occurs with the charging
circuit while driving, the warning,
warning message, and comments
will be displayed to warn the driver.
 Immediately stop the vehicle in a
safe location, stop the engine, and
check the generator drive belt tension and check for damage to the
belt.
 If the belt is properly tensioned, the
charging system could be faulty, so
contact the nearest authorized UD
Trucks dealer. If the charging is
insufficient, refer to the Emergency
Starting items in “JUMP STARTING”.
CAUTION
 Do not drive while the warning
display is shown. Doing so
could result in damage to the
electronic components due to
over-voltage or a discharged
battery.
If the engine oil pressure decreases
below a specified pressure while the
engine is running, an amber warning
(moderate), a warning message and
comments will be displayed.
If the engine oil pressure decreases
further, the color of the warning will
turn red (severe), and at the same
time a buzzer will sound to warn the
driver.
 When this warning message is dis-
played, immediately stop the vehicle in a safe location, stop the
engine, and check the engine oil
level and look for oil leaks.
 If there is an oil leak or other problems, the vehicle must be
inspected and repaired. Contact
the nearest authorized UD Trucks
dealer.
7 - 32
INSTRUMENTS AND CONTROLS
CAUTION
 The engine protection func-
WARNING
 Be careful not to get burned
during inspections conducted
immediately
after
driving
because the engine oil is still
very hot.
7 - 33
tion may provide torque derating to prevent the engine from
being damaged, so have it
inspected and serviced by the
nearest authorized UD Trucks
dealer.
 Absolutely do not drive while
the warning display is shown.
A drop in the oil pressure
could cause the engine to
seize up.
DEF low level warning
When the level of DEF in the tank is
low, this warning and warning message are displayed and a warning
light illuminates to warn the driver.
 Add the specified DEF as soon as
possible when this warning is displayed.
INSTRUMENTS AND CONTROLS
NOTE:
DEF insufficient quality warning
 Try to add DEF ahead of time so
When refilling the DEF tank with liquid other than the specified DEF, the
warning, warning message and
warning light illuminate. When the
warning illuminates, drain the liquid
that was used to refill the tank, and
refill again using the specified urea
water solution.
that the tank does not become
empty.
 After the ignition key is turned
to the ON position, the DEF low
level warning light will be illuminated for about 1 seconds to
check the system.
Initial detected + 1 hour
1 hour after an insufficient DEF quality is detected, engine torque is
reduced by 25%.
Initial detected
Once an insufficient DEF quality is
detected, a warning will be displayed, and a warning light will be
illuminated to warn the driver.
7 - 34
INSTRUMENTS AND CONTROLS
Initial detected + 4 hours
4 hours after an insufficient DEF
quality is detected, engine torque is
reduced by 40%. Furthermore, the
vehicle speed is restricted to 5 mph
(8km/h) when diesel fuel is refueled
up to measurable level, or after
keeping zero vehicle speed for 20
minutes with engine off or idle. However, by first restart or with service
tool DTC cleaning, engine torque is
recovered to 25% decrease.
7 - 35
SCR system tampering warning
CAUTION
 These warning messages are
displayed, contact the nearest
authorized UD Trucks dealer
for inspection and maintenance.
NOTE:
 Only use DEF specified by UD
Trucks
that
satisfies
ISO22241-1 specification.
the
SCR system is designed to be tamper resistant.
When the SCR system malfunctions
due to the following causes, this
warning and warning message are
displayed and the warning light illuminates.
 Disconnected DEF tank level
sensor
 Blocked DEF line or dosing unit
 Disconnected DEF dosing unit
 Disconnected DEF pump
 Disconnected SCR wiring harness
 Disconnected NOx sensor
 Disconnected exhaust temperature sensor
 Disconnected DEF temperature
sensor
INSTRUMENTS AND CONTROLS
Initial detected
Initial detected + 1 hour
Initial detected + 4 hours
Once a tampering is detected, a
warning will be displayed, and a
warning light will be illuminated to
warn the driver.
1 hour after a tampering is detected,
engine torque is reduced by 25%.
4 hours after a tampering is
detected, engine torque is reduced
by 40%.
Furthermore, the vehicle speed is
restricted to 5 mph (8 km/h) when
diesel fuel is refueled up to measurable level, or after keeping zero vehicle speed for 20 minutes with engine
off or idle.
7 - 36
INSTRUMENTS AND CONTROLS
CAUTION
 These warning messages are
displayed, contact the nearest
authorized UD Trucks dealer
for inspection and maintenance.
SCR system fault warning
Engine oil temperature warning
When the SCR system fault, this
warning and warning message are
displayed and the warning light illuminates to warn the driver.
When the engine oil temperature
exceeds a specified temperature, an
amber warning (moderate), a warning message and comments are displayed.
If the engine oil temperature
increases further, the color of the
warning will turn red (severe), and at
the same time a buzzer will sound to
warn the driver.
 Immediately stop the vehicle in a
CAUTION
 This warning message is dis-
played, contact the nearest
authorized UD Trucks dealer
for inspection and maintenance.
7 - 37
safe location and continue fast
idling until the engine oil temperature drops.
 After the engine oil temperature
drops, stop the engine and check
the engine oil level, and look for
engine oil leaks.
 If the engine oil temperature does
not decrease, have the system
inspected and serviced by the
nearest authorized UD Trucks
dealer.
INSTRUMENTS AND CONTROLS
CAUTION
 The engine protection func-
tion may provide torque derating to prevent the engine from
being damaged, so have it
inspected and serviced by the
nearest authorized UD Trucks
dealer.
 Do not continue driving when
the warning is displayed and
the buzzer sounds.
WARNING
 Be careful not to get burned
Engine system warning
When the engine system malfunctions due to the following causes, an
amber warning (moderate), a warning message and comments are displayed.
If a malfunction becomes more
severe, the color of the warning will
turn red (severe), and at the same
time a buzzer will sound to warn the
driver.
 Engine control system malfunction
 DPF system malfunction
during inspections conducted
immediately
after
driving
because the engine oil is still
very hot.
7 - 38
INSTRUMENTS AND CONTROLS
CAUTION
 Do not drive while the engine
system warning is displayed.
The engine protection function may provide torque derating to prevent the engine from
being damaged, so have it
inspected and serviced by the
nearest authorized UD Trucks
dealer.
 If the engine stops or is clearly
producing an abnormal sound
or vibration, contact the nearest authorized UD Trucks
dealer.
Vehicle electrical system
malfunction warning
Meter communication malfunction
warning
When the vehicle electrical system
malfunctions due to following
causes, an amber warning (moderate) or red warning (severe), a warning message and comments are
displayed.
 Accelerator pedal position (APP)
sensor malfunction
 Power relay malfunction
 Switch malfunction
When the meter communication malfunctions, a warning, a warning message and comments are displayed.
When this warning appears, the following will or may occur.
 This
warning message is displayed, have it checked at the
nearest authorized UD Trucks
dealer.
7 - 39
 Items that use CAN communica-
tion such as the tachometer,
engine oil pressure gauge, warnings for engine, etc. may not work
properly.
 If the engine control warning light
illuminates, all communications
with the vehicle will stop.
INSTRUMENTS AND CONTROLS
 This
warning message is displayed, have it checked at the
nearest authorized UD Trucks
dealer.
Engine communication
malfunction warning
When the engine communication
malfunctions, a warning, a warning
message and comments are displayed.
When this warning appears, the following will occur.
 No warnings related to the engine
will appear.
 Engine control warning light will
Vehicle electrical system
communication malfunction
warning
When the vehicle communication
malfunctions, a warning, a warning
message and comments are displayed.
When this warning appears, the following will occur.
 No warnings related to the vehicle
electrical system will appear.
illuminate.
 This
 This
warning message is displayed, have it checked at the
nearest authorized UD Trucks
dealer.
warning message is displayed, have it checked at the
nearest authorized UD Trucks
dealer.
7 - 40
INSTRUMENTS AND CONTROLS
ATM fluid temperature warning
If automatic transmission fluid temperature rises above 250°F (121°C),
the warning, warning message and
comments are displayed and the
warning buzzer will sound.
CAUTION
CAUTION
 If the warning, warning mes-
Failures to take the following
precautions may result in serious transmission damage:
 When the warnings are displayed and a warning buzzer is
sounding, do not stop the
engine until you have performed steps 2-5.
 Never operate the vehicle
when the warnings are displayed.
sage and comments are displayed and the buzzer sounds,
stop the vehicle and operate
the engine at fast idle until the
fluid temperature returns to
normal. Do not stop the engine
immediately. If the warnings
remains on, have the transmission and cooling system
checked and repaired. Do not
operate the vehicle.
1.When the warnings are displayed
and the warning buzzer sounds,
immediately move the vehicle to a
safe place. Apply the parking
brake and shift the transmission to
the neutral position.
7 - 41
2.Operate the engine at a fast idle
with the throttle control knob
located to the left of the steering
column.
3.Idle the engine until the engine
coolant temperature (ECT) gauge
needle points to the middle of the
gauge.
4.While idling the engine, check the
fluid level. If the level is on the low
side of the HOT band, add fluid
through the filler tube. Do not overfill.
5.If the warning light still remains on,
stop the engine. Have the trans-
INSTRUMENTS AND CONTROLS
mission checked by an authorized
UD Trucks dealer.
ATM system warning
The automatic transmission system
warning, warning message and comments will be displayed when the
transmission control module (TCM)
detects a malfunction.
2.When a malfunction occurs and
shifting becomes impossible in the
N position, turn the ignition key to
OFF position to stop the engine
and restart it. When malfunction is
intermittent, the TCM resets and
driving becomes possible.
3.If the warnings still remains on,
stop the engine. Have the transmission checked by an authorized
UD Trucks dealer.
CAUTION
 When a vehicle is stopped and
1.The automatic transmission system warnings will be displayed
when the TCM detects a malfunction. At this time a diagnostic trouble code (DTC) is set in the TCM
and transmission cannot be
shifted. Depending on the malfunction, the TCM does not respond to
gear shifting operation and the current gear is fixed.
engine speed is raised for a
long time with the gear shifted
to other than the N position,
fluid temperature increases
and the transmission will be
damaged. Do not keep the
engine in that circumstance
more than 30 seconds.
7 - 42
INSTRUMENTS AND CONTROLS
WARNING AND
INDICATOR LIGHTS
Engine control warning light
This warning light illuminates when a
problem occurs in the engine control
system.
 This light turns off after about 16
seconds or engine is started and
the system is normal.
Air pressure warning light
If the air pressure drops and the
meter indicator falls below the red
zone, the warning light will turn on
and the buzzer will sound to warn
the driver. The buzzer will stop when
the vehicle stops and the parking
brake is pulled to the park position.
Red zone: 78 psi (539 kPa)
(5.5 kgf/cm2) or less.
 If the warning light illuminates,
immediately stop the vehicle in a
safe location and leave the engine
idling to increase the air pressure.
 If the warning light does not turn off
even though idling is continued,
contact the nearest authorized UD
Trucks dealer.
7 - 43
Lights that illuminate when the ignition key is turned to the ON position.
WARNING
 Immediately stop driving if the
low air pressure warning light
illuminates, the warning buzzer
sounds, or the air pressure
gauge indicator is in the red
zone. Not doing so is very dangerous because the brakes,
clutch, or gearshift could stop
working.
 Immediately stop the vehicle in
a safe location when this warning light illuminates. Continuing to drive in this condition
could cause the spring brake
to operate, which would make
driving impossible.
Operation status
When
normal
When
abnormal
Ignition key ON
before start the
engine
ON
(about 15
seconds)
-
Engine running
and Engine stall
OFF
ON
INSTRUMENTS AND CONTROLS
CAUTION
is empty (the level is zero) and
the engine control warning light
illuminates, add DEF. However,
the engine control warning light
may not turn off.
In this case, turn the ignition key
to the OFF position, wait for
about 10 seconds and then
restart the engine. Then, if the
engine control warning light
turns off, there is no malfunction in the engine control system.
ABS warning light
The warning light comes on when
there is an abnormality in the ABS
(Anti-lock Brake System). Under normal operation, the warning light
comes on with the engine stopped
and the ignition key turned to the ON
position. The warning light goes out
after about 3.0 seconds if there is no
malfunction in the ABS.
 Do not drive while the engine
control light is illuminated.
This could cause decreased
fuel economy or decreased
power, so have it inspected
and serviced by the nearest
authorized UD Trucks dealer.
 If the engine stops or is clearly
producing an abnormal sound
or vibration, contact the nearest authorized UD Trucks
dealer.
NOTE:
 When the amount of aftertreat-
ment diesel exhaust fluid (DEF)
7 - 44
INSTRUMENTS AND CONTROLS
WARNING
 If the vehicle is operated with
the warning light illuminated,
stable braking may not be
obtained depending on road
conditions. Have the vehicle
checked and repaired by an
authorized UD Trucks dealer or
other qualified service facility.
NOTE:
 Take care since the anti-lock
brake system serves as only a
conventional
brake
system
while the warning light is on.
7 - 45
Engine coolant level warning light
When the engine coolant level
decreases below a specified level,
the warning light comes on and at
the same time a buzzer will sound
to warn the driver.
 If the warning light comes on and
the temperature gauge indicator is
still within the normal zone, immediately stop the vehicle in a safe
location, stop the engine, and then
add engine coolant. When supplying the coolant, also check the
cooling system for leaks.
 If the warning light comes on and
the temperature gauge indicator is
approaching to the high temperature zone or in the high temperature zone, keep the engine idling
and do not touch the coolant reservoir tank cap until the engine coolant temperature drops to the
normal range.
INSTRUMENTS AND CONTROLS
CAUTION
 Do not continue driving when
the warning light is illuminated
and the buzzer sounds.
 Continuing to drive with too little coolant should absolutely
not be done because it could
cause overheating.
1.When the warning light comes on
and the warning buzzer sounds,
immediately move the vehicle to a
safe place. Apply the parking
brake and shift the transmission to
the neutral position or P (Park)
position.
2.After the engine cooling system
cools down, open the radiator filler
cap.
If the engine coolant level is below
the bottom of the filler neck, add
the proper coolant solution until
the level reaches the bottom of the
filler neck.
3.Also check the engine coolant
level in the coolant reservoir tank.
If coolant level in the reservoir tank
is below the LOW line, coolant will
be insufficient. Add the coolant to
the HIGH line on the coolant reservoir tank. If an emergency exists
and it is not possible to add the
proper coolant solution, then add
plain municipally supplied water. If
plain water is added in an emergency, restore the genuine Long
Life Coolant that has been diluted
50% as soon as possible.
WARNING
To avoid serious injury from hot
coolant or steam release:
 Do not open the radiator filler
cap while the engine cooling
system is still hot; wait until it
cools. If the radiator cap is
removed right after the engine
is shut off, scalding fluid and
steam may blow out under
pressure and cause serious
burn injuries.
 Be
extremely careful when
opening the radiator filler cap.
Place a thick cloth on the cap
and slowly loosen it to allow a
reduction in pressure in the
cooling system.
CAUTION
 Do not add water or coolant
when engine is hot to avoid
serious damage to the cylinder
block or head.
 Do not operate the engine for a
prolonged period without coolant solution.
4.Check the cooling system for coolant leaks and radiator blockage. If
required have the cooling system
repaired by an authorized UD
Trucks dealer or other qualified
service facility.
7 - 46
INSTRUMENTS AND CONTROLS
Parking brake warning light
The warning light comes on when
the parking brake valve is engaged.
The light also comes on when air
pressure drops below approximately
54 psi (373 kPa) (3.8 kgf/cm2). Be
sure that the warning light is off
before moving the vehicle.
If the air pressure drops to approximately 40 psi (275 kPa) (2.8 kgf/
cm2) in both front and rear brake
system, the parking brake will automatically be applied.
In this case, refer to the item
“Releasing parking brake” in In case
of emergency / Trouble-shooting.
7 - 47
WARNING
Brake warning light
 Never operate the vehicle with
the warning light on. The service brake will not provide normal braking action. The vehicle
should be towed and not to
driven to the UD Trucks dealer.
<Brake shoe clearance (Not applicable to UD3300)>
The warning light comes on and the
warning buzzer sounds if brake shoe
clearance is excessive or if there is a
brake system malfunction. The
buzzer will stop when the vehicle is
stopped and the parking brake is
engaged.
Have the brake system checked and
repaired by an authorized UD Trucks
dealer or a qualified brake service
facility.
INSTRUMENTS AND CONTROLS
WARNING
WARNING
 Never operate the vehicle with
 Never drive the vehicle while
the warning light on and a
warning buzzer sounding. The
brakes may provide less effective action or become totally
ineffective.
the warning light is on and the
warning buzzer is sounding.
The brakes will not provide
normal braking effectiveness
and may become totally ineffective. Determine cause of
brake fluid loss, repair system,
and refill brake fluid.
<Brake fluid level (Not applicable to
UD3300)>
When the fluid level in the brake fluid
reservoir drops below the normal
operating level, the warning light
comes on and a warning buzzer
sounds. The buzzer stops when the
vehicle is stopped and the parking
brake is engaged.
Have the brake system checked and
repaired by an authorized UD Trucks
dealer or a qualified brake service
facility.
Tilt lock warning light
If the tilt lock of the cab is improperly
latched, the warning light will come
on and the warning buzzer will
sound.
When the tilt lock is secure, the
warning light will go off and the warning buzzer will stop sounding.
When the warning light comes on
and the warning buzzer sounds,
immediately move the vehicle to a
safe place. To do this, apply the
brake slowly.
Correct the tilt lock of the cab, and
make sure that the cab is securely
locked and the warning light is off. If
the warning light does not turn off,
have the tilt lock system checked at
7 - 48
INSTRUMENTS AND CONTROLS
an authorized UD Trucks dealer or
other qualified service facility.
WARNING
 Do not operate the vehicle
when the warning light is on
and the warning buzzer is
sounding. Otherwise, if the
brake is used during driving,
the cab could raise, causing a
serious accident.
7 - 49
ATM shift limit warning light
(Allison 1000, 2200 and 2500
series)
The warning light comes on when
there has been an error in operation
or when the safety circuit has been
activated. It indicates that the
change from the current range to
another specified range cannot be
done.
For Allison 3000 series, refer to the
"SHIFT LIMIT warning message" on
page 10-30.
CAUTION
 Do not drive the vehicle if the
warning light remains on. Have
the vehicle checked by an
authorized UD Trucks dealer
Shift limit
Under the following conditions, the
transmission control module (TCM)
prohibits gear shifting for the purpose of transmission protection, as
the reaction of diagnostic trouble
code (DTC) or a safety measure of
optional functions.
1.Idling too high: At 1,000 rpm or
higher, shifting from the Neutral is
prohibited.
2.Forward/reverse
change-over:
When the vehicle is moving at over
a specified speed, forward/reverse
change-over is prohibited. If this
occurs, stop the vehicle, and shift
first to P or N. then depress the
brake pedal and shift to the
desired driving range.
3.Transmission failure: When the
TCM receives abnormal signals,
gear shifting is limited to protect
INSTRUMENTS AND CONTROLS
the system from major troubles.
The SHIFT LIMIT warning light
and the ATM SYSTEM warning
light illuminate and transmission is
fixed to a safety range. When the
lock up clutch is engaged, it will be
disengaged.
Exhaust gas high temperature
indicator light
ATM maintenance information
light
This indicator does not indicate a
system malfunction, however it
alerts the driver of the high temperature of the system.
This light will illuminate when the
ATM should be serviced as soon as
possible for its components such as
fluid, filter or clutch.
DANGER
 Exhaust
component
and
exhaust gas are at extremely
high temperature when this
warning light becomes on.
 When parking vehicle keep
away from people, or any flammable materials, vapors or
structures.
For details, refer to the section
"Automatic transmission maintenance schedule" on page 11-12.
CAUTION
 Do not continue driving the
vehicle with the ATM maintenance information light on.
Doing so may cause damage
to the ATM.
7 - 50
INSTRUMENTS AND CONTROLS
Turn signal and hazard indicator
light
When the turn signal switch is operated, the left or right indicator light
flashes. When the hazard warning
flasher switch is turned to the ON
position, the left and right indicator
lights flash simultaneously.
Exhaust brake indicator light
Intake air heater indicator light
The indicator light will come on if the
exhaust brake switch is turned on
and the exhaust brake is operating.
The indicator light will come on when
the ignition key is turned to the ON
position to preheat intake air. When
the light goes off, the engine is ready
to start.
NOTE:
 Do not crank the engine until the
indicator light goes off.
The intake air heater will not activate
unless the engine coolant temperature drops below normal operating
temperature.
The engine coolant temperature
determines whether the indicator
light stays off or comes on when the
ignition key is turned to the ON position.
7 - 51
INSTRUMENTS AND CONTROLS
High beam indicator light
This indicator light comes on when
the dimmer switch is set to the high
beam position with the lighting
switch in the second position or the
passing switch is operated.
Automatic transmission O/D OFF
indicator light (Allison 1000, 2200
and 2500 series)
This indicator comes on when the
overdrive switch is turned OFF. The
overdrive switch is located on the
selector lever.
POWER MODE indicator light
The indicator light will come on when
the power mode switch is set to the
power mode.
While operating, the indicator light in
the switch come on. (Allison 1000,
2200, 2500 series)
Allison 1000, 2200, 2500 series
While operating, both the indicator
light in the power mode switch and
the indicator light on the multi-display monitor come on. (Allison 3000
series)
7 - 52
INSTRUMENTS AND CONTROLS
SWITCHES AND BUTTONS
Engine throttle control knob
Allison 3000 series
The automatic adjustment of engine
idling speed
 When the knob is turned all the
Allison 3000 series
7 - 53
The engine throttle control knob,
located to the left of the steering column, can be used to adjust engine
idling speed. Normal engine idling
speed is 550 rpm. If equipped with
automatic transmission, make sure
the engine idling speed is 550 rpm at
the forward range.
way to the left (counterclockwise),
automatic idling mode will be
reached, and the engine idling
speed will be adjusted automatically according to the temperature
of the engine coolant.
 Normally, this should be turned all
the way to the left (counterclockwise).
INSTRUMENTS AND CONTROLS
CAUTION
 The manual adjustment mode
is canceled while driving. Set
to the automatic adjustment
mode while driving.
 Turn the knob carefully, or the
engine speed may increase too
quickly.
The manual adjustment of engine
idling speed
 Stop the vehicle and apply the
parking brake before performing
manual adjustment.
 When the knob is turned to the
right (clockwise), the mode
changes from automatic idling
mode to manual adjustment mode,
the engine speed will increase,
and adjustment up to about 980
rpm will become possible.
Engine warm-up switch
 The engine warm-up system oper-
ates the exhaust shutter during
idling to shorten the engine warmup time and temperature of the
engine coolant.
Note that the engine warm-up system can only be used when the
vehicle is stopped.
 For information regarding the operation method, refer to the section
“To quickly warm up the engine” of
Vehicle Operation.
7 - 54
INSTRUMENTS AND CONTROLS
WARNING
 Do not warm up the engine in
areas with poor ventilation.
engine speed is increased, or
the clutch pedal is depressed.
 If the engine coolant temperature rises abnormally when the
engine warm-up switch is ON,
the engine warm-up system will
automatically cancel it.
Windshield wiper, washer and
exhaust brake switch
Windshield wiper and washer
CAUTION
 When
not warming up the
engine, leave the engine warmup switch OFF. Leaving it on
could worsen the fuel economy when idling.
 Leave the engine warm-up
switch OFF when the transmission PTO is operating.
 When turning ON the engine
warm-up switch, put the throttle control knob in the AUTO
position. Turning the engine
warm-up switch to ON when at
high speed could generate
black smoke, although this
only occurs rarely.
NOTE:
 Even if the engine warm-up
switch is ON, the engine warmup system will cancel it if the
vehicle is being driven, the
7 - 55
The windshield wiper control is
located on the lever mounted on the
right side of the steering column.
 Turning this switch turns on the
wipers, and washer liquid is
sprayed while pushing the switch
on the end of the lever.
INT: Intermittent operation
LO: Operates at a low speed
HI: Operates at a high speed
INSTRUMENTS AND CONTROLS
 Operating the wipers when the
wiper blades are stuck or frozen to
the glass will cause the wiper stop
function to operate and temporarily
stop the wipers (for about 10 seconds). When this happens, be sure
to turn off the wiper switch and
remove what is causing the wiper
blades to stick before operating
the wipers again.
WARNING
 Do not use cooling system
solution in the windshield
washer fluid reservoir. When
sprayed on the windshield,
cooling system solution can
significantly affect visibility.
 To reduce the possibility of
washer fluid freezing on the
windshield which may reduce
visibility, use the defroster to
warm the windshield.
CAUTION
Exhaust brake
 Do not operate the windshield
wipers when the windshield is
dry. Dry wiper operation will
scratch the windshield.
 To avoid damage to the washer
motor, do not operate the
windshield washer continuously for more than 20 seconds or with no washer fluid in
the tank.
 To avoid damage to the wiper
blades, do not operate the wipers when the windshield is
iced over.
 The windshield wiper motor is
protected by a circuit breaker
in addition to a fuse. If the
motor overheats, due to overload caused by heavy snow,
etc., the wiper will remain
stopped until the motor cools.
Be sure to have the cause of
the overload corrected.
Operating instructions for exhaust
brake
Exhaust brake provides additional
engine braking effect. Use it as an
auxiliary brake when descending a
prolonged grade or when decelerating from high speeds. The exhaust
brake is controlled by the exhaust
brake switch lever located on the
right side of the steering column.
To apply the exhaust brake, move
the lever upward to the ON position
with the accelerator and clutch pedals released and shift gear in other
than neutral. An indicator light on the
instrument panel comes on when the
7 - 56
INSTRUMENTS AND CONTROLS
lever is in the ON position and the
exhaust brake is operating.
The exhaust brake is activated only
when both clutch and accelerator
pedals are released. The purpose of
these provisions is to protect the
engine and to improve driveability.
To release the exhaust brake, move
the lever downward to the OFF position. Depressing either the accelerator or clutch pedal can release the
exhaust brake, but it is preferable to
use the lever to release the exhaust
brake.
NOTE:
 The wheels could slip when
using the exhaust brake while
driving on slippery roads or
over bumps, etc., which could
cause the ABS to operate and
the exhaust brake to be temporarily cancelled and the indicator light to turn off, but this is
normal ABS operation and is
not a problem. Try to drive carefully taking into consideration
the road conditions, the intervehicular distance, and other
factors.
7 - 57
If the exhaust brake is released by
depressing the accelerator pedal
suddenly and not by operating the
lever, it may cause fuel injection into
the engine with a blocked exhaust
system and subsequent puff of black
smoke and possible exhaust pipe
overheating.
Lighting, dimmer, passing and
turn signal switch
While the vehicle is stationed, confirm exhaust brake actuation by following procedures:
Lighting
This switch lever mounted on the left
side of the steering column operates
and dims the headlights. It also
serves as a turn signal and passing
switch.
1.Move the exhaust brake switch
lever upward to the ON position
2.Confirm that the exhaust brake
indicator light illuminates and
that the engine sound changes
at the same time.
Turn the knob on the end of the
switch lever to the 1st or 2nd position
to operate the following lights.
INSTRUMENTS AND CONTROLS
Light name
Tail light
License plate light
Front position light
Instrument cluster illumination light
Heater or Air conditioner
control illumination light
Automatic transmission
selector control illumination light
Clearance and identification light
Headlight
*Daytime running light
Knob
position
1st
2nd
* The daytime running lights comes
Dimmer, passing and turn signal
on when:
 The ignition key is turned ON.
 The headlight is turned off (with
the lighting switch in the OFF or
1st position).
 The parking brake is released.
(After the headlight comes on, it
will not turn off when operating the
parking brake.)
NOTE:
 If the lighting switch is in the 1st
position, daytime running light
does not go out by turning off
the key switch. The light goes
out when the lighting switch is
turned off.
To operate the left turn signal, pull
the turn lever on the left side of the
steering column down beyond the
resistance. To operate the right turn
signal, push the lever up beyond the
resistance. The lever will automatically return to the neutral position
after the turn is completed. When
operating the left or right signal, confirm that the TURN SIGNAL AND
HAZARD indicator light flashes.
When the ON-OFF intervals are
unusually short, the bulb is probably
burned out.
7 - 58
INSTRUMENTS AND CONTROLS
WARNING
Hazard warning flasher switch
Cruise Control is a device that allows
a vehicle to be driven at a set constant speed without depressing the
accelerator pedal with your foot. This
is useful when driving on expressways and at other times when there
is no need to accelerate or brake frequently. Cruise Control is engaged
by switching it on at the speed you
want to maintain.
 Replace the burned-out bulb
as soon as possible.
To change the headlights to high
beam, push the turn lever forward.
To return the headlights to low beam
pull the lever to its normal position.
An indicator light on the instrument
panel comes on when the headlights
are on high beam.
The headlight high beams can be
momentarily operated as a signal
when passing another vehicle by
pulling the turn lever towards the
driver. The lever will return to the
neutral position when released.
Return the headlights to the low
beam position as a courtesy when
overtaking vehicles or meeting
oncoming traffic.
The hazard warning flasher switch is
located on the lever mounted on the
right side of the steering column.
Use the switch to warn approaching
vehicles during an emergency stop or
other extraordinary conditions. Pull the
switch lever to activate the hazard
warning flashers. When the switch is
operated, both the outside left and
right turn signals and TURN SIGNAL
AND HAZARD indicator lights flash.
Pull the switch lever to turn off the
flashers. The switch can be used with
the ignition key in any position.
NOTE:
 Turn flasher signals do not work
when the switch is operating.
7 - 59
Cruise Control
INSTRUMENTS AND CONTROLS
WARNING
To prevent loss of control and an
accident, do not use Cruise Control under the following road
conditions.
 When the roads are slippery,
such as when they are icy or
snowy or wet.
 When
descending
steep
slopes and engine braking is
not sufficient, thus allowing
the vehicle to exceed the set
speed.
 When driving in traffic conditions that require frequent
acceleration and deceleration,
such as roads with heavy traffic on city streets, winding
roads or roads with sharp
curves.
Cruise Control operation instructions
To set Cruise Control to preferred
constant speed
1.Make sure the exhaust brake
switch is in the OFF position.
2.Turn the Cruise Control main
switch to the ON position. Confirm
that the Cruise Control ON indicator light is illuminated.
3.When the preferred speed is
reached, press and release the
Cruise Control Set and Coast Button located at the end of the combination switch.
7 - 60
INSTRUMENTS AND CONTROLS
To increase the set speed
<Acceleration pedal operation>
There are three ways to increase
speed:
 Depress the accelerator pedal to
<Tip up operation>
 Press and immediately release
(within 0.5 second) the Accelerate
and Resume switch to increase
the set speed 0.6 mph (1 km/h) at
a time.
4.Remove your foot from the accelerator pedal.
To temporarily accelerate
Accelerate by depressing the accelerator pedal.
You can then return to the originally
set speed by removing your foot
from the accelerator pedal and
allowing the vehicle to gradually slow
down to the set speed.
increase to the preferred speed
quickly, and when the preferred
speed is reached, press and
release the Set and Coast Button
to set the speed.
<Set acceleration operation>
 Press and hold the Accelerate and
Resume switch until the preferred
speed is reached, and then
release the switch to set the
speed.
To decrease the set speed
There are three ways to decrease
speed:
<Tip down operation>
 Press and immediately release
(within 0.5 second) the Set and
Coast Button to decrease the set
speed 0.6 mph (1 km/h) at a time.
7 - 61
INSTRUMENTS AND CONTROLS
<Set and Coast operation>
 Press and hold the Set and Coast
Button until the preferred speed is
reached, and then release the button to set the speed.
NOTE:
 If you continue to press and
hold the Set and Coast Button,
the speed will not drop below
approximately 22 mph (35 km/h),
it is set at a speed of approximately 22 mph (35 km/h).
Set and Coast Button to set the
speed.
To temporarily cancel the Cruise
Control
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 selector lever is moved to neutral.
 When the exhaust brake switch is
switched to the operation position.
 When the vehicle speed drops
below approximately 22 mph (35
km/h).
When the Cruise Control is temporarily cancelled, Cruise Control ON
indicator light continues to illuminate
and Cruise Control SET indicator
light turns off.
NOTE:
Cruise Control will be temporarily
cancelled in the following situations.
 When the Set and Coast Button
and the Accelerate and Resume
switch are pressed at the same
time.
 When a malfunction occurs
within the system.
<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
 When the ignition key is turned to
WARNING
the OFF position.
 Before cancelling the Cruise
Control, make sure that no car
is too close. Cancelling the
Cruise Control can significantly reduce vehicle speed.
To resume the speed that was set
before cancellation
When Cruise Control has been temporarily cancelled, pressing and
releasing the Accelerate and
Resume switch will cause the vehicle to resume the speed that was set
before cancellation.
Resume cannot be performed when
vehicle speed is less than 19 mph
(30 km/h).
WARNING
 When
resuming your set
speed, do not press and hold
the Accelerate and Resume
switch for any length of time.
Doing so causes the set speed
to increase.
To cancel the Cruise Control
The following situations will cancel
the Cruise Control and cause the
Cruise Control ON and SET indicator
lights to turn off.
 When the Cruise Control main
switch is switched to the OFF position.
7 - 63
WARNING
 To prevent the vehicle from
accidentally starting to move,
when not using Cruise Control,
switch the Cruise Control main
switch to the OFF position.
INSTRUMENTS AND CONTROLS
Illumination control rheostat
NOTE:
Transmission PTO switch
 When the combination meter is
not illuminated, the brightness
of the multi-display meter
screen cannot be adjusted.
 If a warning or an indicator light
interrupts the monitor display of
the multi-display meter, the
monitor screen is brightened to
alert the driver regardless of the
adjusted illumination.
 The illumination in the combination
meter turns on when the lighting
switch is in the 1st or in the 2nd
position.
 The brightness can be adjusted by
turning the switch to the right and
left. Turn it to the right for brighter
illumination and to the left for
darker illumination.
 When the brightness is adjusted
while the combination meter is illuminated, the brightness of the
multi-display meter screen is
simultaneously adjusted.
This switch located on the instrument panel to the left of the steering
column, couples and uncouples
power flow to the transmission PTO.
To turn the PTO ON, idle the engine,
depress the clutch pedal fully, and
depress the switch. The PTO indicator and operation message will come
on. To turn the PTO OFF, idle the
engine, depress the clutch pedal
fully, and depress the switch. The
PTO indicator and operation message will go out.
7 - 64
INSTRUMENTS AND CONTROLS
Power mode switch (ATM
specification vehicles)
CAUTION
 Never operate the PTO while
Allison 1000, 2200, 2500 series
driving the vehicle.
 Operate the PTO switch only
when the vehicle is stopped.
The transmission gears may
be damaged if the switch is
operated while the vehicle is
moving.
 Turn the PTO switch off before
starting the vehicle.
 Depress the clutch pedal fully
before activating the PTO
switch to the ON or OFF position.
7 - 65
Allison 3000 series
This switch is located on the instrument panel to the right of the steering column (Allison 1000, 2200 and
2500 series) or on the selector
switch to the right of the driver’s seat
(Allison 3000 series).
Select the normal or power mode
with the mode change switch
depending on the driving condition.
When the switch is pushed once, the
power mode will operate. When the
switch is pushed again, operation
stops (normal mode). While operating, the indicator light in the switch
illuminates and also the indicator on
the multi-display comes on (Allison
3000 series only).
INSTRUMENTS AND CONTROLS
Air suspension dump switch
Procedure for returning the bed to
the normal driving height
<UD2600 and UD3300 equipped
with air suspension>
1.Check that there is no person or
object under or near the vehicle.
2.After ensuring the safety around
the vehicle, start the engine and
push off the air suspension dump
switch. The bed is returned to the
normal driving height.
Operation procedure
Operation procedure for lowering
the bed
This switch is located at the right
side of the heater control.
By operating this switch, the vehicle
bed can be lowered by exhausting
air from the air spring at the rear axle
to facilitate loading/unloading work.
1.Stop the vehicle on a level ground.
2.Pull up the parking brake valve
and turn the ignition key to the ON
or ACC position.
3.Before operating the air suspension switch, check that there is no
person or object under or near the
vehicle.
4.After confirming the safety, push
the air suspension dump switch.
Air is exhausted from the air spring
at the rear axle and the bed is lowered.
CAUTION
 Before operating the air sus-
pension dump switch, check
that there is no person or
object under or near the vehicle.
 Before turning ignition key to
the OFF position or releasing
the parking brake, make sure
that the bed is in the normal
driving height.
If the ignition key is turned to
the OFF position or the parking
brake is released while the bed
is in the lowered state, the bed
will be automatically returned
to the normal driving height.
7 - 66
INSTRUMENTS AND CONTROLS
 The
air suspension dump
switch will be activated only
when the parking brake valve
is pulled up and the ignition
key is turned to the ON or ACC
position.
 If the air suspension dump
switch is accidentally pressed
during driving, the bed will not
be lowered for safety but a
warning buzzer will sound.
BY pressing the dump switch
again, the warning buzzer
stops.
7 - 67
Mirror heater switch (Optional)
CAUTION
 After removing the fogging of
the mirrors, immediately turn
off the switch.
If not, the battery may go dead.
This switch is located at the right
side of the steering column.
By turning on the mirror heater
switch, the heaters incorporated in
the right and left outside mirrors are
energized and the mirrors are
defogged.
While the heaters are energized, the
indicator light in the switch stays illuminated.
INSTRUMENTS AND CONTROLS
Power mirror switch (Optional)
Horn
This switch is located on the instrument panel below the heater control.
This switch is used to adjust the
angle of the rear view mirrors on the
driver’s side and passenger side. It
will operate when the ignition key is
turned to the ON position.
 Push the right/left selection switch
and then move the operation
switch up or down, left or right to
adjust the view to the rear.
The horn pad is mounted in the center of the steering wheel. Press on
the pad to sound the horn.
7 - 68
INSTRUMENTS AND CONTROLS
DPF SYSTEM
 The PM reduction device collects
the soot (particulate matter) that is
part of exhaust gas through the
aftertreatment diesel particulate filter (DPF) located in the muffler,
and then continuously regenerates
(burns) the soot by oxidation catalysis.
 When continuous DPF regeneration cannot be performed due to
low speed driving, the automatic
DPF regeneration starts to burn
(regenerate) the soot to prevent
excessive accumulation in the
DPF that is located inside the muffler.
 When
automatic regeneration
does not operate due to low speed
driving or starting/stopping the
engine many times while driving,
manual regeneration must be performed after stopping the vehicle.
 Based on the amount of soot accumulated in the DPF, perform DPF
regeneration following the table
below.
7 - 69
NOTE:
 If a certain amount of soot from
exhaust gas accumulates in the
DPF, the PM reduction device
automatically burns (regenerates)
the
collected
soot.
Depending on the driving condition, soot may not be completely burned (regenerated). In
that case, the DPF clogging
warning light and the indicator
light that is built in the manual
forced regeneration switch will
flash to indicate that manual
DPF regeneration is needed.
INSTRUMENTS AND CONTROLS
Soot deposit
accumulation
Little
Status of the vehicle
Cleaning method
Normal driving
(Continuous regeneration is performed while driving at a high
speed or with a high load, therefore, soot is burned and
cleaned.)
Automatic DPF regeneration
When a certain amount of soot is accumulated, the soot is
automatically burned and cleaned.
Flashing of the DPF clogging warning light Stop the vehicle in a safe location, and then perform manual
and the indicator light that is built in the
DPF regeneration.
manual forced regeneration switch
Large
DPF system warning (Amber) and warning Contact your nearest UD Trucks dealer for inspection.
message are displayed
Device information
DPF clogging warning light
 The DPF clogging warning light
Manual forced regeneration switch
will blink if manual DPF regenaration should be performed due to
soot accumulation in the DPF.
When the warning light blinks, perform the following procedure.
 Also, when the ignition key is
turned to the ON position, it illuminates for 1 second for a bulb
check.
Procedure
Stop the vehicle in a safe location,
and then perform manual DPF
7 - 70
INSTRUMENTS AND CONTROLS
regeneration by operating the manual forced regeneration switch.
Manual forced regeneration switch
 By operating this switch, the soot
collected in the DPF is manually
burned (regenerated) to keep the
function of the exhaust gas cleaning device properly.
For details on how to use this
switch, refer to the “Manual DPF
regeneration operation” section.
 The indicator light that is built in
the switch will blink just as the DPF
clogging warning light blinks if
manual cleaning should be performed due to soot accumulation
in the DPF.
DPF soot level gauge
cates the accumulation level of the
soot in the DPF. Check if necessary.
 For details on how to display, refer
to the “Multi-display monitor” section in “INSTRUMENT AND CONTROLS”.
 Immediately after the vehicle is
stopped or while the system is
in the cleaning mode, the area
around
the
muffler
and
exhaust gas are extremely hot.
Do not stop the vehicle in a
location where there are flammable materials such as dried
grass or paper waste.
 If there are flammable materials around the vehicle, a fire
may occur. This could cause
burns from the heated exhaust
gas.
NOTE:
 While
Automatic DPF regeneration
 To prevent excessive accumula-
tion of soot in the DPF, the soot is
automatically burned and cleaned.
Though engine noise and engine
speed at idle will vary, the vehicle
can be driven as usual.
7 - 71
WARNING
 The DPF soot level gauge indi-
performing automatic
regeneration, engine noise will
vary and engine speed at idle
will increase. This does not indicate a malfunction.
INSTRUMENTS AND CONTROLS
Manual regeneration (when the
DPF clogging warning light
blinks)
 If the vehicle is driven at a low
speed or the engine is started/
stopped many times while driving,
the soot in the DPF may not be
burned and cleaned automatically.
 In this case, the DPF clogging
warning light informs the driver
that the soot in the DPF must be
burned and cleaned manually.
CAUTION
 When the DPF clogging warn-
ing light blinks, operate the
manual forced DPF regeneration switch to perform the
cleaning manually, and then
burn and clean the soot in the
DPF.
If driving is continued, clogging in the DPF or a system
malfunction may occur.
NOTE:
 If the vehicle is driven under any
of the following conditions, the
DPF clogging warning light may
blink many times because the
automatic regeneration may not
operate.
・The vehicle is frequently driven
at a low speed.
・The engine is started/stopped
many times while driving.
・The vehicle is driven many
times for only a short distance.
・The engine is always stopped
before it warms up.
Manual DPF regeneration
operation
 When the DPF clogging warning
light blinks, perform manual DPF
regeneration according to the following procedure, and then burn
and clean the soot in the DPF.
Note that manual regeneration can
be performed when the indicator
light blinks or automatic DPF
regeneration is started.
 The approximate time required for
manual
DPF
regeneration
depends on the conditions the last
time the vehicle was driven and
the engine idling status, however
normally it takes 25 minutes.
1.Stop the vehicle in a safe location,
and then keep the engine idling.
2.Be sure to apply the parking brake.
Place the gearshift lever in the
neutral position. Do not depress
the accelerator pedal.
3.Press the ON side of the manual
forced regeneration switch.
4.When the DPF regeneration starts,
the warning of DPF regeneration
appears on the multi-display monitor. The engine speed at idle will
increase.
7 - 72
INSTRUMENTS AND CONTROLS
device appears on the multi-display monitor.
WARNING
 Do not perform manual DPF
5.When the warning of DPF regeneration by the exhaust gas cleaning
device is no longer displayed on
the multi-display monitor, manual
DPF regeneration is completed.
The engine speed at idle will return
to normal.
6.After manual regeneration is completed, the vehicle can be driven
as usual.
7.To stop manual regeneration partway, press the CANCEL side of
the manual forced DPF regeneration switch. When manual DPF
regeneration is stopped partway,
the warning of regeneration restriction of the exhaust gas cleaning
7 - 73
regeneration in a location with
poor ventilation. Exhaust gas
may cause carbon monoxide
poisoning especially in an
enclosed location, such as in a
garage, indoors, etc.
 Do not perform manual DPF
regeneration in a location
where there are flammable
materials such as dried grass
or paper waste. The temperature of the exhaust gas and the
area around the exhaust pipe
and muffler become high during the cleaning mode. Therefore, if there are flammable
materials nearby, a fire may
occur.
In addition, never allow your
body to contact the exhaust
gas and the area around the
exhaust pipe and muffler.
Doing so may cause burn injuries. If the vehicle is stopped
over a road surface that is
painted, the road surface may
be discolored.
INSTRUMENTS AND CONTROLS
NOTE:
 The
engine speed at idle
increases while manual DPF
regeneration is being performed. This is due to a temperature increase of the exhaust
gas to burn (regenerate) the collected soot. This does not indicate a malfunction.
 While performing manual DPF
regeneration, the aftertreatment
hydrocarbon doser system supports the manual DPF regeneration by automatically injecting
fuel in the exhaust pipe.
 If the temperature of the inside
of the muffler is higher, the manual DPF regeneration is completed in a shorter time.
 Manual DPF regeneration is
completed in a shorter time
when the engine is hot immediately after the vehicle is stopped
than when the engine is cool.
When the engine is cool, the
time required for DPF regeneration takes longer because the
DPF regeneration is performed
after the engine warms up.
The time spent for warming up
the engine depends on the outside temperature, but generally
it takes about 5 to 10 minutes.
Therefore, manual DPF regeneration should be performed
immediately after the vehicle is
stopped (while the engine is still
warm).
 Manual cleaning cannot be performed under the following conditions.
・The engine coolant
temperature (ECT) is low.
(Perform after the engine warms
up.)
・The accelerator pedal (AP) is
depressed.
・The parking brake is released.
・The transmission gear is
placed in any position other
than the neutral position.
 For the models equipped with
the PTO switch, be sure to turn
the PTO switch off when turning
the manual forced aftertreatment DPF regeneration switch
on. The regeneration process
does not start.
 When manual aftertreatment
DPF regeneration is stopped
partway, it is not completed.
Resume manual regeneration
soon.
 If the vehicle is driven before the
regeneration is completed, the
DPF clogging warning light will
blink again.
 Manual DPF regeneration can be
performed as stated above even
if automatic cleaning is being
performed.
When the DPF system warning is
displayed
 If
the soot accumulation level
reaches a specified limit by driving
the vehicle with the DPF clogging
warning light blinking, the DPF
system warning, warning message
and comment are displayed on the
multi-display monitor to alert the
driver. The warning appears in two
different steps, amber and red.
 When it appears, clogging in the
DPF or system malfunction may
occur.
7 - 74
INSTRUMENTS AND CONTROLS
CAUTION
 If the vehicle is continued to be
LEVERS AND CONTROL
Transmission gear shift lever
driven, the engine shutdown
will operate.
 Do not drive the vehicle with
the DPF system warning displayed. The DPF that is
equipped with muffler may be
damaged.
 When the amber DPF system
warning appears, contact your
nearest UD Trucks dealer for
inspection.
 While the amber DPF system
warning appears, engine torque is
reduced to protect the DPF.
 When the red DPF system warning
appears, immediately stop the
vehicle in a safe location and contact your nearest UD Trucks
dealer.
7 - 75
NOTE:
 If
the DPF system warning
appears, the exhaust gas cleaning device may be damaged.
Manual DPF regeneration is not
possible.
The transmission gear shift lever is
located on the right of the driver’s
seat. When shifting gears, depress
the clutch pedal fully and move the
lever firmly. When the shift lever is
moved into reverse, the backup
lights come on and the backup
buzzer sounds. The backup lights
and buzzer are located on the rear of
the vehicle.
INSTRUMENTS AND CONTROLS
Automatic transmission selector
lever (switch)
Allison 1000, 2200 and 2500 series
When the selector lever (switch) is
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.
Parking brake valve
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.
Allison 3000 series
The selector lever (switch) is located
on the right of the driver’s seat.
7 - 76
INSTRUMENTS AND CONTROLS
 When
parking on a grade,
apply chocks to the wheels in
addition to using the parking
brake.
CAUTION
 Release
the parking brake
before driving the vehicle. Failure to release the parking
brake can cause brake damage.
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
ACCESSORIES
Cigarette lighter
CAUTION
 To avoid damage to the lighter,
The cigarette lighter is located at the
right side of the heater control. To
operate the lighter, push it in. The
lighter will pop out to its normal position when heated.
do not hold the lighter in manually.
 Avoid deforming the cigarette
lighter. Using a deformed
lighter could be dangerous, as
it will not pop out. Make sure
that
defective
parts
are
replaced with genuine parts or
equivalent.
 If the cigarette lighter does not
pop out within 20 seconds
after it has been pushed in,
remove it immediately and
have it checked at an authorized UD Trucks dealer or other
qualified service facility.
 Never leave your vehicle with
the cigarette lighter pushed in.
8-1
ACCESSORIES
Ashtray
Power socket
CAUTION
 Do not use a TV while driving.
The use of a TV may shorten
the life of the battery depending on operating or use conditions. Keep the use of a TV to a
minimum when ever possible.
WARNING
The power socket is located at the
right side of the cigarette lighter.
Use the power socket in the cab to
connect commercially available car
accessories. Remove the cap before
use. The following devices can be
connected to the socket.
Device
Charger for mobile
phone
GPS
TV
Wireless device
Computer
8-2
Rated current
2A
2A
9.5A
2.2A
7A
 The use of any device with a
higher current than the allowable load can heat the socket
and cord and cause fire. Use
devices with the allowable load
current.
 The socket is for 12 volts only.
Do not use any car accessory
for 24 volts with the socket. A
trouble may be caused in the
device.
 The socket can be used while
the ignition key switch is in the
ACC position. Before leaving
the vehicle, disconnect the
device from the socket.
The ashtray is located inside of the
right and left doors.
To open the ashtray, pull the tab
upward.
To remove the ashtray for cleaning,
pull the tray upward.
WARNING
 To prevent fire, ensure that any
lit or smoldering materials in
the ashtray are completely
extinguished.
ACCESSORIES
Overhead box
 Be sure to keep the overhead
Cup holder
box closed while driving.
Driving with it open could
allow the items in the box to
fall over and hinder driving.
Store only lightweight items, such as
the vehicle inspection certificate and
magazines, in the large box with the
lid.
CAUTION
The standard weight of objects
stored in the overhead is indicated 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
This is used to hold bottle and cup
for drinks, etc.
CAUTION
 Avoid abrupt starting and brak-
ing to prevent a drink from
being spilt when it is stored in
the cup holder.
8-3
ACCESSORIES
Room light
State of the doors
Room light switch
position
Driver’s
side
ON
Passenger side
Card holder
OFF DOOR
Turn
off
Close
Open
Close
Close
Open
Turn Turn
on
off
Turn
on
Open
 Turning on the room light switch
to ON turns on the room light
regardless of whether or not a
door is open or closed.
 The room light turns off when
the room light switch is turned
to OFF.
 When the room light switch is in
the DOOR position, the room
light will turn on when the
driver’s seat door or the passenger seat door is opened,
and will turn off when the door is
closed.
8-4
This can be used to hold such cards
as telephone cards and highway
cards.
CAUTION
 To prevent theft, do not leave
credit cards in the card holder
when away from the vehicle.
ACCESSORIES
Door pocket
Console box (optional)
Door pockets are located in the left
and right doors. Place road maps,
magazines, etc. inside it.
When the seatback of the center
seat is folded forward, some documents, small items, etc. can be
stored on the reverse side of the
seatback.
8-5
HEATER OR AIR CONDITIONER CONTROL
HEATER OR AIR CONDITIONER CONTROL
AIR CONDITIONER
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 temperature.
<Handling the blower motor filters>
 Both the outside and inside air
intakes have a cartridge air filter.
The air conditioner will not be as
effective if these air filters
become clogged, so inspect and
clean them periodically.
 For information about how to clean
the air filter, refer to "BLOWER
MOTOR FILTERS" on page 11-82.
9-1
HEATER OR AIR CONDITIONER CONTROL
Manual air conditioner
Change the switch and dial selections to match the season to make your driving pleasant.
Operation Panel
9-2
HEATER OR AIR CONDITIONER CONTROL
Name
Position
Purpose and Function
To stop fan operation:
OFF
Fan dial
– HI
COLD
Temperature
control dial
 This stops the air from the fan and the compressor. However, the fan continues
operating at the minimum air level when the mode dial is in the “Defrost” position.
To adjust the fan speed: The fan speed is adjusted manually.
 Turn right: Increases airflow, Turn left: Reduces airflow
Use maximum cooling:
Blows a cool air without passing the air through the heater core.
HOT
Use maximum heating: Blows a warm air after passing the air through the heater core.
COLD - HOT
Adjust the temperature of the air:
This changes the temperature of the air to match the temperature control dial setting.
 Turn right: Increases temperature, Turn left: Lowers temperature
Dial
Vent
Vent & Foot
Foot
Send air from the vent: Set the air outlet to the Vent position.
Send air from the vent and foot vents: Set the air outlet to the Vent & Foot position.
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 position.
Foot & Defrost 2
Send air from the foot and defrost vents:
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.)
Mode dial
Defrost
Send air from the defrost vents:Set the air vents to the Defrost position.
Set the intake vents to outside air.
Run the compressor.
 The minimum air will blow even if the fan dial is set to OFF.
9-3
HEATER OR AIR CONDITIONER CONTROL
Name
Air conditioner
switch
Switch
Position
Purpose and Function
The light turns on/ This switches between the dehumidifier mode (light on) and heater mode (light off).
off each time this  Light on: Compressor is operating normally
is pushed.
 Light off: Heater is operating (compressor is not operating)
Alternates
between turning
Fresh/Recircula- on the inside air
light and outside
tion switch
air light each time
this is pushed.
It switches between insider air recirculation and letting in the outside air.
 Inside air light: Set to inside air recirculation.
 Outside air light: Set to let in the outside air.
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/Recirculation switch to select the inside air.
 When the windshield fogs up easily, set the air vents to Foot &
Defrost.
NOTE:
 Mode dial Foot & Defrost 1
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
When resting in the seat
Use the heater as instructed below when idling the engine to heat the cab during cold weather.
No.
Operation method and description
Adjust the air conditioner temperature higher than normal.
 The air temperature in the cabin rises according to the adjustment of the temperature control dial.
1
NOTE:
 The air temperature in the cabin tends to decrease because the temperature of the engine coolant becomes low. Set the air conditioner temperature higher beforehand to keep the air temperature comfortable.
Push the air conditioner switch and turn off the position light (heater mode).
 The air conditioner compressor stops.
2
NOTE:
 When the position light is on (dehumidifier mode), the air conditioner
cools the incoming air before warming it. Thus, the air temperature from
the vent becomes low.
Push the fresh/recirculation switch to illuminate the position light of the inside air recirculation 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 temperature 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
Illustration
HEATER OR AIR CONDITIONER CONTROL
No.
Operation method and description
Illustration
Turn the warm-up switch to the ON position.
 The exhaust brake operates, and the idle speed increases and then the temperature of engine coolant rises.
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 position.
5
<When resting in the seat after driving>
Push the fresh/recirculation switch to illuminate the position light of the inside air recirculation mode.
 The intake vent is fixed at inside air recirculation.
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
 Moving the mode dial to the Vent &
Putting the mode dial in the Defrost
position will blow warm air from the
defroster on the inside of the windshield.
Foot eliminates the discomfort
caused by the warm air making the
heat too hot, etc.
 The temperature control dial is
used to adjust the air temperature,
and the fan dial is used to adjust
the fan speed as desired.
Switching between inside and
outside air
Normally, the intake vents use outside air, but when you want to
avoid dust, exhaust fumes, etc.,
push
the
Fresh/Recirculation
switch to switch to inside air recirculation.
NOTE:
 When the mode dial is moved to
the Defrost position, the compressor begins to run and the
intake vents are set to outside
air. Note that the compressor
might not turn on due to certain
conditions, such as the outside
air temperature.
 When the mode dial is moved to
the Defrost position, the minimum amount of air will blow
even if the fan dial is set to OFF.
9-8
WARNING
 Do not use inside air recircula-
tion for a long time. Doing so
will cause the air inside the
cab to become foul or the
windshield to fog up, etc.
HEATER OR AIR CONDITIONER CONTROL
Cooling and dehumidifying
 Cooling and dehumidifying can be
done by pushing the air conditioner switch.
 The temperature control dial is
used to adjust the air temperature,
the fan dial is used to adjust the
fan speed, and the mode dial is
used to select the air vents as
desired.
 When you want to quickly cool
down the cab, push the Fresh/
Recirculation switch to switch
inside air recirculation.
Information regarding automobile
refrigerant
 The cooling performance could
drop causing poor cooling if there
is insufficient refrigerant or the
refrigerant compressor belt is
loose.
 If refrigerant is leaking, have it
inspected by the nearest authorized UD Trucks dealer. Also, if the
belt is loose, have it adjusted.
CAUTION
 Use Freon HFC134a to help
protect the environment. Only
use the specified refrigerant to
charge the cooling system.
 To protect the global environment, do not discharge refrigerant into the atmosphere.
9-9
VEHICLE OPERATION
VEHICLE
OPERATION
10 - 1
WARNING
Never drive the vehicle with
 the engine stopped.
 the clutch disengaged (not
applicable to automatic transmission).
 the transmission gear shift
lever in neutral.
These are very hazardous and
can cause loss of control
resulting in death or serious
injury. This is because:
1.You cannot use the engine
brake.
2.When the engine is not running, the brake system will
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.
OPERATING PRECAUTIONS
Following a few precautions will help
lengthen the life and reliability of
your vehicle.
 After starting, warm up the engine
until it runs smoothly.
 Do not race the engine during the
warm-up period.
 Avoid sudden starts and abrupt
stops.
 When you start a loaded vehicle,
use 1st gear. When you go uphill,
use an appropriate lower gear.
 Use the same gears going down a
grade as you used or would use
going up.
VEHICLE OPERATION
BREAK-IN PRECAUTIONS
VEHICLE LOADING
During the initial 600 miles (1,000
km) of operation:
 Observe the “OPERATING PRECAUTIONS” section above.
 Do not exceed 75% of the vehicle
GVWR. See the “BEFORE DRIVING YOUR VEHICLE” section for
details.
Do not exceed the GVWR or the
front and rear GAWRs of the vehicle.
The vehicle GAWRs may be
exceeded before the vehicle load
reaches the GVWR depending on
the body and equipment on the vehicle. Confirm that the vehicle’s tires,
springs and axles are not overloaded. Always balance and secure
the vehicle load. Loading and balance of the load will affect the braking, handling, stability and other
characteristics of your vehicle.
WARNING
 The
vehicle’s stopping distance will increase as the load
of the vehicle increases. Acceleration performance will also
be reduced. In addition, a
loaded
vehicle’s
handling
characteristics differ from
those of an unloaded vehicle.
Depending on the loading, differences in steering response
and vehicle leaning while turning and in curves may occur.
Anticipate these differences
and operate your vehicle
accordingly. Always balance
and secure the vehicle load.
 The muffler (catalyst system in
the muffler) become very hot.
Do not touch it, also do not let
it come in contact with the
sheets or ropes on the rear
body or dry grass on the
ground as they may ignite and
cause a fire.
10 - 2
VEHICLE OPERATION
TOWING TRAILERS
Trailer brakes
Electric brakes and manual, automatic or surge-type trailer brakes are
safe if installed properly and
adjusted to the manufacturer’s specifications. The trailer brakes must
meet local and Federal regulations.
If you own a trailer with a hydraulic
brake system, do not connect the
trailer’s hydraulic brake system
directly to your vehicle’s brake system. The vehicle’s brake system is
only designed to carry the appropriate amount of brake fluid for the
vehicle alone. Connecting a hydraulic trailer braking system could
adversely affect your vehicle’s braking performance.
NOTE:
 The braking system of the tow
vehicle is rated for operation at
the GVWR not GCWR.
Trailer lamps
Trailer lamps are required on most
towed vehicles. Make sure all run10 - 3
ning lights, brake lights, turn signals
and hazard lights are working. Consult your authorized UD Trucks
dealer or the authorized dealer/manufacturer of your trailer for instructions to connect the trailer lamps to
the tow vehicle.
Safety chains
Always connect the trailer’s safety
chains to the frame or hook retainers
of the vehicle hitch.
To connect the trailer's safety chains,
cross the chains under the trailer
tongue and allow slack for turning
corners. If you use a rental trailer,
follow the instructions that the rental
agency provides to you.
Driving while you tow
When towing a trailer:
 Turn off and do not use the cruise
control.
 Consult your local motor vehicle
speed regulations for towing a
trailer.
 Anticipate stops and brake gradually.
 Do not exceed the GCWR rating or
transmission damage may occur.
Servicing after towing
If you tow a trailer for long distances,
your vehicle will require more frequent service intervals. Refer to the
“Vehicle Service and Maintenance”
section for “Type 1” vehicle operation.
Trailer towing safety tips
General
 Ensure that the trailer, safety
chains and electrical connectors
are securely fastened.
 Make sure the truck receiver, draw
bar, and coupler are properly connected and adjusted.
 Check side mirrors for proper visibility, especially when towing a
trailer wider than the truck.
 When towing, operate the vehicle
at lower speeds than you would
when not towing a trailer. The likelihood of trailer sway is greater at
higher speeds.
VEHICLE OPERATION
 When turning, make wide turns to
allow trailer tires to properly clear
any obstacles.
 Be prepared for trailer sway due to
buffeting when larger vehicles
pass in either direction.
Loading
 Keep the center-of-gravity low for
best handling.
 Trailer loads should be evenly dis-
tributed front to back and left to
right.
 Never
exceed truck, trailer,
receiver, ball, tongue, tire or coupler loading recommendations.
Braking
 The
trailer brakes must be
inspected and serviced at intervals
specified by the trailer manufacturer. This includes shoes, drums,
and trailer brake magnets.
 Electric brakes also require periodic adjustment to keep the shoes
properly spaced.
If the brakes get hot when driving
or if they will not hold, chances are
that they need adjustment.
 Anticipate the need to stop; allow
additional distance and time to
stop than normal.
 Do not apply the trailer brakes for
extended periods of time as they
can overheat and lose their effectiveness.
Backing up
 Practice backing up, particularly if
you are a novice. Turn the steering
wheel to the right to move the
trailer’s rear end to the right.
 Sharp steering movements may
cause the trailer to jackknife or go
out of control.
Tires
 All trailer tires should be of the
same size and construction.
 Select tires that meet the trailer
loading requirements.
 Always check tow vehicle and
trailer tire pressure before towing.
STARTING THE ENGINE
Before starting the engine, check to
be sure that:
The MTM is shifted to the neutral position. The engine can
only be started when the shift
lever is in the N (Neutral) position.
For ATM, put the selector lever
(switch) into the P (Park) or N
(Neutral) position.
The transmission PTO switch
(optional) is turned off.
The parking brake is pulled to
the PARK position.
The power steering fluid level
is proper.
The engine oil level and engine
coolant level are proper.
Normal temperature conditions:
Depress the clutch pedal (Not available with automatic transmission)
fully, and then turn the ignition key to
the START position.
10 - 4
VEHICLE OPERATION
Cold weather conditions (Vehicle
with intake air heater system: If so
equipped):
1.When the engine coolant temperature is low, turn the ignition key to
ON position. The indicator light
turns on and pre-heating is carried
out.
2.After the indicator light turns off,
turn the ignition key to the START
position and start the engine. After
starting the engine, the indicator
light will illuminate again and afterheating will be performed for a set
time.
NOTE:
 The engine start control system
is equipped with an automatic
anti-overheating device. (Generally, when attempting to start the
engine for about 15 seconds
and doing so three or four times
in a row, this will cause the
operation of the automatic antioverheating device.)
When
the
anti-overheating
device is operated, a warning
and a warning message will be
displayed. These warnings indi10 - 5
cate that the anti-overheating
function is operating.
This message displays the cooling time (10 to 15 minutes regularly) that is required for the
starter to operate again.
 Turn the ignition key to ON posi-
 When the PTO engine start inter-
rupt warning is operated, a
warning and a warning message
will be displayed. These warnings indicate that the engine is
unable to start because the PTO
switch is in the ON position.
If this occurs, turn the PTO
switch to the OFF position, and
then start the engine.
tion before depressing the
accelerator pedal. When the
ignition key is at LOCK or ACC
position, the fuel system function for cold weather will not
operate.
 Right after stalling the engine,
the engine start control system
inhibits the cranking for about 1
second to avoid the damage for
the starter.
 When the engine does not start
on the first attempt, wait approximate 30 seconds before trying
again.
VEHICLE OPERATION
 Do not keep the starter engaged
for more than 15 seconds at a
time.
WARNING
 Do not start or idle the engine
in
inadequately
ventilated
areas. Carbon monoxide poisoning can cause unconsciousness and is potentially
lethal.
 Avoid
breathing
exhaust
fumes. If you suspect that
exhaust fumes are entering the
cab, stop the vehicle immediately. Open all windows, and
have the vehicle inspected and
repaired immediately. Do not
drive the vehicle if you notice
the presence of any exhaust
fumes in the cab.
 Do not use ether or other starting aids which are flammable.
 Avoid attempting to start your
vehicle by pushing or towing.
Instead, use the jump starting
procedure or tow your vehicle,
as described in this manual, to
the nearest service station.
3.When the engine starts, make sure
the gearshift lever is still in neutral
If the vehicle is equipped with
automatic transmission, the selector lever is still in the N (Neutral) or
P (Parking) position, and release
the clutch pedal (Not available with
automatic transmission).
10 - 6
VEHICLE OPERATION
CAUTION
 Do not attempt to start the
engine with a power source of
more than 12 volts.
 After the engine starts, do not
turn the ignition key to the
START position. This could
cause damage to the starter
motor and/or engine.
 Do not attempt to start the
vehicle until the intake air
heater indicator light goes out.
WARMING UP ENGINE
To avoid shortening engine life,
engine warm-up is necessary. The
warm up is performed by adjusting
the engine throttle control knob.
Adjusting engine idling speed
The automatic adjustment of engine
idling speed.
 When the engine throttle control
knob is turned all the way to the
left, automatic idling mode will be
reached, and the idling speed will
be adjusted automatically according to the temperature of engine
coolant.
Refer to "Engine throttle control
knob" on page 7-53.
 Normally, the knob should be
turned all the way to the left (counterclockwise).
 When the knob is turned to the
right (clockwise), the mode
changes from automatic idling
mode to manual adjustment mode,
the engine speed will increase,
and adjustment up to about 980
rpm will become possible.
10 - 7
VEHICLE OPERATION
 The standard idling speed is 550
rpm.
 Warm-up has been completed
when the idling speed drops.
The manual adjustment of engine
idling speed.
 When the engine has started,
gradually release the accelerator
pedal and set a slightly higher
idling speed with the throttle control knob.
 Perform warm-up operation until
the needle of the engine coolant
temperature gauge starts to move.
 When the needle of the engine
coolant temperature gauge starts
to move, return the throttle control
knob to the standard idling speed.
NOTE:
 Never drive with higher idling
speed than standard. That could
result in excessive fuel consumption and reduced clutch
life.
 Failure to warm up the engine
will shorten engine life.
WARNING
WARNING
 Driving with the throttle con-
 Do not warm up the engine in
trol knob set to any speed
higher than standard idling
speed is dangerous and could
cause the vehicle to suddenly
accelerate, even when the
vehicle is stopped with the
engine running.
an insufficiently ventilated
location such as a garage or
indoors. This can be dangerous and can cause carbon
monoxide poisoning.
To warm up more quickly
If you wish to make the heater or
defroster work more quickly after
starting the engine, or to enhance
the effectiveness of the heater in
cold weather, activate the exhaust
brake and the idle speed increases.
Activation
1.Put the parking brake in the PARK
position.
2.Shift the gear shift lever to the “N”
position.
3.Start the engine and turn the
warm-up switch to ON to engage
the exhaust brake, and the idle
speed increases and begin engine
warm-up. During this time, the
switch’s built-in indicator light will
illuminate.
10 - 8
VEHICLE OPERATION
Deactivation
Turn the warm-up switch to OFF to
turn off the indicator lights and cancel engine warm-up.
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
STOPPING THE ENGINE
After vehicle operation, idle the
engine for 3 to 5 minutes before
stopping the engine. After the engine
is cooled by idling, stop the engine.
Follow the instructions in the "Engine
stop" on page 7-4. Turn the ignition
key to the OFF position.
VEHICLE OPERATION
DRIVING ON GRADES
1.When driving up a grade, operate
the vehicle in a lower transmission
gear at the engine speed (about
1,400 rpm) for which the engine
develops its maximum torque.
Sustained high speed operation
may cause severe engine failure.
2.When descending a grade, first
use engine braking by selecting
the same gear which was used or
would be appropriate for going up
the grade. Supplement the engine
braking with exhaust braking and
finally with service brakes, as necessary, to maintain a safe vehicle
speed.
WARNING
WARNING
 Do not rest your foot on the
 Operating the engine in the red
brake pedal or use the foot
brakes for extended periods.
Such can cause the brake
drums to overheat, the linings
to wear excessively and/or
cause a drop in braking pressure resulting in a reduction in
braking
effectiveness
and
increased stopping distances.
zone of the tachometer can
cause severe engine damage
and serious injury.
 Do not downshift if the engine
speed is in the red zone of the
tachometer.
3.When downshifting, wait until
engine speed corresponds to the
road speed of the next lower gear
before shifting. Do not allow the
engine to overspeed. Do not operate the engine at speeds within the
tachometer red zone.
4.Check the operation of the brakes
before you begin the descent of an
extended or steep grade.
10 - 10
VEHICLE OPERATION
DRIVING IN DIFFICULT
CONDITIONS
1.Ice, snow, loose sand, mud or wet
surfaces present hazardous driving conditions. Tire traction is
decreased, stopping distance
becomes unpredictable and heavy
braking, sudden maneuvers or
excessive speeds can result in
loss of vehicle control.
CAUTION
 When a wheel spins when trac-
tion is poor, do not spin the
wheels for a long time or the
differential could seize up.
2.On slippery surfaces, avoid quick
movements of the steering wheel
or transmission shift lever. Gently
apply the brakes steadily and
evenly to avoid skidding and wheel
lockup. Decrease your vehicle
speed and allow for extra stopping
distances.
3.Always make sure your tires are in
good condition. Badly worn or
10 - 11
improperly inflated tires provide
poor traction and increase the hazards of driving on slippery surfaces.
4.A loaded vehicle handles differently from an empty one. Be prepared
for
longer
stopping
distances, slower acceleration,
more leaning on curves, different
steering response. A vehicle
should be evenly loaded.
5.When driving on slippery surfaces
or on curves, be sure to use the
service brake together with the
exhaust brake.
OPERATING WITH MANUAL
TRANSMISSION
Your UD Trucks vehicle is equipped
with a manual transmission with 6
forward and 1 reverse gears. The
gear shift pattern is shown on the
shift lever knob.
CAUTION
 Never
drive
the
vehicle
through a flooded area. If the
water is deep enough to reach
the bottom of the oil pan, this
will cause failure of the cooling
fan, slippage of the drive belts,
or failure of the engine due to
water sucked into the air
intake.
Familiarize yourself and others operating the vehicle with the manual
transmission, the gear shift pattern
and clutch operation. When using
the clutch, be sure that the clutch is
fully engaged or disengaged. Never
operate the vehicle with the clutch
partially engaged.
VEHICLE OPERATION
WARNING
To avoid engine and clutch failure which may result in serious
injury:
 Do not operate your vehicle
with a worn or damaged
clutch.
 Do not operate the vehicle with
your foot resting on the clutch
pedal.
 Do not use the clutch to hold
your vehicle on a grade.
To reduce the possibility of loss
of vehicle control:
 Do not allow the vehicle to
coast with the clutch pedal
depressed or with the transmission in neutral.
 Do not operate the vehicle with
the clutch partially engaged.
 Always use 1st gear when
starting to move the vehicle.
CAUTION
 Do not ride the clutch pedal.
“Riding the clutch” by resting
your foot on the clutch pedal
while driving can lead to premature clutch failure.
 Avoid shifting the transmission into first gear while the
vehicle is moving. Shifting into
first gear while moving may
damage the transmission.
 Stop the vehicle completely
before shifting from forward to
reverse or from reverse to forward.
 When shifting down or up, shift
the lever being careful not to
pass the correct shift gate.
When shifting from 6th to 5th
gear, push the shift lever to the
right. If this is not done during
shifting 6th to 5th, a misdownshift to 3rd gear may occur,
resulting in engine overspeeding 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
disengage the clutch.
2.With the clutch pedal fully
depressed, shift the gear shift lever
to the neutral position.
10 - 13
3.Release the clutch pedal. When
downshifting, raise the engine
speed using the accelerator pedal.
4.Fully depress the clutch pedal
again.
5.While holding the pedal down, shift
to the next gear.
6.Release the clutch pedal. When
downshifting, wait until engine
speed corresponds to the road
speed of the next lower gear
before shifting. Do not overspeed
the engine.
VEHICLE OPERATION
OPERATING WITH
AUTOMATIC TRANSMISSION
Your UD trucks vehicle may be
equipped with an optional automatic
transmission. The automatic transmission has the operation flexibility
of manual selecting and holding in
lower driving ranges.
This permits the driving selection of
the most suitable forward gear range
to match varying road and load conditions.
ALLISON 1000, 2200 and 2500
automatic transmission (1000:
Optional for UD1800 and UD2000)
(2200: Optional for UD2300 and
UD2600)
(2500: Optional for UD3300)
The Allison 1000, 2200 and 2500
automatic transmissions have 5 forward and 1 reverse gear ranges.
1000 and 2200 series
2500 series
(P): Park Position —
 This position is used when starting
the engine, for warming up the
engine, and when stopped or
parked. The engine can only be
10 - 14
VEHICLE OPERATION
started when the shift lever is in
the P (Park) or N (Neutral) position.
 When shifting from Park to any
other range, depress the brake
pedal while shifting.
 Shifting is not done if the engine
speed is high (1,000 rpm or more).
Use P (Park) for the following.
 to turn on or turn off the engine
 to check vehicle accessories
 to operate the engine in idle for
longer than five minutes
 for stationary operation of the
power takeoff (if your vehicle is
equipped with a PTO)
This position places the transmission
in N (Neutral) and engages the park
pawl.
(R): Reverse Position —
 This position is used when moving
the vehicle backwards. You must
first stop the vehicle before shifting
from a forward gear to Reverse, or
from Reverse to a forward gear.
 This range cannot be shifted to
while driving (although the shift
10 - 15
lever will move). At this time the
SHIFT LIMIT warning light comes
on. If this occurs, stop the vehicle,
and shift first to P (Park) or N
(Neutral). Then depress the brake
pedal and shift to the desired driving range.
(N): Neutral Position —
 This position is used when starting
the engine, for warming up the
engine, and when stopped. The
engine can only be started when
the shift lever is in the P (Park) or
N (Neutral) position.
 When shifting from Neutral to a
driving range, depress the brake
pedal while shifting. At this time
the SHIFT LIMIT warning light illuminates. If this occurs, return the
shift lever to the P (Park) or N
(Neutral) position, then depress
the brake pedal and shift to the
desired driving range.
 Shifting will not be done if the
engine speed is high (1,000 rpm or
more).
NOTE:
 When shifting from Neutral to
any other range, approximately
1 second is required for the
transmission clutch to connect.
If the accelerator pedal is
depressed during this time,
excessive stress is placed on
the transmission. Wait until the
clutch has connected and then
gradually depress the accelerator pedal.
(D): Driving Position —
 This is the position used during
normal driving.
Gears will change from 1 - 5 when
the overdrive (O/D) switch is on,
and from 1st to 4th when it is off.
VEHICLE OPERATION
(3): Third Range —
 This position is used when engine
braking is needed while the vehicle
is descending a slope. Shifting
between gears 1 - 3 is done automatically.
(2): Second Range —
 This position is used when strong
engine braking is needed. Shifting
between gears 1 - 2 is done automatically.
(1): First Range —
 This position can be used during
rough road conditions, when freeing the vehicle from mud or deep
snow, when driving at very slow
speed through narrow spaces,
when climbing or descending
steep slopes, or when the maximum amount of engine braking
force is required. The transmission
remains in 1st gear and does not
shift.
WARNING
 Always
apply the service
brakes when selecting R
(Reverse). The range selected
may not be obtained, resulting
in unexpected vehicle motion.
 Do not allow the vehicle to
coast in N (Neutral). If you let
the vehicle coast in N (Neutral), there is no engine braking and you could lose control.
Coasting can also cause
severe transmission damage.
WARNING
Without applying the service
brakes, parking brake, or emergency brake:
 Do not make shifts from R
(Reverse) to N (Neutral).
Selecting N (Neutral) does not
apply vehicle brakes unless an
auxiliary system to apply the
parking brake is installed.
 Do not make shifts from N
(Neutral) to a forward range or
from N (Neutral) to R (Reverse)
to avoid sudden movement of
the vehicle.
 Do not make shifts from a forward range to N (Neutral).
Selecting N (Neutral) does not
apply vehicle brakes unless an
auxiliary system to apply the
parking brake is installed.
10 - 16
VEHICLE OPERATION
WARNING
WARNING
 D (Drive) and other forward
 If you just downshift or just
ranges may not be obtained
due to an active inhibitor. The
range selected may not be
obtained, resulting in unexpected vehicle motion. Always
apply the service brakes when
selecting D (Drive) or other forward ranges.
 The
transmission incorporates a hold feature to prohibit
upshifting above the range
selected during normal driving. For downhill operation,
select a lower transmission
range. If the engine-governed
speed is exceeded in the held
range, however, the transmission may upshift to the next
higher range. To avoid loss of
vehicle control, use the vehicle
brakes to prevent exceeding
engine governed speed in the
held range.
use service brakes when going
downhill, you can lose control
and cause injury and/or property damage. To avoid loss of
control, use a combination of
downshifting, braking, and
other retarding devices.
Downshifting to a lower transmission
range
increases
engine braking and helps you
to maintain control. The transmission has a feature to prevent
automatic
upshifting
above
the
lower
range
selected. However, during
downhill operation, if engine
governed speed is exceeded in
the lower range, the transmission may upshift to the next
higher range. This will reduce
braking and could cause a loss
of control. Apply the vehicle
brakes or other retarding
device to prevent exceeding
engine governed speed in the
lower range selected.
10 - 17
CAUTION
 Do not idle in R (Reverse) or D
(Drive) for more than 5 minutes. Doing so may cause
transmission overheating and
damage. Always use P (Park)
or N (Neutral) if you need to
idle over 5 minutes.
<Operating with automatic
transmission>
Check before engine start
 Always use the right foot to oper-
ate the accelerator pedal and the
brake pedal in order to prevent
depressing either by accident.
Shift lock system
<Model without P position
(2500 series)>
 When shifting the selector lever for
the first time after turning the ignition key to the ON position, the
selector lever cannot be shifted
from N to another position if the
brake pedal is not depressed.
Moreover, when the shift lever is
VEHICLE OPERATION
left engaged in the N position for
about 5 minutes even after shifting
the selector lever for the second
time, it cannot be shifted from the
N position. In this case, depress
the brake pedal and operate the
selector lever.
 When the ignition key is in the
ACC or LOCK position, the selector lever cannot be shifted from N
to another position even if the
brake pedal is depressed.
 When the selector lever is in any
position other than the N position
・The key cannot be removed from
the ignition key switch. Place
the selector lever to the N
position and then remove the key.
・The ignition key cannot be turned
from ACC to the LOCK position.
 When shifting the selector lever
from N to another position,
depress the brake pedal first and
then operate the lever. If the lever
is operated first, it does not move
so that the shift lock mechanism is
not released.
 If the selector lever cannot be
shifted from N to another position
even when the brake pedal is
depressed, press the shift lock
release button. While pressing the
button, the selector lever can be
shifted.
NOTE:
 If this situation occurs, contact
your nearest UD Trucks dealer
for inspection.
<Model with P position
(1000 and 2200 series)>
 The
selector lever cannot be
shifted from the P position if the
brake pedal is not depressed.
 When the ignition key is in the
ACC or LOCK position, the selector lever cannot be shifted from the
P position even if the brake pedal
is depressed.
 When the selector lever is in any
position other than the P position
・The key cannot be removed from
the ignition key switch. Place the
selector lever in the P position
and then remove the key.
・The ignition key cannot be turned
from ACC to the LOCK position.
 When shifting the selector lever
from P to another position,
depress the brake pedal first and
then operate the lever. If the lever
is operated first, it does not move
so that the shift lock mechanism is
not released.
 If the selector lever cannot be
shifted from the P position even
when the brake pedal is
10 - 18
VEHICLE OPERATION
depressed, press the shift lock
release button. While pressing the
button, the selector lever can be
shifted.
NOTE:
 If this situation occurs, contact
your nearest UD Trucks dealer
for inspection.
 Release the parking brake. Lift
 When parking, first stop the vehi-
your foot off of the brake pedal.
 When traveling forward, acceleration begins from 1st gear. According to the engine load and speed,
the transmission will automatically
shift from 1st gear, to 2nd, to 3rd...
up to the maximum gear for the
selected range.
cle, then shift to P (Park) or N
(Neutral). Then slowly release the
brake pedal and check that the
lock has been engaged. Then
firmly set the parking brake.
 Each time you park the vehicle or
leave the operator’s station with
the engine running, do the following.
1.Bring the vehicle to a complete
stop using the service brake.
2.Ensure that the engine is at low
idle rpm.
3.Put the transmission in P (Park)
or N (Neutral).
4.Engage the P (Park) range by
slowly releasing the service
brake.
5.Apply the emergency brake and/
or parking brake, if present, and
make sure it is properly
engaged.
6.If the operator’s station will be
unoccupied with the engine running, chock the wheels and take
any other steps necessary to
keep the vehicle from moving.
Engine start
NOTE:
 Check that the parking brake has
 The engine protection function
been pulled up.
 Check that the shift lever is in the
P (Park) or N (Neutral) position,
then start the engine. (The engine
will not start if the lever is in
another position.) Check that the
warning light turns off after the
engine has started.
Starting to move the vehicle
 Depress the brake pedal with your
right foot. Select a gear range. To
move the vehicle forward, select D
(Drive), to move backwards select
R (Reverse).
 The gear will not shift if the engine
speed is high.
10 - 19
may provide torque derating to
prevent the engine from being
damaged, in this case, also shift
shock might occur.
Stopping and parking
 When stopping temporarily, leave
the shift lever in the D (Drive) position. Be sure to keep the brake
pedal depressed with the right
foot. In this way, there is no need
to return the shift lever to N (Neutral).
 When stopping for 5 minutes or
longer, shift to the N (Neutral) or P
(Park) position.
VEHICLE OPERATION
NOTE:
 When the vehicle is in motion,
attempting to shift to the P
(Park) range may produce only a
clicking sound without actually
shifting. Be sure to use the
brake to stop the vehicle before
shifting to P (Park).
Accelerator pedal control
The position of the accelerator pedal
influences the automatic shifting.
When the pedal is fully depressed,
the transmission will automatically
upshift near the governed speed of
the engine. A partially depressed
position of the pedal will cause the
upshifts to occur at a lower engine
speed.
WARNING
 When depressing the accelera-
tor pedal or when the engine
speed is higher than the idling
speed, do not shift the selector
lever from N to the forward or
R range.
It is very dangerous as the
vehicle might jump suddenly
forward or backward. The
transmission might also be
damaged.
Downshift or reverse inhibitor feature
The transmission hydraulic system
will not permit a shift into any forward
gear at a speed that will cause
excessive engine overspeed. Any
lower forward range may be selected
at any time, but the actual engagement of the gears in that range will
not occur until road speed is reduced
— downshifting is progressive as
road speed decreases. The inhibitor
effect will cause downshifts to occur
at slightly higher speeds than normal
automatic downshifts.
If the shift lever is accidentally
moved to reverse while traveling forward, the transmission is designed
not to shift into reverse gear until
road speed is very low. To avoid shift
shock, always come to a full stop
before shifting from forward to
reverse or from reverse to forward.
10 - 20
VEHICLE OPERATION
Using the engine to slow the vehicle
To use the engine as a braking force,
shift the selector to the next lower
range. If the vehicle is exceeding the
maximum speed for a lower gear,
use the service brakes to slow the
vehicle to an acceptable speed
where the transmission may be
downshifted safely.
Parking brake (2500 series)
There is no park position in the
transmission shift pattern. Therefore,
always put the selector in neutral
and apply the parking brake to hold
the vehicle when it is unattended.
Driving on ice or snow
Here is where all of your ability as a
professional driver comes into focus
regardless of what transmission you
have. If possible, reduce your speed
and select a lower range before you
lose traction. Select the range that
will not exceed the speed you expect
to maintain. Accelerate or decelerate
very gradually to prevent losing traction. It is very important to slow gradually when a lower range is selected.
It is important that you reach the
lower range selected before attempt10 - 21
ing to accelerate. This will avoid an
unexpected downshift during acceleration.
Rocking out
If the vehicle is stuck in deep sand,
snow, or mud, it may be possible to
rock it out. Shift to D (Drive) and
apply steady, light throttle (never full
throttle). When the vehicle has
rocked forward as far as it will go,
apply and hold the vehicle service
brakes. Allow the engine to return to
idle; then select R (Reverse).
Release the brakes and apply a
steady, light throttle and allow the
vehicle to rock in R (Reverse) as far
as it will go. Again, apply and hold
the service brakes and allow the
engine to return to idle. This procedure may be repeated in D (Drive)
and R (Reverse) if each directional
shift continues to move the vehicle a
greater distance. Never make N
(Neutral)-to-D (Drive) or directional
shift changes when the engine rpm
is above idle.
WARNING
 To avoid injury or property
damage caused by sudden
movement of the vehicle, do
not make shifts from N (Neutral) to a forward range or R
(Reverse) when the accelerator
pedal is depressed. The vehicle will lurch forward or rearward and the transmission can
be damaged. Avoid this condition by making shifts from N
(Neutral) to a forward range or
R (Reverse) only when the
throttle is closed.
VEHICLE OPERATION
CAUTION
 If the wheels are stuck and not
turning, do not apply full
power for more than 30 seconds in either D (Drive) or R
(Reverse). Full power for more
than 30 seconds under these
conditions will cause the
transmission to overheat. If the
transmission overheats, shift
to N (Neutral) and operate the
engine at 1,200 to 1,500 rpm
until it cools (2 to 3 minutes).
Converter driven PTO
<PTO configuration>
The PTO is mounted on the left and/
or right side of the transmission
housing. The PTO drivetrain consists
of a large drive gear in the transmission, an idler gear arrangement, and
a smaller driven gear in the PTO.
The drive gear is integral to the
transmission rotating clutch housing, which rotates at the same speed
as the torque converter turbine. With
this drive configuration the PTO
rotates in the same direction as the
engine.
Two types of transmission-mounted
PTOs may be used with these transmission models.
 A constant-drive PTO is used in
applications which require full-time
PTO operation. The PTO driven
gear is in constant mesh with the
drive gear and cannot be disengaged.
 Clutch drive and sliding gear PTOs
are used in applications which
require only part-time operation of
the PTO or the capability to
engage or disengage the driven
equipment. For clutch drive PTOs,
the following applies: 1) the
engagement/disengagement provision is facilitated by a hydraulic
clutch mechanism in the PTO
assembly; 2) the PTO can be
engaged or disengaged at any
time (except at engine speeds that
exceed drive speed limits imposed
on the driven equipment).
CAUTION
 Do no use or install a sliding
gear PTO where the sliding
gear meshes directly with the
PTO driver gear. The PTO
driver gear may be damaged
when the sliding gear slides
into the PTO drive gear, producing metal particles that can
cause transmission damage.
<PTO engagement — Sliding gear
PTOs>
CAUTION
 Never engage the sliding gear
PTO by clashing the gear
teeth. This may damage the
PTO unit. Stop the clashing by
releasing the vehicle brakes
and allowing the vehicle to
move slightly or by moving the
shift selector from a drive
range to N (Neutral) and back
to a drive range.
Engage the PTO drivetrain as follows.
10 - 22
VEHICLE OPERATION
 Turn the PTO switch on.
 Set the engine speed at idle.
 Place shift selector lever in D
(Drive).
 Shift the PTO power shift clutch
lever to Drive.
 Bring the engine up to speed.
 Shift to N (Neutral).
Disengage the PTO drivetrain as follows.
 Stop the vehicle.
 Idle the engine.
 Set the brake.
 Place the shift selector in a drive
range.
 Stop the PTO-driven equipment.
 Disengage the power takeoff.
 Return the transmission shift
selector to N (Neutral).
 Turn the PTO switch to off.
<PTO Engagement—Clutch Driven>
The PTO will engage only when the
PTO switch is on, the throttle position is low, and engine speed and
output speed are within the limits
specified by body builders.
10 - 23
<PTO operation>
CAUTION
 Do not exceed the engagement
and operational speed limits
imposed on the driven equipment during the operation of
the PTO. Exceeding the speed
limits produces high hydraulic
pressure in the PTO that can
damage the PTO components.
Consult the vehicle manufacturer’s literature for these
speed limits.
 Some vehicles creep in range
at low vehicle speeds while
maintaining a specified engine
speed for PTO operation (e.g.,
paint stripers and feed lot
trucks). For PTO operation at
low speeds, do not use the
brakes to limit vehicle speed
while using the throttle to
maintain an engine speed
above idle when the transmission is in range. Such operation
will
cause
the
transmission
to
overheat.
Extended operation at elevated
temperatures will result in
transmission damage.
The transmission operates in either
converter mode or torque converter
clutch mode. In converter mode, the
torque converter (lockup) clutch is
not engaged and the PTO is driven
through the torque converter, producing a torque at the PTO drive
gear that is always greater than the
input torque. In torque converter
clutch mode, the torque converter
(lockup) clutch is engaged, the PTO
drivetrain is driven at a speed proportional to the engine speed.
The PTO drive is normally in continuous converter mode operation
when the transmission is in P (Park)
and R (Reverse). Torque converter
clutch operation in N (Neutral) is
available for some applications. If
the PTO is used with the transmission in D (Drive) or another forward
range, transmission shifts (both converter/torque converter clutch mode
shifts and shifts between gears) are
based on the automatic shift
sequence of the transmission shift
controls. PTO drive gear speed will
be affected each time a shift occurs.
With the vehicle stopped and the
engine at idle, PTO output speed is
VEHICLE OPERATION
dependent upon the transmission
gear selection.
 If the transmission is in D (Drive)
or R (Reverse), the PTO output
speed is zero.
 If the transmission is in N (Neutral)
or P (Park), the PTO output will
rotate slowly.
In some vehicles, the transmission
will shift into N (Neutral) regardless
of the shift selector position under
the following conditions.
 the PTO is enabled
 the transmission output speed is
near zero
 the throttle position is near zero
To reselect a range, the operator
must shift into N (Neutral), then shift
to the desired range.
<PTO overspeed protection>
CAUTION
 Do not exceed the engagement
and operational speed limits
imposed on the driven equipment during the operation of
the PTO. Exceeding the speed
limits produces high hydraulic
pressure in the PTO-driven
components that can damage
the PTO-driven components.
Consult the vehicle manufacturer’s literature for these
speed limits.
 When the PTO is disengaged
due to overspeed, the PTO will
be automatically re-engaged at
user specified speed, which is
typically relatively low. The
resultant re-engagement shock
could cause damage to a highinertia PTO system.
ALLISON 3000 automatic
transmission (Optional for
UD2600 and UD3000)
The Allison automatic transmissions
have 6 forward and 1 reverse gear
ranges.
Selector switch
The Range selector switch is used to
shift the gear to the desired driving
range from among 6 forward ranges
and the reverse range. When the
switch is pushed, the selected range
is displayed on the left side of the
digital display of the selector. With
the
or
switch, the range can
be selected. While driving forward,
each time the
switch is pushed
once, the selector range is shifted
downward by one gear, and each
time the
switch is pushed once,
the selector range is shifted upward
by one gear. The selected range is
displayed on the left side of the digital display of the selector, and the
range in operation on the right side.
10 - 24
VEHICLE OPERATION
Relationship between switch operation and digital display
Range
operation
10 - 25
Digital display
Automatic transmission range
Selection
range
Range in
operation
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
R
VEHICLE OPERATION
(R): Reverse Position —
 This position is used when moving
the vehicle backwards. The
backup light comes on and the
back buzzer sounds and the back
buzzer sounds in the cabin.
(N): Neutral Position —
 This position is used when starting
the engine, for warming up the
engine, and when stopped.
(D): Driving Position —
 This is the position used during
normal driving. Shifting between
gears 1 - 6 is done automatically,
according to engine load and
speed.
(5): Fifth Range —
 This position is used when a small
amount of engine braking is
needed. Shifting between gears 1 5 is done automatically.
(4): Fourth Range —
 This position is used when engine
braking is needed while the vehicle
is descending a slope. Shifting
between gears 1 - 4 is done automatically.
(3): Third Range —
 This position is used when strong
engine braking is needed while the
vehicle is descending a slope.
Shifting between gears 1 - 3 is
done automatically.
(2): Second Range —
 This position is used when strong
engine braking is needed. Shifting
between gears 1 - 2 is done automatically.
(1): First Range —
 This position can be used during
rough road conditions, when freeing the vehicle from mud or deep
snow, when driving at very slow
speed through narrow spaces,
when climbing or descending
steep slopes, or when the maximum amount of engine braking
force is required. The transmission
remains in 1st gear and does not
shift.
WARNING
 Always
apply the service
brakes when selecting R
(Reverse). The range selected
may not be obtained, resulting
in unexpected vehicle motion.
 Do not allow the vehicle to
coast in N (Neutral). If you let
the vehicle coast in N (Neutral), there is no engine braking and you could lose control.
Coasting can also cause
severe transmission damage.
WARNING
Without applying the service
brakes, parking brake, or emergency brake:
 Do not make shifts from R
(Reverse) to N (Neutral).
Selecting N (Neutral) does not
apply vehicle brakes unless an
auxiliary system to apply the
parking brake is installed.
10 - 26
VEHICLE OPERATION
 Do not make shifts from N
(Neutral) to a forward range or
from N (Neutral) to R (Reverse)
to avoid sudden movement of
the vehicle.
 Do not make shifts from a forward range to N (Neutral).
Selecting N (Neutral) does not
apply vehicle brakes unless an
auxiliary system to apply the
parking brake is installed.
WARNING
 D (Drive) and other forward
ranges may not be obtained
due to an active inhibitor. The
range selected may not be
obtained, resulting in unexpected vehicle motion. Always
apply the service brakes when
selecting D (Drive) or other forward ranges.
10 - 27
 The
transmission incorporates a hold feature to prohibit
upshifting above the range
selected during normal driving. For downhill operation,
select a lower transmission
range. If the engine-governed
speed is exceeded in the held
range, however, the transmission may upshift to the next
higher range. To avoid loss of
vehicle control, use the vehicle
brakes to prevent exceeding
engine governed speed in the
held range.
WARNING
 If you just downshift or just
use service brakes when going
downhill, you can lose control
and cause injury and/or property damage. To avoid loss of
control, use a combination of
downshifting, braking, and
other retarding devices.
 Downshifting to a lower trans-
mission
range
increases
engine braking and helps you
to maintain control. The transmission has a feature to prevent
automatic
upshifting
above
the
lower
range
selected. However, during
downhill operation, if engine
governed speed is exceeded in
the lower range, the transmission may upshift to the next
higher range. This will reduce
braking and could cause a loss
of control. Apply the vehicle
brakes or other retarding
device to prevent exceeding
engine governed speed in the
lower range selected.
VEHICLE OPERATION
CAUTION
 Do not idle in R (Reverse) or D
(Drive) for more than 5 minutes. Doing so may cause
transmission overheating and
damage. Always use N (Neutral) if you need to idle over 5
minutes.
NOTE:
 You must first stop the vehicle
before shifting from a forward
gear to Reverse, or from
Reverse to a forward gear.
 The maximum speed varies by
range. Select an appropriate
range depending on situations.
 When shifting to lower speed
gears, the transmission is done
within the range where an
engine overrun is not caused.
 When the vehicle speed gets
excessively
high
on
a
downslope, etc., the transmission may upshift to a higher
range than the selected range
due to activation of the safety
device. In that case, use the ser-
vice brake to drive at a safe
speed.
<Operating with automatic transmission>
Check before engine start
 Always use the right foot to operate the accelerator pedal and the
brake pedal in order to prevent
depressing either by accident.
Engine start
 Check that the parking brake has
been pulled up.
 Before starting the engine, make
sure that “N N” is displayed on the
digital display. The engine can only
be started when “N N” is displayed
on the digital display. If “N N” is not
displayed, push the N switch to
display “N N”.
10 - 28
VEHICLE OPERATION
 Keeping
the
brake
pedal
depressed with the right foot, push
the switch and select the range. To
move the vehicle forward, select D
(Drive), to move backwards select
R (Reverse).
ing to the engine load and speed,
the transmission will automatically
shift from 1st gear, to 2nd, to 3rd...
up to the maximum gear for the
selected range.
NOTE:
 Shifting with the power mode
switch can be done only during
the engine running.
 The engine protection function
may provide torque derating to
prevent the engine from being
damaged, in this case, also shift
shock might occur.
NOTE:
 After the engine is started, warm
up the engine. When the fluid
temperature is low during wintertime, only “N”, “R” and the
lowest speed gear of “D” can be
used.
 When the engine can be started
in any range other than “N”,
there is something wrong. Contact the nearest authorized UD
Trucks dealer.
 Avoid attempting to start your
vehicle by pushing or towing.
Starting to move the vehicle
 With the power mode switch,
select normal or power mode.
10 - 29
CAUTION
 If the engine speed is high, the
gear is not engaged. Then, turn
the engine throttle control knob to
the AUTO position to lower the
speed.
 To start the vehicle on a level
ground, select the “D” range.
 Release the parking brake. Lift
your foot off of the brake pedal.
 When traveling forward, acceleration begins from 1st gear. Accord-
 If the phenomenon in which
upshifts and downshifts are
repeated (shift hunting) occurs
while driving, shift to a lower
speed gear range using the
switch.
VEHICLE OPERATION
 When the accelerator pedal is
gradually depressed to accelerate the vehicle or to maintain
the constant speed when
climbing slopes, kickdown
may occur, leading to an
increase of the engine speed,
but it is not a failure.
 Before shifting the range from
“N” to “D” or “R” or from “D”
to “R”, allow the engine to idle.
Before shifting the range to the
position above the 1st gear,
release the accelerator pedal.
SHIFT LIMIT warning message
The selector digital display, LH
(selection range) character (can be
“R”, “6”, “5”, “4”, “3”, “2” or “1”)
flashes when there has been an
error in operation or when the safety
circuit has been activated. It indicates that the change from the current shift to another specified shift
cannot be done.
Stopping and parking
 When stopping temporarily, leave
the shift lever in the D (Drive) position. Be sure to keep the brake
pedal depressed with the right
foot. In this way, there is no need
to return the selector switch to N
(Neutral).
 When stopping for 5 minutes or
longer, shift to the N (Neutral) position.
 When parking, first stop the vehicle, then shift to N (Neutral). Then
slowly release the brake pedal and
check that the lock has been
engaged. Then firmly set the parking brake.
 Each time you park the vehicle or
leave the operator’s station with
the engine running, do the following.
1.Bring the vehicle to a complete
stop using the service brake.
2.Ensure that the engine is at low
idle rpm.
3.Put the transmission in N (Neutral).
10 - 30
VEHICLE OPERATION
4.Apply the emergency brake and/or
parking brake, if present, and
make sure it is properly engaged.
5.Slowly release the service brake.
6.If the operator’s station will be
unoccupied with the engine running, chock the wheels and take
any other steps necessary to keep
the vehicle from moving.
Accelerator pedal control
The position of the accelerator pedal
influences the automatic shifting.
When the pedal is fully depressed,
the transmission will automatically
upshift near the governed speed of
the engine. A partially depressed
position of the pedal will cause the
upshifts to occur at a lower engine
speed.
10 - 31
WARNING
 When depressing the accelera-
tor pedal or when the engine
speed is higher than the idling
speed, do not shift the selector
switch from N to the forward or
R range.
It is very dangerous as the
vehicle might jump suddenly
forward or backward. The
transmission might also be
damaged.
Downshift or reverse inhibitor feature
The transmission hydraulic system
will not permit a shift into any forward
gear at a speed that will cause
excessive engine overspeed. Any
lower forward range may be selected
at any time, but the actual engagement of the gears in that range will
not occur until road speed is reduced
— downshifting is progressive as
road speed decreases. The inhibitor
effect will cause downshifts to occur
at slightly higher speeds than normal
automatic downshifts.
If the selector switch is accidentally
pushed to reverse while traveling forward, the transmission is designed
not to shift into reverse gear until
road speed is very low. To avoid shift
shock, always come to a full stop
before shifting from forward to
reverse or from reverse to forward.
Using the engine to slow the vehicle
To use the engine as a braking force,
shift the selector to the next lower
range. If the vehicle is exceeding the
maximum speed for a lower gear,
use the service brakes to slow the
vehicle to an acceptable speed
where the transmission may be
downshifted safely.
Parking brake
There is no park position in the
transmission shift pattern. Therefore,
always put the selector in neutral
and apply the parking brake to hold
the vehicle when it is unattended.
Driving on ice or snow
Here is where all of your ability as a
professional driver comes into focus
VEHICLE OPERATION
regardless of what transmission you
have. If possible, reduce your speed
and select a lower range before you
lose traction. Select the range that
will not exceed the speed you expect
to maintain. Accelerate or decelerate
very gradually to prevent losing traction. It is very important to slow gradually when a lower range is selected.
It is important that you reach the
lower range selected before attempting to accelerate. This will avoid an
unexpected downshift during acceleration.
Rocking out
If the vehicle is stuck in deep sand,
snow, or mud, it may be possible to
rock it out. Shift to D (Drive) and
apply steady, light throttle (never full
throttle). When the vehicle has
rocked forward as far as it will go,
apply and hold the vehicle service
brakes. Allow the engine to return to
idle; then select R (Reverse).
Release the brakes and apply a
steady, light throttle and allow the
vehicle to rock in R (Reverse) as far
as it will go. Again, apply and hold
the service brakes and allow the
engine to return to idle. This procedure may be repeated in D (Drive)
and R (Reverse) if each directional
shift continues to move the vehicle a
greater distance. Never make N
(Neutral)-to-D (Drive) or directional
shift changes when the engine rpm
is above idle.
WARNING
 To avoid injury or property
damage caused by sudden
movement of the vehicle, do
not make shifts from N (Neutral) to a forward range or R
(Reverse) when the accelerator
pedal is depressed. The vehicle will lurch forward or rearward and the transmission can
be damaged. Avoid this condition by making shifts from N
(Neutral) to a forward range or
R (Reverse) only when the
throttle is closed.
CAUTION
 If the wheels are stuck and not
turning, do not apply full
power for more than 30 seconds in either D (Drive) or R
(Reverse). Full power for more
than 30 seconds under these
conditions will cause the
transmission to overheat. If the
transmission overheats, shift
to N (Neutral) and operate the
engine at 1,200 to 1,500 rpm
until it cools (2 to 3 minutes).
When descending slopes or downshifting
 When descending a slope, down-
shift to D54321 depending on the conditions of the slope
and use engine braking. In addition, use exhaust braking in combination for safe driving.
 Be careful not to let the engine
overrun while driving (especially,
descending slopes).
10 - 32
VEHICLE OPERATION
BRAKE OPERATION
UD1800 thru UD2600 equipped with
air-over-hydraulic service brakes
and spring-activated rear wheel
parking brakes. UD3300 equipped
with full-air service brake and springactivated rear wheel parking brake.
Auxiliary exhaust braking and engine
braking provide additional braking
action.
Service brakes
1.For normal stops, supplement the
service brakes with engine braking
by downshifting the transmission
at the same time that the service
brakes are applied.
WARNING
 Avoid
applying the service
brakes when the manual transmission/automatic transmission is in neutral. When the
transmission is in neutral,
there is neither engine braking
nor exhaust braking. This
results in an increased load on
the service brakes and eventual reduced braking efficiency.
10 - 33
2.When descending a grade, first
use engine braking by selecting
the same transmission gear which
would be appropriate for going up
the grade. Supplement the engine
braking with exhaust braking and
finally with service brakes as necessary to maintain a safe vehicle
speed.
3.Do not abruptly apply the brakes
except in an emergency. Always
maintain sufficient distance from
the vehicle in front of you. Allow for
additional stopping distance as
vehicle load increases and when
operating your vehicle on slippery
road surfaces.
CAUTION
 Driving through deep water
may get the wheel brakes wet
and stopping distance will be
longer than normal.
Make sure there is no other
vehicles around you, then dry
the brakes by applying them
gently several times while the
vehicle is moving slowly.
WARNING
 Do not rest your foot on the
brake pedal while driving.
Avoid extended braking with
the service brakes only. Either
may cause the brake drums to
overheat, the linings to wear
excessively, and/or cause a
drop in braking pressure
resulting in a reduction in
braking
effectiveness
and
increased stopping distances.
 Repeated brake pedal pumping
uses air needed for braking
action and reduces braking
effectiveness.
 Never operate the vehicle
when the AIR PRESSURE
warning light is on or the low
air pressure warning buzzer is
sounding.
 Check the low air pressure
warning system regularly.
 When the vehicle has been
parked for long periods in cold
climates, moisture on the
brake linings may freeze, making the brakes inoperative.
Check braking action by operating the brakes while driving
the vehicle at a low speed.
VEHICLE OPERATION
(ABS) Anti-lock Brake System
The ABS, when it activates, properly
controls the slippage of wheels and
effectively utilizes frictions between
tires and road surfaces. It is a device
that enhances safety, but it does not
enable you to drive beyond the limitations. Follow the precautions
below, and always drive safely.
 Confirm that the warning light illu-
minates when the ignition key is
turned to the ON position and that
it goes out after about 3.0 seconds.
 The motor operating sound may
be temporarily heard from the
frame side when the vehicle speed
reaches 4 mph (7 km/h) each time
after the engine is started. This is
the sound of the ABS operation
check, and it is not a malfunction.
 When the ABS is in operation, the
operating sound is intermittently
heard. This is not a malfunction.
 The stopping distance on slippery
road surfaces will be longer than
on normal, dry, paved road sur-
faces.
Also, in deep snow, on gravel
roads, or when tire chains are
installed, if the ABS activates, the
stopping distance may be slightly
longer than the models without
ABS.
Always take into account the road
conditions, tire conditions, etc.,
maintain a safe distance from the
vehicle in front of you, and drive at
safe speeds.
 The ABS helps to prevent the
wheel slippage when the brake is
applied, and it does not function for
the slippage when the accelerator
pedal is applied or when turning.
Also, even if the ABS activates, on
a frozen and very slippery road,
the steering wheel operation can
be difficult due to the loss of control.Always drive at safe speeds,
and avoid abrupt braking or steering operations as much as possible.
 When driving with the transmission
in a lower gear position on a frozen
and slippery road, engine braking
may lock the driving wheel, and
the vehicle can become unstable.
In this case, release the clutch,
and apply the brake.
 When decelerating on slippery or
uneven road surface with the auxiliary brake (exhaust brake) applied,
if wheel slippage occurs, the auxiliary brake may be automatically
released and the indicator light
goes out. This is a normal operation of ABS, and it is not a malfunction. Pay attention to the road
conditions and the distance
between vehicles, and always
drive safely.
CAUTION
 When installing an electronic
device such as radio or communication equipment, be
careful not to affect the function of the ABS. Contact an
authorized UD Trucks dealer if
you have any unclear points.
10 - 34
VEHICLE OPERATION
Parking brake
 Before operating the vehicle,
<Spring-activated rear wheel parking brake>
release the parking brake.
Make sure that the PARKING
BRAKE warning light goes out.
If the parking brake is not
released, the brake system
may be damaged resulting in a
loss of braking effectiveness.
 When parking on a slope or off
the road, use wheel chocks in
addition to the parking brake.
The rear axle brake shoes are
mechanically actuated by a spring
system when the parking brake are
applied. To apply the parking brake,
pull the parking brake valve on the
cab floor in rear of the transmission
gear shift lever. Push the valve down
to release the parking brake.
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 when someone is
working near the rear axle. The
movements of the parking
brake actuating rod may cause
serious injury.
10 - 35
PARKING YOUR VEHICLE
Whenever it is possible, park the
vehicle on a level ground. When
parking on a slope or off the road,
use wheel chocks in addition to the
parking brake.
WARNING
 Always place the transmission
in neutral position (Manual
transmission) or P (Park) or N
(Neutral) position (Automatic
transmission) to prevent unintended engine startup resulting
from
sudden
or
unexpected vehicle movement.
 Always set the parking brake.
 Do not leave the vehicle unattended with the engine running.
 Avoid parking in a place where
there are flammable objects
such as dry grass, etc. They
may ignite and cause a fire due
to the high temperature of the
engine and exhaust system.
VEHICLE OPERATION
To park the vehicle
1.Shift the transmission to the neutral position (Manual transmission)
or P (Park) or N (Neutral) position
(Automatic transmission).
2.Apply the parking brake.
3.Idle the engine for 3 to 5 minutes
to lower the engine temperature
before stopping the engine.
CAUTION
 Neglecting to idle the engine
properly may damage the
engine especially after completing a high-load or highspeed run.
AFTER PARKING YOUR
VEHICLE
1.Check for oil, water and fluid leaks.
2.Drain any condensate from the air
reservoir.
3.In cold climates drain water from
the fuel filter. If water remains, it
may freeze resulting in damage to
the fuel filter.
4.Perform all necessary service and
repairs.
IN COLD WEATHER
Starting the engine in cold
weather
The diesel engine utilizes a compression ignition system and therefore starting the engine in cold
weather may be difficult compared to
a gasoline engine.
In order to facilitate cold weather
starting, adhere to the following procedures.
Starting method
WARNING
 Do not use ether to assist with
4.Stop the engine and turn all
switches to OFF.
5.Remove the ignition key.
6.Lock the doors.
starting since it is highly toxic
and flammable and could
cause a fire or explosion.
Fuel
 Use diesel fuel ASTM 1-D in cold
weather.
 Avoid getting water in the fuel sys-
tem. Water in the fuel system will
freeze and make starting the
10 - 36
VEHICLE OPERATION
engine impossible. At the end of
each daily operation, drain water
from the fuel filter.
 Always fill the fuel tank up to its
specified level to prevent condensation.
Oil
 The lubricating oil thickens as it
gets colder, slowing engine cranking speed. Be sure to use proper
lubricating oil in order to offer less
resistance to the cranking effort of
the engine.
See the "Oil viscosity and relation
between viscosity and temperature:" on page 11-32.
Battery
 If the battery is not fully charged,
the battery electrolyte may freeze
and the resultant expansion may
damage the battery.
To maintain maximum efficiency,
the battery should be checked regularly, at least once a month, and
10 - 37
maintained in the fully-charged
condition.
WARNING
may be faulty and should be
repaired.
WARNING
 Do not attempt to jump start a
 Failure to drain water could
vehicle having a frozen battery; the battery may rupture or
explode. If a frozen battery is
suspected or if ice can be seen
in each cell, do not attempt to
start the vehicle with jumper
cables.
cause freezing in the air lines
and result in serious injury due
to insufficient braking power.
Anti-freeze
 Check the UDXtra Long Life Diesel
Engine
Antifreeze/Coolant
to
assure proper winter protection.
For details, see the "ENGINE
COOLING SYSTEM" on page 1124.
Draining air reservoir
 At the end of each daily operation,
always drain water from the air
reservoir. If a large quantity of
water accumulates, the air dryer
VEHICLE OPERATION
IDLE SHUTDOWN (Optional)
Cold Weather Operation of Allison
Automatic Transmission
The following chart is the minimum
fluid temperature at which the transmission may be safely operated in a
forward or reverse range. When
ambient air temperature is below the
minimum fluid temperature limit and
the transmission is cold, warm-up is
required.
Run the engine at idling for at least
20 minutes with the transmission in
neutral before operating in a forward
or reverse range.
CAUTION
 Failure to observe the mini-
mum fluid temperature limit
can result in transmission malfunction or reduced transmission life.
Coolant heater
 At temperatures below –4°F
(–20°C), an engine block immersion coolant heater is recommended to aid cold weather
starting by keeping the engine
warm. For details, please consult
your UD trucks dealer.
The Idle shutdown function saves
fuel consumption and reduces emission gas when a vehicle is standing
still and ignition key is ON position.
<Function Overview>
This function stops the engine automatically if a predefined time has
elapsed since the entry conditions
are fulfilled when the vehicle is
standing still and the ignition key
position is ON.
The warning period is 30 seconds
before the engine stops. The displayed message and audible alarm
warn the driver during this period.
The warning to the driver continues
until turn the ignition key to OFF
position.
10 - 38
VEHICLE OPERATION
CAUTION
 If the vehicle is left as it is after
engine was shut down automatically by this function, it
results in low battery.
 It is not easy to operate steering because the power steering is not available just after
engine shutdown.
<Entry Condition>
The idle shutdown function starts the
timer to stop the engine if following
all conditions are fulfilled.
AND Engine has been warmed up.
AND The engine is running and the
vehicle is standing still.
AND Accelerator pedal is released.
AND Parking brake is applied.
(This condition can be applied
according to the customer
needs.)
<Override Condition>
The idle shutdown function does not
shutdown the engine if any of following conditions is fulfilled.
10 - 39
 PTO switch is ON.
 DPF is being regenerated.
 Brake pedal is depressed during
the warning period.
 Engine load is over the threshold.
 External lever is in use.
 Any of the entry conditions is not
fulfilled.
 Just after engine was run at high
load.
 Any failure occurs in the engine
system.
<Engine restart>
1.Turn the ignition key to LOCK
(OFF) position, and a audible
alarm will stop sounding.
2.Turn the ignition key to the START
position.
VEHICLE SERVICE AND MAINTENANCE
VEHICLE
SERVICE AND
MAINTENANCE
CLEAN AIR ACT
Heavy-duty engine rebuilding
practices.
§ 86.004-40
The provisions of this section are
applicable to heavy-duty engines
subject to model year 2004 or later
standards and are applicable to the
process of engine rebuilding (or
rebuilding a portion of an engine or
engine system). The process of
engine rebuilding generally includes
disassembly, replacement of multiple
parts due to wear, and reassembly,
and also may include the removal of
the engine from the vehicle and
other acts associated with rebuilding
an engine. Any deviation from the
provisions contained in this section
is a prohibited act under section 203
(a) (3) of the Clean Air Act (42
U.S.C. 7522 (a) (3)).
1.When rebuilding an engine, portions of an engine, or an engine
system, there must be a reasonable technical basis for knowing
that the resultant engine is equivalent, from an emissions standpoint,
to a certified configuration (i.e., tolerances, calibrations, specifications) and the model year(s) of the
resulting engine configuration
must be identified. A reasonable
basis would exist if:
A.Parts installed, whether the parts
are new, used, or rebuilt, are such
that a person familiar with the
design and function of motor vehicle engines would reasonably
believe that the parts perform the
same function with respect to
emissions control as the original
parts; and
B.Any parameter adjustment or
design element change is made
only:
a.In accordance with the original
engine manufacturer's instructions; or
b.Where data or other reasonable
technical basis exists that such
parameter adjustment or design
element change, when performed
on the engine or similar engines, is
not expected to adversely affect inuse emissions.
2.When an engine is being rebuilt
and remains installed or is reinstalled in the same vehicle, it must
be rebuilt to a configuration of the
same or later model year as the
original engine. When an engine is
being replaced, the replacement
engine must be an engine of (or
rebuilt to) a configuration of the
same or later model year as the
original engine.
3.At time of rebuild, emissionsrelated diagnostic trouble codes
(DTCs) or signals from on-board
diagnostic (OBD) monitoring systems may not be erased or reset
11 - 1
VEHICLE SERVICE AND MAINTENANCE
without diagnosing and responding
appropriately to the DTCs, regardless of whether the systems are
installed to satisfy requirements in
§ 86.004-25 or for other reasons
and regardless of form or interface. Diagnostic systems must be
free of all such DTCs when the
rebuilt engine is returned to service. Such signals may not be rendered inoperative during the
rebuilding process.
4.When conducting a rebuild without removing the engine from the
vehicle, or during the installation of
a rebuilt engine, all critical emissions-related components listed in
§ 86.004-25 (b) not otherwise
addressed by paragraphs 1
through 3 of this section must be
checked and cleaned, adjusted,
repaired, or replaced as necessary, following manufacturer recommended practices.
5.Records shall be kept by parties
conducting activities included in
11 - 2
paragraphs 1 through 4 of this section. The records shall include at
minimum the mileage and/or hours
at time of rebuild, a listing of work
performed on the engine and
emissions-related control components including a listing of parts
and components used, engine
parameter adjustments, emissions-related DTCs or signals
responded to and reset, and work
performed under paragraph 4 of
this section.
A.Parties may keep records in whatever format or system they choose
as long as the records are understandable to an EPA enforcement
officer or can be otherwise provided to an EPA enforcement officer in an understandable format
when requested.
B.Parties are not required to keep
records of information that is not
reasonably available through normal business practices including
information on activities not conducted by themselves or informa-
tion that they cannot reasonably
access.
C.Parties may keep records of their
rebuilding practices for an engine
family rather than on each individual engine rebuilt in cases where
those rebuild practices are followed routinely.
D.Records must be kept for a minimum of two years after the engine
is rebuilt.
VEHICLE SERVICE AND MAINTENANCE
MAINTENANCE INTERVALS
Abbreviations:
A = Check and adjust if
necessary
R = Replace or change
I = Inspect, clean and correct or
replace as necessary
T = Tighten to specified torque
L = Lubricate
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
Items
Miles x 1,000
Kilometers x1,000
First
3
6
5
10
9
15
10
16
12
20
15
25
Every
18 20
30 32
24
40
30
48
36
60
50 72 Months Reference
page
80 120 (every)
BASIC MECHANICAL SYSTEM
♦ Valve clearance
♦*Cylinder compression pressure
♦*Engine mounting
A
24
A
36
A
36
FUEL SYSTEM
♦Low and High idle speed
*Fuel filters (Main and primary fuel filter)
Fuel hose and pipe
(Fuel filter to supply pump, Fuel tank to
fuel filter, Engine to fuel tank)
A
-
Once for every 2 engine oil and filter replacements
A
R
-
11-39
R:36
11-43
LUBRICATION
*Engine oil and oil filter:
Type 1
(With UDXtra Engine oil)
Type 2
*Engine oil and oil filter:
Type 1
(With Non-UDXtra Engine oil)
Type 2
(Refer to note 1.)
Type 1/Type 2: For type of operation details refer to page 11-33
NOTE: 1. Non-UDXtra engine oil details refer to page 11-31.
11 - 4
R
R
R
R
12
12
6
6
11-33
VEHICLE SERVICE AND MAINTENANCE
Engine (Cont’d)
Items
Miles x 1,000
Kilometers x1,000
First
3
6
5
10
9
15
10
16
12
20
15
25
Every
18 20
30 32
24
40
30
48
36
60
50 72 Months Reference
page
80 120 (every)
COOLING SYSTEM
*Cooling fan
*Drive belts
Engine coolant
*Radiator and heater hoses and clamps
I
12
R
12
48
12
11-28
11-24
12
24
6
11-44
11-75
11-27
Initial inspection at first 6,000 miles (10,000 km)
R: Every 320,000 miles (500,000 km)
A
11-27
11-46
INTAKE AND EXHAUST SYSTEM
*Air cleaner element
Intake air hose and clamps
*Charge air cooler body
R
R
I
♦*Charge air cooler hoses
♦ Turbocharger rotor operation
Exhaust pipe and muffler attachment
loose and damage
♦*DPF
♦*CCV filter
♦*DEF filter
♦*DPF sensor hose
♦*DPF regeneration system
A
I
24
I
24
12
11-75
I: Every 155,000 miles (250,000 km) or 4,500 hours
-
11-70
R: Every 62,000 miles (100,000 km)
12
11-50
R: Every 150,000 miles (240,000 km) or 7,000 hours
-
11-48
R: Every 36 months
36
I: Every 12 months
12
11-71
11 - 5
VEHICLE SERVICE AND MAINTENANCE
Engine (Cont’d)
Items
Miles x 1,000
Kilometers x1,000
First
3
6
5
10
9
15
10
16
12
20
15
25
Every
18 20
30 32
24
40
30
48
36
60
50 72 Months Reference
page
80 120 (every)
ELECTRICAL EQUIPMENT
I
Starter bearing grease
♦ Starter brush
♦ Alternator assy
11 - 6
12
I
R: Every 218,000 miles (350,000 km)
24
-
VEHICLE SERVICE AND MAINTENANCE
Chassis
Items
Miles x 1,000
Kilometers x1,000
Months (every)
First
3
6
5
10
1
2
9
15
10
16
4
12
20
15
25
6
Every
18 20
30 32
8
24
40
10
30
48
12
36
60
50 72
80 120
Reference page
CLUTCH
Clutch fluid
Clutch pedal play
I
R
I
♦ Clutch disc
♦ Clutch piping
11-66
11-65
I
I
MANUAL TRANSMISSION
♦
I
Breather
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
♦ Center bearing
♦ Condition of propeller shaft
I
I
T
DIFFERENTIAL GEAR
Differential gear oil
R
R
11-60
11 - 7
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
Items
Miles x 1,000
Kilometers x1,000
Months (every)
First
3
6
5
10
1
2
9
15
10
16
4
12
20
15
25
6
Every
18 20
30 32
8
24
40
10
30
48
12
36
60
50 72
80 120
Reference page
STEERING SYSTEM
♦ Gear box
Power steering fluid and filter
Steering wheel free play
T
R
I
I
T
♦ Steering linkage
♦ Power steering rubber hose
R
11-62
11-60
R: Every 24 months
AXLE AND WHEEL
♦ Front axle (I-beam)
♦ Clearance between front axle and
I
I
knuckle
♦ Kingpin cotter pin
♦ Wheel alignment
♦ Rear axle housing
♦ Breather
♦ Front wheel bearing (Refer to note 1.)
♦ Front wheel bearing grease
♦ Rear wheel bearing (Refer to note 1.)
♦ Rear wheel bearing grease
Wheel nut (Refer to note 2.)
NOTE:
11 - 8
T
I
I
I
I
R
I
R
I
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.
11-86
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
Items
Miles x 1,000
Kilometers x1,000
Months (every)
First
3
6
5
10
1
2
9
15
10
16
4
12
20
15
25
6
Every
18 20
30 32
8
24
40
10
30
48
12
36
60
50 72
Reference page
80 120
AIR-OVER-HYDRAULIC BRAKE SYSTEM (UD1800 thru UD2600)
♦ Service brake valve
Air dryer
I
I
11-64
♦ Air dryer repair kit
♦ Air compressor and air pressure governor (air
R: Every 12 months
I
dryer integrated model)
♦ Brake piping
♦ Brake hose
♦ Air booster repair kit
I
R: Every 12 months
R: Every 12 months
Brake fluid
♦ Wheel cylinder repair kit
♦ Brake lining clearance (Refer to note 1.)
♦ Brake lining
♦ Brake drum
♦ Parking brake system (note 2.)
♦ Parking brake chamber diaphragm (note 2.)
NOTE:
I
R
11-62
R: Every 12 months
I: Every 2,500 miles (4,000 km) or 1 month
I
I
I
R: Every 24 months
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)
Items
Miles x 1,000
Kilometers x1,000
Months (every)
First
3
6
5
10
1
2
9
15
10
16
4
12
20
15
25
6
Every
18 20
30 32
8
24
40
10
30
48
12
36
60
50 72
Reference page
80 120
AIR BRAKE SYSTEM (UD3300)
♦ Service brake valve
Air dryer
I
I
11-64
♦ Air dryer repair kit
♦ Air compressor and air pressure governor
♦ Brake piping
♦ Brake hose
♦ Rear and front brake chamber diaphragm
♦ Brake chamber push rod stroke (Refer to
I: Every 2,500 miles (4,000 km) or 1 month
♦ Rear brake chamber spring cylinder (Refer
R: Every 36 months
note 1.)
R: Every 12 months
I
I
R: Every 12 months
R: Every 24 months
to note 2.)
♦ Brake lining
♦ Brake drum
♦ Parking brake system
NOTE:
11 - 10
I
I
I
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
VEHICLE SERVICE AND MAINTENANCE
Chassis (Cont’d)
Items
Miles x 1,000
Kilometers x1,000
Months (every)
First
3
6
5
10
1
2
9
15
10
16
4
12
20
15
25
6
Every
18 20
30 32
8
24
40
10
30
48
12
36
60
50 72
80 120
Reference page
SUSPENSION
Leaf spring
Shock absorber
♦ U-bolt and nut
I
11-67
11-68
I
T
I
Air bellows (Air suspension)
Leveling valve (Air suspension)
Air leakage (Air suspension)
♦ Looseness and damage (Air suspension)
Shock absorber (Air suspension)
I
I
I
I
I
I
I
I
I
11-68
11-68
11-68
I
I
I
11-68
I
ELECTRICAL SYSTEM
Battery electrolyte level
Battery terminal
Specific gravity of battery electrolyte
I
11-76
11-77
11-77
I
I
OTHERS
♦ Acoustical shielding
Grease lubrication
I
L: Every 5,000 miles (8,000 km) or 1 month
11-16
11 - 11
VEHICLE SERVICE AND MAINTENANCE
Automatic transmission maintenance schedule
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)
Control Main**
Internal
Lube/Auxiliary
Change fluid when indi- Change filter when indiChange filter when indicated
cated by controller or 48 cated by controller or 48
Overhaul
by controller or 48 months,
General or severe
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.
Vocation
Fluid* (#1)
#1 OIL LIFE MONITOR
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
#2 FILTER LIFE MONITOR
The ATM maintenance indicator will flash beginning with the first TCM initialization after reaching the time and mileage parameters, indicating that the filter has reached the end of its designed life. The indicator will continue to flash
for two minutes after D (Drive) has been selected. Thereafter, the indicator will illuminate and flash upon each TCM
initialization, continuing to flash for two minutes after the selection of D (Drive) each time, until service is performed
and the indicator is reset.
Failure to perform maintenance and reset the ATM maintenance indicator after an additional 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.
TRANSMISSION HEALTH MONITOR
The ATM maintenance indicator will be illuminated, indicating the need for clutch maintenance, when the remaining
clutch life reaches approximately 10 percent, or if the running clearance exceeds a maximum value which may indicate a non-wear-related issue. The indicator will be lit steadily upon initialization of the TCM, and will remain on
steady at all times, continuing to operate in this manner until service is performed and indicator is reset. If reset does
not occur within 100 hours, the ATM system light will be illuminated (in addition to the ATM maintenance light) and
the TCM will register a diagnostic trouble code (DTC).
The indicator will reset automatically upon elimination of the clutch clearance condition which initiated it.
11 - 13
VEHICLE SERVICE AND MAINTENANCE
UD2600 and UD3300 (Allison 3000 series)
Filter Type
A disassembled
type (Incorporated
in the oil pan)
TES 295 Fluids*
(includes
TranSynd® )
Fluid and Filter Change Interval
High capacity** Main and
Fluid Change Intervals
Lube Filter Change Intervals
Whichever is first of the
Whichever is first of the
following:
following:
・If the wrench icon in the selec- ・If the wrench icon in the
selector is flashing on and
tor is illuminated steady for 2
off for 2 minutes after D
minutes after D (Drive) is
(Drive) selected
selected
・Any time the fluid is
・60 calendar months**
changed
NOTE: Always replace main
・60 calendar months**
and lube filters with the fluid
change**.
Suction Filter Assembly
Change Interval
At time of transmission
overhaul
TRANSMISSION HEALTH MONITOR (TM)
This prognostic feature determines clutch life status of the transmission’s clutches and alerts you when clutch maintenance is required. It helps avoid costly repairs and downtime by taking the guesswork out of scheduling routine
transmission maintenance, and it ensures your transmission is operating at its maximum performance level. The
clutch life status is determined by monitoring the cumulative changes and the calculated running clearance of the
transmission clutches.
11 - 14
VEHICLE SERVICE AND MAINTENANCE
CLUTCH MAINTENANCE NOTIFICATION
The TM determines when clutch maintenance is needed. If any of the clutches (except lockup) reaches a remaining
life of approximately 10 percent or if any of the clutch running clearances (except lockup) exceeds a maximum
value, then the wrench icon in the selector is steadily illuminated from just after ignition key on until ignition key is
turned the OFF position. if TM mode has been accessed via the shift selector, an “ok” or “Lo” is displayed. The “ok”
message means no clutch maintenance is needed, and the “Lo” message means an unacceptable clutch life status
exists and clutch maintenance is required.
DTC (Diagnostic Trouble Code) P2789, Clutch Adaptive Learning at Limit, sets if multiple warnings have occurred
due to the TM actively detecting issues with the clutch system and illuminating the ATM system light.
11 - 15
VEHICLE SERVICE AND MAINTENANCE
GREASE LUBRICATION POINTS
Lubrication point
No. of points
Lubrication point
No. of points
1
Rear helper spring
2RL
9
Steering column
2
Rear spring pin & shackle pin
3RL
10
Door hinge
2RL
3
Propeller shaft journal & yoke
3 to 6
11
King pin
2RL
4
Clutch release shaft
2
12
Tie rod end (Not applicable to UD1800
thru UD2300)
1RL
5
Clutch release sleeve
1
13
Parking brake chamber arm shaft
(Not applicable to UD1800 and UD2000)
1RL
6
Cab mounting front torsion bar contact
seat
1RL
14
Rear brake camshaft and slack adjuster
(UD3300)
2RL
7
Front spring pin & shackle pin
3RL
15
Front brake camshaft and slack adjuster
(UD3300)
2RL
8
Cab mounting main hook & pin
1
Recommended lubricants (Chassis grease)
Specifications
Parts
NLGI No. 1
1, 6, 8, 10
NLGI No. 2 or NLGI No. 3
2, 3, 4, 5, 7, 9, 11, 12, 13, 14, 15
11 - 16
1
VEHICLE SERVICE AND MAINTENANCE
UD2300
: Lubricate with a grease gun.
RL
x2
*
: Apply grease manually with a stick. Do not apply with finger or hand.
: Lubrication points located on both left and right sides of vehicle.
: Number of grease nipples or points.
: Refer to enlarged view.
UD2600
11 - 17
VEHICLE SERVICE AND MAINTENANCE
UD3300
UD3300
11 - 18
VEHICLE SERVICE AND MAINTENANCE
BEFORE PERFORMING
MAINTENANCE
WARNING
 Incomplete or improper ser-
vice or repair could cause
vehicle malfunction resulting
in serious injury or vehicle
damage.
 If you must work under the
vehicle while it is jacked up,
use safety stands and wheel
chocks.
Use care when inspecting, servicing
or repairing the vehicle. Heed the
warnings and follow the instructions
given on the labels and in this manual.
If you have any questions, contact
your authorized UD Trucks dealer or
qualified service facility before proceeding. Assure that the service or
repair has been completed properly.
Before performing any service or
maintenance on your UD Trucks
vehicle;
 Park the vehicle on a level ground.
 Shift the transmission to the NEU-
Used oil, coolant, fuel, etc.
TRAL position (Manual transmission) or P (Park) or N (Neutral)
position (Automatic transmission).
 Apply the parking brake and chock
the wheels.
 Allow the engine to cool before
attempting to service the vehicle.
 Whenever
possible,
perform
inspections with the engine off and
cooled.
It is illegal and harmful to the environment to dispose of used oil or
coolant, fuel, etc., by pouring it on
the ground, into sewers, or into bodies of water. Only use authorized
recycling facilities that may be provided by the local government or a
service facility. If any doubt, contact
local government authorities or your
authorized UD Trucks dealer or qualified service facility.
WARNING
When you must inspect or service a part or system with the
engine running:
 Remove
neckties,
rings,
watches, other jewelry and
loose articles.
 Keep articles, hands, clothes,
hair and tools away from the
drive belts and fan.
 Avoid shorting the battery terminals.
 Be sure that sufficient ventilation is available.
 Avoid contact with hot surfaces.
11 - 19
VEHICLE SERVICE AND MAINTENANCE
CAB
Opening the front lid
Opening and closing the front lid
1.Pull the lever located near the
underside of the left front pillar to
release the front lid lock.
CAUTION
 Crush hazard. Turn off wipers
before servicing.
 Before opening the front lid,
set the wiper arms to their normal positions. If the front lid is
opened with the wiper arms
tilted forward, the front lid will
contact the wiper arms. This
could damage the wiper arms
and front lid.
 Before driving, make sure the
front lid is securely locked.
11 - 20
3.When opening the front lid, be sure
to set the lever into the hole that is
indicated with the mark located on
the front lid.
2.Disengage the front lid hook. Push
up the front lid and secure it with
the rod.
VEHICLE SERVICE AND MAINTENANCE
Closing the front lid
1.Put away the rod.
2.Lower the front lid slowly.
3.Push down the front lid until it
clicks into place.
4.Make sure that the front lid is
locked.
WARNING
 When opening the front lid, be
sure to set the lever into the
hole that is indicated with the
mark located on the front lid.
If the lever is placed on other
locations, the lever may disengage and the front lid may then
close. This may cause an
injury.
CAUTION
Tilting the cab
Your UD Trucks vehicle provides
easy access for routine service and
maintenance. Many inspection and
maintenance procedures can be performed without tilting the cab. For
those that require tilting, the cab of
your UD Trucks vehicle can be lifted
with one person. The torsional spring
lifting system raises the cab automatically after it is released with little
or no upward pressure from the
operator.
Before tilting the cab
Before tilting the cab indoors, make
sure that there is sufficient clearance
above the cab (height clearance; H)
and in front of the cab (advance
clearance; F). The vehicle requires
minimum clearances of 13.1 ft (4 m)
in height and 4.9 ft (1.5 m) forward of
the cab.
1.Stop the vehicle on a level ground.
2.Shift the transmission to the neutral position and apply the parking
brake.
3.Make sure the engine is not running.
4.Chock the wheels as necessary.
5.Remove loose or heavy articles
from the cab.
6.Close the cab doors.
 To prevent possible damage,
before washing inside the front
lid, close the heater air inlet to
protect it from water.
11 - 21
VEHICLE SERVICE AND MAINTENANCE
cab frame. The torsional springs
will cause the cab to raise slightly.
Tilting the cab
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.
1.Remove the lock pin from the tilt
lock lever.
2.Pull the tilt lock lever out all the
way. This releases the main hook
which holds the cab body to the
11 - 22
3.While holding the grip (located on
the lower left side of the cab) on
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 manually.
4.Tilt the cab all the way forward until
the tilt strut is straight and insert
the safety pin into the pin hole on
the side of the tilt strut.
VEHICLE SERVICE AND MAINTENANCE
WARNING
To avoid the chance of serious
injury and/or property damage
when working on engine with the
cab tilted:
 Make sure that the parking
brake is firmly applied, the
wheels are blocked, and the
transmission shift lever is in N
(Neutral),
before
starting
engine.
 Be careful not to touch the
transmission control cable
when the engine is running.
Otherwise, the transmission
gears could engage and the
vehicle could move suddenly.
 Keep yourself, your clothing
and your tools away from moving parts such as the cooling
fan and drive belts when the
engine is running.
NOTE:
 Cover the air cleaner opening to
prevent dust or rainwater from
entering when leaving the cab
tilted for a long time.
Lower the cab
1.Check that no cloth, gloves, or
tools are left on or around the
engine, the exhaust manifold or
other hot surfaces.
3.While supporting the cab with your
hand on the grip, under the left
side of the cab, pull the tilt strut
rearward and lower the cab.
CAUTION
 Tools left in the engine com-
partment can damage the vehicle.
 Flammable materials left on or
near hot surfaces can be a fire
hazard.
2.Remove the safety pin from the pin
hole and store it in the storage
hole on the tilt strut.
WARNING
 When the tilt strut is pulled
rearward, the weight of the cab
may cause it to lower. Maintain
your secure grip on the grip
and lower the cab in a controlled manner.
4.Lower the cab all the way to its
normal position.
5.Check to be sure that the main
hook on the rear center portion of
11 - 23
VEHICLE SERVICE AND MAINTENANCE
the cab firmly engages the main
hook pin, located at the center of
the cab mounting bracket.
6.Replace the lock pin in the tilt lock
lever.
11 - 24
WARNING
ENGINE COOLING SYSTEM
 If the cab has not been com-
pletely locked, when the ignition key is turned ON, the
warning light will come on and
the warning buzzer will sound
at the same time. Relock the
cab.
 Do not operate the vehicle
without engaging the lock pin
in the tilt lock lever. If the lock
pin cannot be inserted, then
the main hook is not engaged
with the main hook pin. If not
properly engaged, then the cab
could rise accidentally while
the vehicle is moving which
could cause loss of vehicle
control and serious injury.
The engine cooling system was filled
at the factory with UDXtra Long Life
Diesel Engine Antifreeze/Coolant
with a 50/50 antifreeze/water mixture. UDXtra Long Life Diesel Engine
Antifreeze/Coolant contains rust and
corrosion inhibitors. UDXtra Long
Life Diesel Engine Antifreeze/Coolant provides protection against
freezing to approximately –31°F (–
35°C). UDXtra Long Life Diesel
Engine Antifreeze/Coolant must
remain in the system within 4 years
or 320,000 miles (500,000 km) to
provide protection against freezing,
boiling, rust and corrosion. Do not
use additional cooling system additives or inhibitors. They may interfere
with the proper operation of the cooling system.
Check the engine, radiator, hoses
and pipes daily. Repair any leaks.
Replace swollen and worn hoses
and tighten loose clamps.
Check the ENGINE COOLANT
LEVEL warning light daily. If the
warning light comes on, follow the
VEHICLE SERVICE AND MAINTENANCE
instructions in the “INSTRUMENTS
AND CONTROLS” of this manual.
Checking engine coolant level
WARNING
To avoid serious injury from hot
coolant or steam release:
 Do not open the radiator filler
cap while the engine cooling
system is hot; wait until it
cools.
 Be extremely careful when
opening the radiator filler cap.
Place a thick cloth on the cap
and slowly loosen it to allow a
reduction in pressure in the
cooling system.
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.
 Wash the coolant off with
clean water and then with soap
immediately when the coolant
gets on to your skin or cloth.
 Tighten the coolant container
cap and store it out of the
reach of children.
Open the front lid.
Check the engine coolant level daily
only when the engine is cool. Check
the coolant level in the coolant reservoir tank located behind the front lid.
The coolant level should be between
the MAX and MIN lines. If the coolant level is below the MIN line, add
the proper coolant solution to the
MAX line.
NOTE:
 Coolant will automatically be
supplied from the reservoir tank
to the radiator. Do not remove
the radiator filler cap.
Long Life Coolant
For the coolant, use UDXtra Long
Life Diesel Engine Antifreeze/Coolant that has been diluted 50% year
round. The LLC has an additive for
rust prevention and anti-freezing. It
is not necessary to add commercially
available antifreeze or rustproof
agent.
Precautions for use of LLC
 The service period of LLC is 4
years
or
320,000
miles
11 - 25
VEHICLE SERVICE AND MAINTENANCE
(500,000 km). After the service
period, clean the cooling system completely and replace the
coolant.
 When the engine coolant level
has dropped due to natural
water dissipation while using
Long Life Coolant, add genuine
Long Life Coolant that has been
diluted 50%.
Dilution Water
Dilution water for the cooling system
should be clean, free from deposit
and scale forming materials, and
corrosive chemicals.
11 - 26
CAUTION
 Antifreeze made with methoxy
propanol or propylene glycol
is not recommended for use
with UD Trucks engines. These
types of antifreeze can damage
engine internal seals and coolant hoses and create a potential fire hazard due to lower
flash points than ethylene glycol type antifreeze.
 Use only municipally supplied
water in the cooling system.
River, well or other water produces scale in the cooling system, which may cause damage
to the engine or cooling system.
 Do not add water without adding ethylene glycol antifreeze
to the engine cooling system,
except in an emergency. If
plain water is added in an
emergency, restore the proper
mixture of antifreeze and water
as soon as possible.
CAUTION
 If
the coolant should get
extremely low and the engine
very hot, let the engine cool
before adding coolant; then,
with the engine running, add
coolant slowly. Adding cold
coolant to a hot engine may
crack the cylinder head or cylinder block. Never use water
alone.
Checking and cleaning radiator
To maintain cooling system efficiency and keep the engine from
overheating, always keep the front
surface of the radiator core clean.
Remove insects, dirt and other
debris by directing pressurized air at
the rear surface of the radiator core.
VEHICLE SERVICE AND MAINTENANCE
CAUTION
 Do not direct pressurized air to
the front surface of the radiator
(that is, with the air hose
pointed toward the engine).
Doing so will force insects, dirt
and other debris into the radiator core and possibly cause
engine overheating.
Clean charge air cooler body
When mud, debris, etc., becomes
attached to the front of the core, the
passage of cooling air is impaired, so
it is recommended that this material
should be removed completely by
washing with a non corrosive detergent and water solution. (Refer to
instructions on the detergent container.)
Cooling fan and fan shroud
Check the cooling fan and fan
shroud for proper installation, cracks
or damage. Replace or repair faulty
parts or damage.
Deformed fins also can impair cooling, and should be repaired.
Clean the inside by blowing with air
when changing charge air cooler
hoses.
CAUTION
The charge air cooler is used to cool
the overheated intake air charged by
the turbocharger, and is installed at
the front of the radiator.
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.
NOTE:
 Do not use water to clean the
inside of the charge air cooler
body. Using water will impair
cooling due to corrosion.
11 - 27
VEHICLE SERVICE AND MAINTENANCE
WARNING
 To prevent hand injury, never
get your hand near the fan
when the engine is running. If
vehicle has an automatic fan
clutch, the fan may slow when
the coolant is cool, but it can
still cause hand injury.
CAUTION
 Do not modify the crankshaft
or fan pulleys to increase the
rated speed of the engine or
fan. Doing so may cause the
cooling fan blades to break
possibly resulting in injury.
Also, such modification constitutes tampering with the noise
control system.
11 - 28
Changing coolant
WARNING
To avoid serious injury from hot
coolant or steam release:
 Do not open the radiator filler
cap and drain cocks while the
engine cooling system is hot;
wait until it cools.
 Be extremely careful when
opening the radiator filler cap.
Place a thick cloth on the cap
and slowly loosen to allow a
reduction in pressure in the
cooling system.
 Be careful not to spill coolant
over the hot exhaust system
which can cause fire, serious
injury and/or property damage.
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.
VEHICLE SERVICE AND MAINTENANCE
WARNING
 Never drink Long Life Coolant,
Unless the cooling system is treated
with corrosion preventive, rust and
scale will eventually clog up passages in the radiator and water jackets. This condition is aggravated in
some localities by formation of insoluble salts from the water used.
CAUTION
 Do not use chemical mixtures
to stop radiator leaks except in
an emergency. Never use such
solutions in place of needed
radiator repair.
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.
 Wash the coolant off with
clean water and then with soap
immediately when the coolant
gets on to your skin or cloth.
 Tighten the coolant container
cap and store it out of the
reach of children.
To clean the cooling system
1.Open the radiator filler cap.
2.Place containers under the radiator drain cock and the cylinder
block drain cock.
Except for Allison 3000 series
specification vehicles
11 - 29
VEHICLE SERVICE AND MAINTENANCE
Allison 3000 series specification
vehicles
3.Open the radiator drain cock and
the cylinder block drain cock.
NOTE:
 The radiator drain cock has a
specified turning direction and
must be turned to the position
directly below the mark when
draining water.
 Drain water by turning the radiator drain cock round approximately 7 to 8 times.
Be careful not turn the radiator
drain cock round more than 9
times. Doing so may cause the
drain cock to fall off.
11 - 30
4.Drain all coolant solution from the
system into the containers.
For Allison 3000 series specification vehicles, drain coolant from
two drain cocks: one is located on
the oil cooler coolant hose and the
other is located under the radiator.
5.Shut the drain cocks. Fill the cooling system with a proper mixture of
water and a good quality cooling
system detergent. (Refer to the
additional instructions on the
detergent container)
6.Start the engine and run it at a high
idling speed until the indicator
points to the middle region of the
engine
coolant
temperature
gauge. Maintaining the above
engine coolant temperature with
the thermostat open, run the
engine and allow the detergent to
circulate throughout the cooling
system for at least 15 minutes.
7.Stop the engine. Open the drain
cocks and completely drain the
detergent from the system.
8.Shut the drain cocks and fill the
cooling system with plain water.
Start the engine and run it at a
moderate speed in the same manner as described in step 6.
9.Stop the engine. Open the drain
cocks and drain the rinsing water.
10.Repeat the rinsing procedure 2 or
3 times until the discharged rinsing
water appears clean.
11.Close the drain cocks.
To fill up the cooling system (With
coolant)
Use the following refill procedure to
remove air from the system and provide proper engine coolant level.
1.Fill the radiator slowly with the
proper coolant solution up to the
filler opening. Add coolant solution
up to the MAX level of the coolant
reservoir tank. Capacities are
shown below.
VEHICLE SERVICE AND MAINTENANCE
US
mea- Liters
sure
With manual transmission 6.9 gal
26
Except for
Allison
6.6 gal
25
With automatic trans- 3000 series
mission
Allison
30
3000 series 7.9 gal
Then properly close the radiator
filler cap and the reservoir tank
cap.
2.Operate the engine at a slightly
higher than normal idling speed
with the throttle control knob until
the engine coolant temperature
indicator points the middle region
of the gauge. Run the engine an
additional 10 minutes to allow the
air to escape from the engine cooling system.
3.Stop the engine. After the engine
has completely cooled down,
remove the radiator filler cap and
check the engine coolant level in
the radiator. If low, add coolant to
the radiator filler opening.
Reinstall the radiator filler cap.
4.Check the engine coolant level in
the coolant reservoir tank. If the
level is between the MIN and MAX
lines, it is normal. If it is below the
MIN level, add coolant solution up
to the MAX level.
5.If the added coolant solution is
more than 16.9 US fl oz (500 milli
liter), check and correct for any
sign of leakage, then repeat steps
1 to 4.
6.Check the drain cock for leaks.
ENGINE OIL AND OIL FILTERS
Engine oil recommendations
To extend the lubrication performance of your engine “UDXtra
Engine oil” or equivalent is available,
which has been specifically tested
and approved for UD Trucks
engines.
Please contact an authorized UD
Trucks dealer for further details
about “UDXtra Engine oil”.
Please consult the following instructions to select and use the proper
lubricant from a reliable supplier to
enhance trouble-free operation and
service life of the engine.
Oil grade: VDS-4
Oil quality
UD TRUCKS North America recognizes engine oils that meet or
exceed the standards given by
American Petroleum Institute (API)
for the oil classifications listed in this
manual.
Only oils licensed to carry the API
symbol should be used. Lubricants
meeting API standards have pro11 - 31
VEHICLE SERVICE AND MAINTENANCE
vided maximum engine life when
used together with the recommended oil and oil filter change intervals.
UDXtra (or VDS-4) diesel engine oil
is mandatory for use in all 2010
emission compliant engine.
UDXtra (or VDS-4) oils exceed the
API CJ-4.
For a complete list of approved oils,
see your UD TRUCKS dealer.
Also, refer to Technical Bulletin EN42, Approved Oils, UDNA.
NOTE:
 UD Trucks recommends using
the engine oil designated above
for the proper function of the
DPF system, and also use ultra
low sulfur diesel fuel (0.0015%
[15 ppm] by weight) only and
low-ash fuel must be less than
1% in weight.
Oil viscosity and relation between
viscosity and temperature:
The viscosity grade defines the
thickness of the oil. The oil must be
thin enough at low temperatures for
easy cold starts and thick enough to
protect at high temperatures. An oil
11 - 32
is not fully defined until both the API
quality classification and the viscosity grade are specified.
Choose the viscosity grade for the
typical ambient air temperature
(AAT) for the application.
Multi grade oils have a broad range
that suit operation in changing temperature.
The standard oil weight for UD
TRUCKS engines is 10W/30.
UD TRUCKS recommends the viscosities shown in the viscosity/ temperature table for UD TRUCKS
engines.
NOTE:
 Select the oil viscosity accord-
ing to the next diagram, basing
your selection on the maximum
and the minimum ambient air
temperatures.
CAUTION
 Use of diesel fuel other than
ULSD (Ultra Low Sulfur Diesel
fuel) and engines oils other
than UDXtra (or VDS-4), will
adversely affect performance,
efficiency and durability of the
Aftertreatment DPF system
and the engine may not run at
all.
 Manufacture’s warranties can
also be rendered void due to
usage of improper fuel.
Unapproved fuel additives
(including engine oil) are NOT
permitted.
VEHICLE SERVICE AND MAINTENANCE
 DO NOT add extra oil addi-
tives. Additives such as breakin oils, top oils, graphitizes,
and friction - reducing liquids
are not necessary and can
harm the engine.
Periodic service interval
Type of
operation
Type 1
Type 2
UDXtra
Engine oil
24,000 mile
(40,000 km)
30,000 mile
(48,000 km)
*Non-UDXtra
Engine oil
15,000 mile
(25,000 km)
20,000 mile
(32,000 km)
*Non-UDXtra engine oil refer to page
11-31.
Type of operation
Type 1
1.Unpaved road
2.Dusty road
3.Heavy long distance transport
4.Mountain road operations
5.Sort-haul distribution operations
6.Construction operations (off-road)
7.Light duty in city operations
8.Annually mileage up to 65,000
miles (100,000 km)
Checking engine oil level
WARNING
Type 2
1.Light long duty distance transport
2.Mainly on motor ways and express
highways
3.Annually mileage over 65,000
miles (100,000 km)
4.Paved and flat road operations
 To avoid serious injury from
hot engine and engine oil, only
check engine oil level and perform maintenance after engine
has cooled.
Check the engine oil level before
driving your vehicle each day. Check
the oil level with the engine off.
When checking the oil level after
stopping the engine, wait at least 30
minutes to allow the oil to return to
the oil pan.
To check the engine oil level
1.Park the vehicle on a level ground.
2.Remove the oil level gauge (dipstick) located on the left hand side
of the engine. Wipe the gauge
clean with an oil rag and reinsert it.
Remove the gauge and check the
oil level. Maintain the engine oil
level between the MAX and MIN
11 - 33
VEHICLE SERVICE AND MAINTENANCE
marks on the engine oil level
gauge.
CAUTION
 Do not drive the vehicle with
the engine oil level below the
LOW mark on the engine oil
level gauge. An insufficient
quantity of engine oil can
cause engine seizure.
 Use care to keep dirt and
debris from entering the crankcase through the oil filler port
when adding engine oil.
WARNING
3.If oil level is low, add engine oil of
the proper viscosity for the anticipated temperature range during
the service interval through the oil
filler port located on the valve
cover on top of the engine. Do not
add oil above the MAX mark on
the engine oil level gauge.
11 - 34
 Be careful not to spill oil. Do
not add oil if engine or exhaust
system are hot. Spilling oil on
hot parts can result in a fire.
Changing engine oil
WARNING
 To avoid serious injury from
4.Change the oil if it shows signs of
contamination such as discoloration and changes in oil texture.
See the instructions under the caption "Changing engine oil"on page
11-34.
5.After adding oil, wait at least 10
minutes, then recheck the oil level.
6.After checking, securely insert the
engine oil level gauge.
hot engine and engine oil, only
change oil after engine has
cooled.
CAUTION
 Try to avoid direct skin contact
with used oil. If skin contact is
made, wash thoroughly with
soap or hand cleaner as soon
as possible.
VEHICLE SERVICE AND MAINTENANCE
Engine oil capacity
With oil filter
Without
oil filter
US
measure
18.4 qt
Liter
18.0 qt
17.0
17.4
The engine oil change interval varies
with the type of engine oil used and
vehicle driving conditions. If the vehicle is driven for extended periods of
time at high or low speeds, in dusty
areas, with frequent idling or carrying
heavy loads, engine oil will deteriorate faster and require more frequent
changing.
As the temperature rises, the engine
oil’s viscosity decreases, reducing its
lubricating effect. To choose an oil
with the proper viscosity for the
anticipated ambient air temperature
range, refer to "Oil viscosity and relation between viscosity and temperature:"on page 11-32.
3.Place a container under the drain
plug in the bottom of the oil pan.
Remove the plug and drain the oil
into the container.
plug in the drain hole and tighten
the drain plug.
Replace washer with new ones for
each remove the drain plug.
Tightening torque:
40 to 44 ft·lbf (54 to 59 N·m)
(5.5 to 6.0 kgf·m)
5.Replace the oil filter. Refer to "Oil
filter"on page 11-36 for the instructions.
6.Add engine oil through the oil filler
port.
7.After refilling the engine oil, wait for
at least 10 minutes, then using the
oil level gauge (dipstick) check the
oil level. If the engine oil level is
low, add additional oil. Wait 10
minutes, then recheck the oil level.
Repeat this procedure until the
engine oil reading on the engine oil
level gauge is between MAX and
MIN.
To change the engine oil
1.Park the vehicle on level ground.
2.Remove the oil filler cap.
4.When all the oil has been drained
from the oil pan, replace the drain
11 - 35
VEHICLE SERVICE AND MAINTENANCE
To replace the filter
Oil filter
CAUTION
CAUTION
 Do not handle hot oil filter
 Just after driving, the engine
without hand protection. Failure to do so may result in burn
injury.
oil is still hot and can burn
you. Before changing or
checking the oil, let it cool
down until you can touch the
oil without getting burned.
NOTE:
 Use genuine UD Trucks filter or
equivalent in quality and design.
Use of an inferior filter could
diminish operation of the engine
and emission controls.
 Always replace the oil filter at
the same time that the engine oil
is replaced.
As oil is full in the cartridge after an
engine stops, it is needed to drain
the oil. The following is an outline of
the procedure.
1.Remove the air draining plug, and
loosen the drain plug until it spins
free.
2.The oil will drain within approximately 5 minutes and the cartridge
can then be removed.
3.Tighten the drain plug.
Tightening torque:
9.4 to 16.7 ft·lbf (12.8 to 22.6 N·m)
(1.3 to 2.3 kgf·m)
4.Place a new cartridge, turn it 3/4 to
1 time after the seal contacts.
NOTE:
 Make sure the oil drain plug is
tightened to the listed specification prior to the installation of
the new cartridge.
5.Add approximately of engine oil
and install the filler cap tightly.
With oil filter
Without
oil filter
US
measure
18.4 qt
Liter
18.0 qt
17.0
17.4
6.Start the engine and check for oil
leaks.
11 - 36
VEHICLE SERVICE AND MAINTENANCE
WARNING
 After replacement of the oil fil-
ter, operate the engine to
check if there is any oil leakage around the oil filter. Oil
leakage can cause a fire.
7.Stop the engine and wait at least
10 minutes.
Recheck the level and fill to the
MAX mark if necessary.
FUEL SYSTEM
WARNING
 Keep flames and heat away
from the fuel system since the
fuel is flammable and can
cause a fire or explosion.
A problem with the components that
supply fuel to the engine can cause
low fuel pressure. This can decrease
engine performance.
1.Check the fuel level in the fuel
tank. Make sure the breather valve
of the fuel tank is not clogged with
dirt.
2.Check the fuel lines for fuel leakage. Be sure the fuel supply line
does not have a restriction or a
bad bend.
Fuel tank
Water in the diesel fuel will accumulate at the bottom of the fuel tank. A
small area near the drain cock traps
the water. When water has accumulated in the fuel filter, it has also
accumulated in the fuel tank. Drain
the accumulated water from the fuel
tank when the fuel filter is drained.
To minimize loss of fuel, drain the
fuel tank as it approaches empty. Do
not re-use any fuel drained with the
water.
To drain water from the fuel tank
1.Put a container under the fuel tank
drain plug.
2.Remove the drain plug from the
bottom of the fuel tank.
 Wipe any spilled oil off the engine.
 Do not run the engine with the oil
level below the MIN mark, or with
the filler cap and/or level gauge
removed.
11 - 37
VEHICLE SERVICE AND MAINTENANCE
3.Allow all the water to drain from
the tank.
4.When fuel begins to drain from the
tank, replace the drain plug.
Tighten the drain plug.
Tightening torque:
36 to 51 ft·lbf (49 to 69 N·m) (5 to
7 kgf·m)
WARNING
 Wipe off any leaked fuel, as it
could cause a fire.
CAUTION
 Check the packing of the drain
plug for damage. If damaged,
replace with a new one.
Fuel requirements
Use only ultra-low sulfur diesel fuel
which contains less than 15 ppm
(parts per million) by volume of sulfur.
 Do not use ether or other start-
ing aids which are flammable.
CAUTION
CAUTION
 The
aftertreatment
DPF*
requires diesel fuel with a sulfur content of less than 15 ppm
(0.0015%) by weight. If the sulfur content is higher than 15
ppm (0.0015%) by weight, the
DPF system and engine may
be damaged.
DPF*: Diesel Particulate Filter system
Use good quality ASTM 2-D
Expected
temperature
Above
+20°F (-7°C)
Below
+20°F (-7°C)
Preferred fuel grade
Grade Ultra Low Sulfur
Grade 2-D S15
Grade Ultra Low Sulfur
Grade 1-D S15
Use diesel fuel with cetane number
45 or higher. Check with the service
establishment to be sure you get the
properly blended fuel for the season.
11 - 38
WARNING
 Use diesel fuel only. Do not
use gasoline or any other nondiesel fuel.
NOTE:
 Fuel additives should not be
used.
 For prolonged idling operation,
operation in temperatures below
32°F (0°C), or operation in high
altitude areas (above 5,000 ft.,
1,500 m), winterized 2-D may be
used.
 If gasoline is put into the fuel
tank by mistake, completely
drain the fuel system to remove
the gasoline.
VEHICLE SERVICE AND MAINTENANCE
Keep fuel clean and prevent water
from entering the fuel system.
Feeding clean fuel to the engine
depends both upon the supplier and
the user.
For example, when fuel is supplied
from a corroded storage tank, the
fuel should be filtered before it is put
into the fuel tank of the vehicle.
Water in fuel adversely affects the
fuel injection system and engine.
Water and dirt should be removed
from fuel contaminated during storage.
When filling the fuel tank in the rain
or snow, care should be taken not to
allow water in the fuel tank.
Do not forget to screw on the fuel
tank cap securely.
Fuel filling
CAUTION
WARNING
 Keep flames and heat away
from the fuel system since the
fuel is flammable.
Any of these can result in serious injury and/or property
damage due to fire.
 Wipe off any leaked fuel, as it
could cause a fire.
Keeping your fuel tank filled with fuel
will help reduce condensation within
the tank.
Fuel cap
 Never
operate your vehicle
without a fuel cap. If the fuel
cap needs to be replaced, use
a UD Trucks cap or an equivalent. Use of an incorrect fuel
cap could result in a fuel system or emission control system malfunction.
Fuel filter
Your UD Trucks vehicle is equipped
with a main fuel filter and primary
fuel filter with water separator.
The fuel filters remove dirt and the
water separator removes water from
the fuel.
NOTE:
WARNING
 Use of an incorrect fuel cap or
operating the vehicle without a
fuel cap could result in a fire.
 Failure
to perform periodic
maintenance can cause fuel filters to clog and the fuel supply
to decrease or to stop.
Periodic maintenance of the fuel filter should be performed.
If the fuel is contaminated with dirt,
more frequent maintenance on fuel
11 - 39
VEHICLE SERVICE AND MAINTENANCE
filter is required as shown in
"Engine"on page 11-4.
If you are not certain concerning the
proper interval, contact your authorized UD Trucks dealer. Use genuine
UD Trucks fuel filters or equivalent.
Consult your authorized UD Trucks
dealer regarding the quality and
interchangeability of fuel filters.
WARNING
Fuel is flammable and can cause
fire or explosion. To minimize
this hazard, do the following:
 Be sure to drain the fuel into a
container and dispose of it
properly.
 If fuel is spilled on engine
parts, wipe it off entirely.
 Do not smoke when performing maintenance on the fuel
system. Keep flame and heat
away from the fuel system.
11 - 40
 Use a filter wrench to loosen
the fuel filter. Use of an ordinary tool (for example, chaintype tool) can scratch or dent
the peripheral surface of the
fuel filter. If the fuel filter is
damaged, it can cause fuel to
leak.
 After
replacing the filter,
inspect the external surface of
the fuel filter checking for
scratches and dents. It is dangerous to use a scratched or
dented fuel filter, since it can
cause fuel to leak.
 After replacement of the element, operate the engine to
check if there is any fuel leakage around the fuel filter.
Inspect the water level in the fuel filter daily through the transparent
case. Drain water before it reaches
the upper portion of the transparent
case.
Main filter
To replace the fuel filter
1.Clean outside the filter not to get
dust into the filter at the disassembly. Prepare a tray for drained fuel
(approx. 2.1 qt [2.0 liter]) and a
hose (inner diameter 0.2 in [5 mm],
length 3.3 ft [1 m]).
2.Put the hose in the drain plug, and
loose the drain plug and air purge
plug to drain the fuel. The fuel will
be received by the tray. [loosen
until you can see an o-ring on the
plug (approx. 0.2 in [5 mm]).
3.After draining, loosen the case and
remove the case and element from
the housing.
VEHICLE SERVICE AND MAINTENANCE
4.Install a new o-ring for the case
lubricating it with clean diesel fuel.
5.After putting a new element into
the case, place it to the housing
and tighten the case to the following torque.
Tightening torque:
26 to 29 ft·lbf (35 to 40 N·m)
(3.6 to 4.1 kgf·m)
6.Tighten the drain plug and air
purge plug securely by hand.
7.After the filter change, purge the
air from the fuel system. For air
purging details, refer to "Purging
air from fuel system"on page 1143.
8.Start engine and check the fuel
system for leaks.
WARNING
Primary fuel filter
To drain water from the fuel filter
 Using improper fuel filters can
shorten the life of the engine
and/or fuel injection system.
Such fuel filters can become
damaged or may leak fuel
which can result in serious
injury and/or property damage
due to fire.
1.Stop the engine, prepare a tray to
receive drained water.
2.Loosen the drain plug and drain
the water (approx. 6.8 USfl oz [200
milli liter] into the tray).
3.After finish the draining, tighten the
drain plug securely by hand.
11 - 41
VEHICLE SERVICE AND MAINTENANCE
To replace the fuel filter
1.Clean outside the filter not to get
dust into the filter at the disassembly. Prepare a tray for drained fuel
(approx. 2.1 qt [2.0 liter]).
2.Loosen the drain plug to drain the
fuel. The fuel will be received by
the tray.
3.After draining, loosen the case and
remove the case and element from
the housing.
4.Change the o-ring for case to new
one and put some clean diesel on
the new o-ring.
5.After putting a new element into
the case, place it to the housing
and tighten the case to the follow11 - 42
ing torque.
Tightening torque:
26 to 29 ft·lbf (35 to 40 N·m)
(3.6 to 4.1 kgf·m)
6.Tighten the drain plug surely by
hand.
7.Remove the fuel inlet plug on top
of the filter and pour diesel fuel
fully in it, and tighten the plug to
the following torque.
Tightening torque:
1.7 to 2.5 ft·lbf (2.3 to 3.4 N·m)
(0.2 to 0.3 kgf·m)
8.After the filter change, purge the
air from the fuel system. For air
purging details, refer to "Purging
air from fuel system"on page 1143.
9.Start engine and check the fuel
system for leaks.
WARNING
 Using improper fuel filters can
shorten the life of the engine
and/or fuel injection system.
Such fuel filters can become
damaged or may leak fuel
which can result in serious
injury and/or property damage
due to fire.
VEHICLE SERVICE AND MAINTENANCE
Purging air from fuel system
If air gets into the fuel system, it will
cause inconsistent fuel injection and
possible engine malfunction. It is
therefore necessary that any air be
bled off which may have found its
way into the fuel system while
changing fuel filters, or when the fuel
lines have been otherwise disconnected.
To purge air from the fuel system
2.Put the hose in the air purge plug
and loose the plug. Let the other
side of the hose get into the tray.
(loosen until you can see an orings on the plug).
3.Push the priming pump then the
fuel is pumped up from the tank
and get into the filter.
4.Keep pushing the priming pump
until clear fuel with no air is exiting
the air purge plug.
5.After the air has been removed,
tighten the air purge plug securely
by hand.
Fuel hose and clamp
Check the fuel rubber hose and
clamp of the fuel system for looseness cracks or damage. Replace
faulty parts if necessary.
WARNING
 Keep flames and heat away
from the fuel system since the
fuel is flammable.
Any of these can result in serious injury and/or property
damage due to fire.
 Wipe off any leaked fuel, as it
could cause a fire.
Fuel tubing
1.Prepare a tray for drained fuel
(approx. 2.1 qt [2.0 liter]) and a
hose (inner diameter 0.2 in [5 mm],
length 3.3 ft [1 m]).
Check the fuel tubing for fractures,
damage or improper installation.
Replace faulty parts if necessary.
Whenever the fuel tubing is disconnected, be sure to purge air from the
fuel system.
11 - 43
VEHICLE SERVICE AND MAINTENANCE
WARNING
 Keep flames and heat away
from the fuel system since the
fuel is flammable.
Any of these can result in serious injury and/or property
damage due to fire.
 Wipe off any leaked fuel, as it
could cause a fire.
AIR CLEANER ELEMENT
To inspect the air cleaner service
indicator
The air cleaner service indicator is
installed near air cleaner.
Check whether a red signal is shown
on the service indicator for clogging
of the air cleaner element.
If the dust indicator signal is red, and
if it often becomes red after resetting
by pushing the button on the end,
replace the element.
To replace the air cleaner element
Never clean the viscous type (wet
type) air cleaner element.
11 - 44
CAUTION
 If the viscous type (wet type)
element is sprayed with compressed air, washed, hit, or
struck, the filter function can
be seriously deteriorated, and
early clogging may occur.
1.Unlock the clips and remove the
air cleaner cover.
2.Remove the element.
VEHICLE SERVICE AND MAINTENANCE
NOTE:
 If the vacuator valve is broken
or missing, water and dirt can
easily enter the air cleaner.
Install a new vacuator valve.
3.Clean the cover and inside of the
case with a clean, dry cloth.
or be damaged by excessive
tightening.
7.Reinstall the new element in the
reverse sequence of removal.
 Be sure that all three clips are
locked securely when replacing
the element and housing cover.
 Install the rubber seal so that it
may not be twisted.
CAUTION
 Failure to completely install
5.Check the rubber seal and hose
for breakage and the clamps for
looseness. If broken, replace it
with a new part. If the clamps are
loose, tighten them.
6.Replace the element.
NOTE:
4.Clean the vacuator valve. Be sure
it is not broken or missing.
the clips may cause a defect in
the element packing surface,
allow dust into the engine, and
cause premature wear of pistons and liners.
8.After finishing replace of the element, press the reset button at the
end of the indicator to reset.
 Be sure to use genuine UD
Trucks element. Do not use an
inferior element because it may
aspirate dust due to a bad seal
11 - 45
VEHICLE SERVICE AND MAINTENANCE
DRIVE BELT
meter”. For daily inspections
without the sonic tension meter,
checking the amount of deflection of the belt using a hand is
allowed.
Check air conditioner belts for proper
tension by applying pressure of 22
lbf (98 N) (10 kgf) with your finger to
the belt at measuring as shown in
the figure. If necessary, adjust them
to their specified tensions.
WARNING
 Do not check or adjust drive
belt, unless engine is off and
the transmission is in N (Neutral).
Engage the parking brake securely.
Visually check the drive belt daily for
cracks and damage. If a belt is in
poor condition, have it replaced by
an authorized UD Trucks dealer or
other qualified service facility.
NOTE:
 The belt tension measurement
is recommended to be performed using a “sonic tension
11 - 46
VEHICLE SERVICE AND MAINTENANCE
Air conditioner belt tension
Belt
When new
When adjusted
When measuring with a sonic tension meter
Specific weight
Frequency
Length of span
of the belt
Number of ribs
(Hz)
in (mm)
(gf/rib·m)
202 - 216
175 - 187
4
10.7 (272)
14.5
0.32 - 0.36 (8.2 - 9.1)
0.39 - 0.43 (10 - 11)
Fan belt
To adjust belt tension
Because this engine is equipped
with a belt tensioner, the adjustment
of belt deflection is not necessary.
However, it is necessary to confirm
that the indicator (engraved line) of
the belt tensioner is in the belt
usable range by performing the
visual check from the X position (X
arrow view). Also, check the belt for
damage at this time.
Air conditioner belt:
1.Loosen the lock nut A of the idler
pulley.
2.Adjust the adjusting bolt B and
adjust the deflection of the belt at
measuring point Y so that it comes
within the standard range.
The tension of the belt can be
increased by turn the adjusting bolt
B clockwise.
Belt deflection
22 lbf (98 N) (10 kgf) by
depressing
in (mm)
3.After adjustment, securely tighten
the lock nut A.
Tightening torque:
Lock nut A
22.4 to 28.9 ft·lbf
(30.4 to 39.2 N·m)
(3.1 to 4.0 kgf·m)
11 - 47
VEHICLE SERVICE AND MAINTENANCE
 If there are any abnormalities of
pulleys motion.
 If the pulleys do not return when
releasing the belt.
AFTERTREATMENT DEF
FILTER
Replacement of DEF filter
The main filter is provided under the
supply
module
(DEF
pump).
Replace the filter on a regular basis.
If the indicator (raised line) is out of
stretched belt indicator, or if the belt
is damaged, replace the belt with a
new one.
To inspect the belt tensioner
Push down the belt between the pulleys with a constant force. Check to
see that the tension pulleys move
with constant speed.
Then release the belt and check to
see that the tension pulleys return to
the original position by the spring
force.
Replace the belt tensioner when any
of the following conditions exist.
 If the pulleys do not move when
pushing down the belt.
11 - 48
NOTE:
 DEF is a very safe liquid, but it
might cause a very slight irritation for some people. If it is
spilled on the body, wash it off
with water, and if it is drunk mistakenly, drink 1 or 2 cups of
milk. If milk is not available,
drink water. In all case, consult a
physician.
VEHICLE SERVICE AND MAINTENANCE
 To prevent dirt getting into the
DEF system, clean the DEF lines
and the DEF tank before removing them.
 Always plug DEF lines to prevent dirt getting into the DEF
system and the crystallization of
the DEF.
Replacement procedure
1.Switch off the engine.
NOTE:
 Wait at least two minutes before
4.Remove the equalizing element.
removing DEF hoses to allow
the automatic draining of the
DEF system and to depressurise
the DEF system.
2.Disconnect all electrical power to
the vehicle by disconnecting the
battery negative (–) terminal.
Fetch equipment and place a suitable container under the DEF
pump.
3.Remove the filter cover from the
pump.
5.Insert the puller, and remove the
filter using the puller.
6.Clean the sealing surface of the
housing with water only.
7.Install the new filter.
11 - 49
VEHICLE SERVICE AND MAINTENANCE
on the cover.
Tightening torque:
15 to 18 ft·lbf (20 to 25 N·m)
(2.0 to 2.5 kgf·m)
CCV FILTER
Replacement of CCV filter
The CCV (blow-by gas reducing system) filter captures oil contained in
blow-by gas. Replace it on a regular
basis.
8.Apply a thin film of engine oil to the
o-ring on the new equalizing element.
Install the new equalizing element.
10.Connect the battery negative (–)
terminal.
11.Start the engine and ensure there
is no leakage.
NOTE:
 If any DEF splashed onto any
part, completely wipe it off.
9.Install the filter cover. Tighten the
filter cover to the torque specified
11 - 50
1.Clean the area around the CCV filter cap to prevent dirt from entering during replacement.
2.Turn the filter cap counterclockwise for removal and replace the
element.
3.After replacing the cap O-ring with
a new one, apply engine oil lightly
and install the cap. Tighten the cap
VEHICLE SERVICE AND MAINTENANCE
securely until it is raised and
stopped.
NOTE:
 Since blow-by gas, which is
reduced after intake, includes a
trace of oil mist, oil comes in
contact with the inner surfaces
of the air intake parts even
under normal operation environment due to operation over a
long period of time. This is not a
failure.
CAUTION
 Be sure to turn the filter cap by
hand. Use of a tool may damage the cap.
 Be sure to replace the element
at the specified time. Use of
the element after the replacement period may cause clogging of the element, resulting
in increase of oil mist in the
blow-by gas that is reduced
after intake.
TRANSMISSION GEAR OIL
WARNING
 To avoid possible burn injury,
allow the transmission to cool
before checking or changing
the transmission oil.
Check the vehicle daily for transmission oil leakage. If there is any evidence of oil leakage, locate and
correct the cause. Visually check the
transmission oil level. If low, add oil
until the level reaches the bottom of
the filler plug hole.
To check the manual transmission
gear oil level
1.Remove the transmission filler
plug and visually check that the oil
level reaches the bottom of the
filler hole.
11 - 51
VEHICLE SERVICE AND MAINTENANCE
CAUTION
 To prevent dirt and debris from
entering the transmission,
clean the filler plug, transmission housing, and surrounding
area before checking.
 If the transmission oil level is
low, the transmission will not
operate normally and could
malfunction. Check to determine the cause of low oil level.
Correct the condition before
operating the vehicle.
2.After checking the oil level, replace
the filler plug gasket with a new
one.
11 - 52
3.Reinsert the plug and tighten the
plug.
Tightening torque:
UD1800 thru UD3300
MLS63
72 to 89 ft·lbf (98 to 120 N·m)
(10 to 12 kgf·m)
UD2600 and UD3300
MLS63
72 to 94 ft·lbf (98 to 130 N·m)
(10 to 13 kgf·m)
MPS63
87 to 101 ft·lbf (118 to 137 N·m)
(12 to 14 kgf·m)
To check the automatic transmission fluid level (Allison 1000, 2200
and 2500 series)
 Check the fluid while the vehicle is
on level ground and the parking
brake applied. Start the engine and
run for at least one minute at 900
to 1,000 rpm to clear the system of
air. Shift the transmission to Drive,
Reverse, and then to Neutral to fill
the clutch cavities and fluid passages.
 Always clean around the end of
the filler tube before removing the
dipstick. Dirt or foreign matter must
not be permitted to enter the fluid
system. It can cause valves to
stick, cause undue wear of transmission parts, or clog passages.
Check the fluid level by one of the
following procedures and report
any abnormal fluid level to your
maintenance personnel.
VEHICLE SERVICE AND MAINTENANCE
operated until a hot check can
be made.
 A cold fluid check may be made
<COLD CHECK>
when engine coolant temperature
gauge starts to move. (Reference;
approximately 86°F: 30°C)
 Run the engine for at least 1 minute to clear the fluid system of air.
 With the engine running at idle,
wipe the dipstick clean and check
the fluid level. Any level within the
COLD band is satisfactory for
operating the vehicle. If the level is
not within the COLD band, add or
drain fluid as necessary to bring
the level to the middle of the COLD
band.
 Perform a hot check at the first
opportunity after driving vehicle for
at least 30 minutes. (Reference;
Sump temperature is 160 to
200°F: 71 to 93°C.)
NOTE:
<HOT CHECK>
 The purpose of the cold check is
 Operate the transmission in a drive
to determine if the transmission
has enough fluid to be safely
range for at least 30 minutes to get
operating temperature. (Reference; 160 to 200°F: 71 to 93°C)
NOTE:
 The fluid must be hot to ensure
an accurate check. The fluid
level rises as temperature
increases.
 Park the vehicle on a level spot,
shift to (N) neutral and apply the
parking brake. Let the engine run
at idle speed.
 Wipe the dipstick clean and check
the fluid level. The safe operating
level is any level within the HOT
band on the dipstick.
 If not within this range, add or
drain fluid as necessary to bring
the level to the middle of the HOT
band.
11 - 53
VEHICLE SERVICE AND MAINTENANCE
fluid level is within the COLD band
range. If the fluid level is not within
the range, refill fluid.
To check the automatic transmission fluid level (Allison 3000 series)
Inspection with the fluid dipstick
 Check the fluid while the vehicle is
<HOT CHECK>
on level ground and the parking
brake applied. Start the engine and
run for at least one minute at 900
to 1,000 rpm to clear the system of
air.
 Idle the engine.
 With the engine at idle, depress
the brake pedal and shift the range
to D (Drive) or R (Reverse) to fill
the whole hydraulic circuit with
fluid.
 Shift the range to N (Neutral).
 With the engine at idle and the
range in the N (Neutral) position,
inspect the fluid level.
 After warming up the engine and
driving for about 10 to 15 minutes,
pull the fluid dipstick out of the filler
tube, wipe fluid off the dipstick surface, 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
fluid level is within the HOT band
range.
 If the fluid level is within the HOT
band range, the inspection is completed. If the fluid level is not within
the range, refill fluid.
<COLD CHECK>
 Pull the fluid dipstick out of the filler
tube, wipe fluid off the dipstick surface, 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
CAUTION
 Before the inspection, be sure
to apply the parking brake.
Then, while the engine is running at idle, conduct the
inspection. If the inspection is
conducted while the engine
stops, the apparent amount
becomes large.
 If
the
fluid
temperature
increases, the fluid level
increases. Be sure to conduct
a final check while the fluid
temperature is high after
warming-up.
 Before the inspection, clean
around the end of the filler
tube to prevent dust, mud or
water from entering the filler
tube. If dust, mud or water
enters, a failure of the transmission may be caused.
Inspection with the electronic fluid
level sensor
 Warm up the engine, drive the
vehicle for about 10 to 15 minutes,
stop on a level ground, and then
shift to the N (Neutral) range.
 The vehicle has been stationary for
about 2 minutes to allow the fluid
to settle.
 Run the engine at an idle.
 Push
the
and
switches of
the selector at the same time.
Fluid level is proper:
“O L” “O K” “O K” are displayed by
two letters in sequence, 6 letters in
total, on the digital display.
NOTE:
 To recover the fluid level check
mode, push the N switch of the
selector.
 If the measuring conditions have
been satisfied, the results will be
displayed on the digital display
about 2 minutes later.
Fluid level is low:
“O L” “L O” “O 1” are displayed by
two letters in sequence, 6 letters in
total, on the digital display. If the last
figure is 1, 1 quart of fluid must be
added.
Fluid level is high:
“O L” “H I” “O 2” are displayed by two
letters in sequence, 6 letters in total,
on the digital display. If the last figure
is 2, 2 quarts of fluid must be
released.
11 - 55
VEHICLE SERVICE AND MAINTENANCE
 If the measuring conditions have
Manual transmission gear oil
change
not been satisfied, “O L” “ -- ”
“E L” are displayed by two letters
in sequence, 6 letters in total, on
the digital display. The meanings
of the last two figures are as indicated in the following table.
To change the manual transmission gear oil
WARNING
 To avoid possible burn injury,
Code
“O L”
*
“ -- ”
Cause of code
“X * ”
Waiting period is not complete
“E L”
Engine speed (rpm) too low
“E H”
Engine speed (rpm) too high
“S N”
N (Neutral) must be selected
“T L”
Sump fluid temperature too low
“T H”
Sump fluid temperature too high
“S H”
Output shaft rotation
“F L”
Sensor failure (may be speed sensor, throttle sensor,
temperature sensor, or oil level sensor - but this indication does not identify which has failed)
: The display is a flashing numeral, counting down from 8 to 1 until the
waiting period is complete.
11 - 56
allow the transmission to cool
before checking or changing
the transmission oil.
1.Place a container under the drain
plug. Remove the drain plug and
completely drain the transmission
oil.
VEHICLE SERVICE AND MAINTENANCE
2.After draining, replace the gasket
of the drain plug with a new one.
Reinsert the plug and tighten the
plug.
Tightening torque:
UD1800 thru UD3300
MLS63
72 to 89 ft·lbf (98 to 120 N·m)
(10 to 12 kgf·m)
UD2600 and UD3300
MLS63
72 to 94 ft·lbf (98 to 130 N·m)
(10 to 13 kgf·m)
MPS63
87 to 101 ft·lbf (118 to 137 N·m)
(12 to 14 kgf·m)
NOTE:
 The drain plug contains a mag-
net. Remove any iron filings on
the plug before reinstalling the
plug.
Oil refill capacity (Approximately)
PTO
MLS63
MPS63
Without
With
Without
With
Oil capacities
US qt (liters)
7.2 (6.8)
7.8 (7.3)
8.3 (7.8)
8.8 (8.3)
4.Visually check the oil level and add
oil, if necessary, until it reaches the
bottom of the filler plug hole.
Automatic transmission fluid
change
Have the automatic transmission
fluid changed by an authorized UD
Trucks dealer or other qualified service facility. Use only the transmission
fluid
listed
in
the
"RECOMMENDED
LUBRICANTS"on page 13-5.
Automatic transmission fluid
filter (Allison 1000, 2200 and 2500
series)
WARNING
 Do not handle hot filter without
hand protection. Failure to do
so may result in burn injury.
To replace the filter
1.Drain the fluid when the transmission is at normal operating sump
temperature 160 to 200°F (71 to
93°C). Hot fluid flows quicker and
drains more completely.
3.Fill the transmission with fresh oil
through the filler plug hole located
on the side of the transmission.
11 - 57
VEHICLE SERVICE AND MAINTENANCE
2.Remove the drain plug from the oil
pan and allow the fluid to drain into
a suitable container.
3.Using a filter wrench, remove the
control-main filter by rotating it
counterclockwise.
4.Remove the magnet from the filter
attachment tube or from the top of
the filter element.
5.Clean any metal debris from the
magnet. Report any metal pieces
larger than dust to your maintenance personnel.
6.Reinstall the magnet onto the filter
attachment tube.
7.Lubricate the O-ring on the controlmain filter with transmission fluid.
8.Install, by hand, the control-main
filter until the O-ring on the controlmain filter touches the converter
housing.
9.Turn the filter ONE FULL TURN
ONLY by hand, after O-ring contact.
11 - 58
CAUTION
 Turning the filter more than
Allison 3000 series
A disassembled type of filter is used
and incorporated in the oil pan.
ONE FULL TURN after gasket
contact will damage the filter.
10.Reinstall the drain plug and sealing washer.
Tightening torque:
22 to 30 ft·lbf (30 to 40 N·m) (3.1
to 4.1 kgf·m)
11.After refill, check the fluid level
and add the proper fluid, if necessary.
For the fluid check procedure,
refer to "To check the automatic
transmission fluid level (Allison
1000, 2200 and 2500 series)"on
page 11-52.
12.Start the engine. Check the filter
and seal for leaks.
1.Clean the periphery of the filter
cover to prevent dust from entering
at the time of removal of the filter.
2.Remove the mounting bolts of the
filter cover and pull out the cover
and filter downward.
3.Replace the filter, O-ring and seal
with new ones and install to the
cover. When installing, apply a
light coating of clean oil to the
entire perimeter of O-ring and seal.
4. Install the cover and filter combined in one unit into the transmission body.
VEHICLE SERVICE AND MAINTENANCE
Tightening torque:
37.6 to 45.0 ft·lbf (51 to 61 N·m)
(5.2 to 6.2 kgf·m)
5.After replacement, be sure to refill
fluid. After refilling, check the fluid
level.
DIFFERENTIAL GEAR OIL
CAUTION
 Before removing the differen-
Gear oil
Inspect the vehicle daily for differential oil leakage. If there is any evidence of leakage, locate and correct
the cause. Check oil level and, if low,
add oil.
tial filler plug, clean the plug
and surrounding area to prevent dirt and debris from entering filler hole.
WARNING
 Check and/or change the dif-
ferential gear oil only after the
rear axle cools to avoid possible burn injuries.
To check the differential gear oil
level
1.Remove the filler plug and visually
check the oil level. The level
should reach the bottom of the
filler plug hole.
2.Add oil, if necessary.
3.Replace the gasket of the filler
plug with a new one. Reinsert the
plug and tighten the plug.
Tightening torque:
95 to 108 ft·lbf (128 to 147 N·m)
(13 to 15 kgf·m)
11 - 59
VEHICLE SERVICE AND MAINTENANCE
Oil change
WARNING
Tightening torque:
95 to 108 ft·lbf (128 to 147 N·m)
(13 to 15 kgf·m)
NOTE:
 Check and/or change the dif-
 The drain plug contains a mag-
ferential gear oil only after the
rear axle cools to avoid possible burn injuries.
net. Remove any iron filings on
the plug before reinserting the
plug.
1.Place a container under the differential drain plug. Remove the drain
plug and drain the oil completely.
3.Fill the differential with fresh oil.
Check the oil level. Add oil until the
level reaches the bottom of the
filler plug hole.
Oil refill capacity (Approximately)
2.After draining, replace the gasket
of the drain plug with a new one.
Install the plug and tighten the
plug.
11 - 60
US measure
Liters
UD1800,
UD2000 and
UD2300LP
6.9 qt
6.5
UD2300HD
9.5 qt
9
UD2600 and
UD3300
13.8 qt
13
STEERING SYSTEM
Wheel free play
To check for free-play, start and idle
the engine. Set the front wheels to
the straight-ahead position and
lightly rotate the steering wheel to
the right and left until the front
wheels move. Steering wheel play
on the circumference of the steering
wheel should be 0.39 to 1.57 inches
(10 to 40 mm) for UD1800, UD2000
and UD2300 or 1.18 to 1.97 inches
(30 to 50 mm) for UD2600 and
UD3300. If the play exceeds 1.57
inches (40 mm) for UD1800,
UD2000 and UD2300 or 1.97 inches
(50 mm) for UD2600 and UD3300,
have it corrected by an authorized
UD Trucks dealer or other qualified
service facility.
VEHICLE SERVICE AND MAINTENANCE
Steering fluid level
WARNING
If the steering fluid is low or contaminated, the power steering may not
operate normally which could
adversely affect steering control. If
the fluid level is low, check the steering system for leaks and correct the
condition before operating the vehicle. If the fluid is contaminated, have
it replaced by an authorized UD
Trucks dealer or qualified service
facility.
 Do not operate your vehicle
with excessive steering wheel
free-play. If free-play exists,
have the vehicle thoroughly
inspected by an authorized UD
Trucks dealer or qualified service facility.
WARNING
 To avoid possible burn injury,
allow the steering system to
cool before checking or changing the steering fluid.
 Do not operate the vehicle
when the steering fluid is low
or contaminated.
CAUTION
 Do not allow dirt or debris to
enter the fluid reservoir when
open. Always clean the fluid
reservoir and cap before
removing the cap.
 Check for proper fluid level
before engine start.
To inspect the steering fluid level
1.Visually inspect the steering system for fluid leaks.
2.The fluid level should be between
the HIGH and LOW lines. If the
fluid level is below the LOW line,
add steering fluid to the HIGH line.
11 - 61
VEHICLE SERVICE AND MAINTENANCE
Steering fluid and filter change
Have the steering fluid and filter
changed by an authorized UD
Trucks dealer or other qualified
steering system repair facility. Use
only DEXRON®II or higher fluid.
11 - 62
SERVICE BRAKE SYSTEM
WARNING
Brake fluid level check
 Brake fluid loss may indicate a
Maintain the fluid level in the reservoir between the HIGH and LOW
marks on the brake fluid reservoir. If
the fluid level is below the LOW mark
then add brake fluid.
leak in the brake system. Have
the brake system checked
immediately by an authorized
UD Trucks dealer or other
qualified brake repair facility.
 To avoid fire hazard, do not
allow brake fluid to contact the
hot parts of the exhaust system.
 To avoid possible burn injury,
allow the engine and brake
system to cool before checking or changing brake fluid.
 If the brake (and clutch) fluid is
accidentally ingested, force
the person to vomit and secure
medical help immediately. If
the brake (and clutch) fluid
gets in an eye, flood the eye
with lots of water and get medical attention immediately.
VEHICLE SERVICE AND MAINTENANCE
CAUTION
 Remove any dirt accumulation
from the brake fluid reservoir
cap and surrounding area
before removing the reservoir
cap. Do not allow dirt, debris,
water or other foreign materials to enter the reservoir while
it is open.
 Use only approved DOT 3 fluid
from a sealed container.
 Do not add brake fluid above
the HIGH mark.
 Do not allow brake fluid to contact the painted surfaces of
your vehicle. Brake fluid contact may result in paint damage.
 Remove the reservoir strainer
and clean any foreign matter
from it. If the reservoir contains sediment, have the reservoir inspected and cleaned by
an authorized UD Trucks
dealer or other qualified brake
repair facility.
Brake fluid change
Draining air reservoir
Have the brake fluid changed by an
authorized UD Trucks dealer or
other qualified brake system repair
facility. Use only DOT 3 fluid from a
sealed container.
To drain accumulated water from
the air reservoir
1.Open the drain cocks.
NOTE:
 After the brake fluid has been
changed, operate the service
brakes several times to assure
proper operation.
CAUTION
 Do not expose the brake fluid
to moisture when checking,
adding or changing the brake
fluid. Brake fluid absorbs
moisture. When it does, its
boiling point drops which can
cause vapor lock and corrosion of brake system components.
 Do not add brake fluid which
has been exposed to moisture
to the system. Use fresh DOT 3
fluid from a sealed container
only.
2.Allow the water to drain.
3.After draining, release the drain
cock rings and close the drain
cocks.
WARNING
 Do not drive vehicle unless
accumulated water has been
drained. If not, water could get
into
brake
system
and
adversely effect brake function.
11 - 63
VEHICLE SERVICE AND MAINTENANCE
CAUTION
Air dryer
 As vehicles are equipped with
an air dryer, water will normally not drain from the air
reservoir when the drain cock
is opened. However, a small
amount of water may drain out
under humid conditions. If a
large amount of water is
drained, the air dryer may not
be functioning properly. Check
the air dryer.
WARNING
Visually check to be sure that water
drains from the drain port of the air
dryer. Water will drain when the air
pressure governor stops pressurization. The governor stops pressurization when the air pressure in the
reservoir reaches the upper level of
the normal operating pressure
range. When the sound of air supplied to the reservoir can no longer
be heard, or when the sound of the
engine changes, this condition has
been reached.
If no water drains from the air dryer,
drain the water from the air reservoir.
If a large amount of water is drained,
11 - 64
have the air dryer repaired by an
authorized UD Trucks dealer or
other qualified brake system repair
facility.
If the drained liquid contains a large
amount of oil, additionally have the
air compressor checked.
To avoid brake failure:
 Visually check to be sure that
water or air is discharged from
bottom drain port.
 Replace desiccant, filters and
gasket annually.
 Do not allow drain port to clog
with foreign material.
VEHICLE SERVICE AND MAINTENANCE
CLUTCH
Clutch pedal free play
To check clutch pedal free play,
depress the clutch pedal by hand
until resistance is felt. The play, the
distance from the point where the
clutch pedal normally rests and
where resistance is felt should be
1.18 to 1.97 inches (30 to 50 mm). If
the play is less than 1.18 inches (30
mm) or more than 1.97 inches (50
mm), then adjust the clutch pedal
free play.
Adjusting clutch pedal free play
To adjust the clutch master cylinder
First adjust the master cylinder
located on the clutch pedal.
1.Loosen the lock nut on the push
rod.
2.Turn the push rod until it touches
the piston and there is no play.
Under this condition, return the
push rod 4/5 turn and make sure
the free play is approximately 0.04
inches (1 mm).
3.Tighten the lock nut while holding
the push rod stationary with a
wrench.
To adjust the outer lever assembly
After adjusting the clutch master cylinder, adjust the clutch booster outer
lever assembly located at the left
side of the transmission.
1.Remove the return spring.
2.Loosen the push rod lock nut.
3.Adjust the play of the outer lever to
0.177 to 0.217 inches (approx. 4.5
to 5.5 mm) by turning the push rod.
MLS63
11 - 65
VEHICLE SERVICE AND MAINTENANCE
Checking clutch fluid
MPS63
4.Tighten the lock nut.
5.Reinstall the return spring.
6.Check clutch disc wear with the
wear indicator installed near the
left side clutch booster. Clutch disc
wear is within acceptable limits
when the pointer at the wear indicator is between MIN and SET. If
the pointer goes past MIN, have
the clutch disc replaced by an
authorized UD Trucks dealer or
qualified service facility.
11 - 66
MLS63
NOTE:
 DOT 3 brake fluid is used as
clutch fluid. Be sure to handle it
carefully. (Refer to "Brake fluid
level check"on page 11-62.)
MPS63
The clutch fluid level should be
between the HIGH and LOW marks
on the fluid reservoir located behind
the front lid. If the fluid level is low,
add DOT 3 brake fluid until the level
is between the HIGH and LOW
marks. Also check the clutch fluid for
contamination. If the fluid appears
contaminated, have the clutch fluid
changed.
VEHICLE SERVICE AND MAINTENANCE
WARNING
 To avoid fire hazard, do not
allow clutch fluid to contact
the hot parts of the exhaust
system.
CAUTION
 Do not expose the clutch fluid
to moisture when checking,
adding or changing the clutch
fluid. Clutch fluid absorbs
moisture. When it does, its
boiling point drops which can
cause corrosion of clutch system components.
 Do not add clutch fluid which
has been exposed to moisture
to the system. Use fresh DOT 3
fluid from a sealed container
only.
 Do not allow clutch fluid to
contact the painted surfaces of
your vehicle. Clutch fluid contact may result in paint damage.
Changing clutch fluid
Have the clutch fluid changed by an
authorized UD Trucks dealer or
other qualified brake system repair
facility. Use only DOT 3 fluid from a
sealed container.
SUSPENSION
Leaf spring
Check the leaf spring for damage,
displacement of leaves or looseness. If loose, align the leaves and
tighten bolts and nuts to the specified torque. Periodically have the Ubolt nut retightened by an authorized
UD Trucks dealer or qualified service
facility.
Tightening torque:
Front spring U-bolt nut
UD1800, UD2000 and UD2300
174 - 203 ft·lbf
(235 - 275 N·m) (24 - 28 kgf·m)
UD2600 and UD3300
362 - 398 ft·lbf
(490 - 539 N·m) (50 - 55 kgf·m)
Rear spring U-bolt nut
UD1800, UD2000 and UD2300
195 - 239 ft·lbf
(265 - 324 N·m) (27 - 33 kgf·m)
UD2600 and UD3300
362 - 398 ft·lbf
(490 - 539 N·m) (50 - 55 kgf·m)
11 - 67
VEHICLE SERVICE AND MAINTENANCE
Air spring
WINDSHIELD WASHER FLUID
Check the air bellows for damage,
air leakage, looseness and leveling
valve for proper functioning.
Periodically have the U-bolt nut
retightened by an authorized UD
Trucks dealer or qualified service
facility.
Tightening torque:
U- bolt nut
406 - 455 ft·lbf
(550 - 617 N·m) (56 - 63 kgf·m)
Shock absorber
Check the shock absorber for proper
installation, damage or leakage. If
leakage is present, have the shock
absorber checked or replaced by an
authorized UD Trucks dealer or qualified service facility.
WARNING
 Do not use cooling system
solution in the windshield
washer
reservoir.
When
sprayed on the windshield,
cooling system solution can
significantly diminish visibility.
Open the front lid, and check the
fluid level in the windshield washer
reservoir daily. If low, add an appropriate washer fluid solution. Also,
check that fluid is properly sprayed
onto the windshield.
In cold weather, use a windshield
washer anti-freeze with water at the
proper mixture ratio. Follow the antifreeze manufacturer’s instructions
for the mixture ratio.
Replenishing washer fluid
The windshield washer reservoir
located behind the front lid.
1.Open the front lid, and check the
washer reservoir fluid level.
11 - 68
2.If it is low, add more washer fluid
via reservoir cap opening
NOTE:
 Do not overfill the windshield
washer reservoir.
VEHICLE SERVICE AND MAINTENANCE
OUTSIDE MIRRORS
Adjusting outside mirrors
1.Set the stay by aligning it with the
matching mark.
2.Adjusting the outside mirror position.
 Since the plain mirror on the upper
side cannot be adjusted using the
mirror alone, adjust it by moving
the mirror housing. The convex
mirror on the lower side can be
adjusted using the mirror alone.
To check the mirror heater
(Optional)
On a vehicle equipped with a mirror
heater, check the following points.
 Check the heater harness for slack
and twist.
CAUTION
 Do not yank the heater har-
Check the outside mirrors daily for
damage, position and visibility. Also
check that the mirror mounting bolts
are properly tightened.
 For vehicles equipped with power
mirror, refer to the "Power mirror
switch (Optional)"on page 7-68.
ness by hand or hang on the
heater harness. The heater
harness may be broken.
11 - 69
VEHICLE SERVICE AND MAINTENANCE
EMISSIONS CONTROL
SYSTEMS
To maintain efficient emissions control systems operation, have the
emission control system maintenance in the VEHICLE SERVICE
AND MAINTENANCE performed at
the intervals indicated.
CAUTION
 Do not modify, alter, discon-
nect or remove any part of the
vehicle which could affect,
directly or indirectly, vehicle
emissions.
 Do not operate your vehicle if
you notice engine misfire, a
significant loss of performance
or other improper operation.
Consult your UD Trucks dealer
or other qualified service facility for service.
11 - 70
Exhaust Aftertreatment System
Maintenance
Regular maintenance for the DPF
The vehicle must be taken to an
authorized UD Trucks dealer to
remove the ash from the Aftertreatment Diesel Particulate Filter and
clean the Aftertreatment Hydrocarbon Doser.
Emissions Maintenance
Emissions Maintenance Interval –
EPA / CARB defines this as the
adjustment, cleaning, repair, or
replacement shall be recommended
at intervals no less than described
below.
Injector tips (cleaning only), crankcase ventilation
valve, EGR filters and coolers:
Medium Heavy Duty:
Miles: 50,000
Hours: 1500
the DPF needs to be cleaned regularly to maintain its performance
(either every 155,000 miles
[250,000 km] or 4,500 hours). This
is because unburnable ash will
accumulate in the filter during
regeneration; otherwise, the soot
accumulated in the DPF can be
burned to regenerate the filter.
 For details on the cleaning information about the muffler that is
equipped with the DPF, contact
your nearest UD trucks dealer.
 The DPF ash level gauge that is
displayed on the multi-display
monitor indicates the amount of
ash accumulation.
Injectors, Turbocharger, ECM, sensors, actuators, EGR components
(except filter and coolers), Aftertreatment DPF plus related components,
this includes ash cleaning
Medium Heavy Duty:
Miles: 150,000
Hours: 4500
 The muffler that is equipped with
VEHICLE SERVICE AND MAINTENANCE
CAUTION
 The muffler that is equipped
DPF ash level gauge
 The DPF ash level gauge indicates
the accumulation level of the ash
in the filter.
 For details on how to display the
meter, refer to the “Multi-display
monitor” section in “INSTRUMENT
AND CONTROLS”.
 When the level reaches “H”, it indicates that the filter should be
cleaned. The system simultaneously indicates the DPF maintenance warning, warning message
and comment to alert the driver of
cleaning the DPF.
DPF maintenance warning
with the DPF for the PM reduction 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
engine output decrease may
occur.
NOTE:
 Ash is mainly generated from
the elements included in engine
oil additives. Always use the
specified engine oil to minimize
ash generation.
 The soot collected in the DPF
that is built in the muffler for the
PM reduction device is burned
to be regenerated. However, ash
is unburnable during regeneration and accumulates in the filter. Thus, the filter must be
cleaned regularly.
To keep the DPF efficiency, it
recommend that the manual
11 - 71
VEHICLE SERVICE AND MAINTENANCE
forced regeneration is performed once a year even if the
DPF soot level indicates. For
details on the manual forced
regeneration, refer to the "DPF
SYSTEM"on page 7-69
 The accumulation level shown
in the DPF ash level gauge is
calculated by the control unit
using the fuel consumption
data. Therefore, the gauge indication may differ from the filter
cleaning interval of the muffler
that is equipped with the filter
for the PM reduction device
(either every 155,000 miles
[250,000 km] or 4,500 hours).
Use the DPF ash level gauge
indication as a reference.
11 - 72
VEHICLE SERVICE AND MAINTENANCE
NOISE CONTROL SYSTEM
To assure noise control system
integrity, the maintenance services
shown in the following chart must be
performed at the intervals indicated.
When inspecting the exhaust system
confirm that all components are
intact and securely fitted. Also check
all exhaust system components for
holes, leaks and corrosion. Do not
perform any prohibited act to the
noise control system as described in
the following chart.
Control System
Tampering with Noise Control
System Prohibited
Federal law prohibits the following
acts or the causing thereof:
(1) The removal or rendering inoperative by any person other than for
purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any
new vehicle for the purpose of noise
control prior to its sale or delivery to
the ultimate purchaser or while it is in
use, or
(2) the use of the vehicle after such
device or element of design has
been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed
below.
WARNING
 To avoid serious injury from
hot engine and exhaust system, perform maintenance
after engine has cooled.
Prohibited Acts
Air Intake System
Removal or rendering inoperative air cleaner,
intake resonator or intake duct, and piping.
Acoustical Shielding
Removal of cab shields or acoustical insulation.
Removal of engine enclosures.
Cooling System
Removal or rendering inoperative fan clutch.
Removal of fan shrouds or radiator side shields.
Engine and Drive Line System
Removal or rendering engine speed governor
inoperative so as to allow engine speed to exceed
manufacturer specifications.
Exhaust System
Removal or rendering inoperative exhaust system
components including muffler, pipe shield or piping.
11 - 73
VEHICLE SERVICE AND MAINTENANCE
Noise Control System Maintenance
Schedule
In order to comply with federal noise
regulation, the UD Trucks vehicle
Abbreviations:
A = Check and adjust if
necessary
Items
T = Tighten to specified torque
Miles x 1,000
Kilometersx1,000
First
3
6
5
10
9
15
10
16
High idling speed
Cooling fan
Air intake system hose and clamps
Air cleaner element
Exhaust manifolds mounting nuts
Muffler with catalyst and exhaust pipe clamps
Splash shields, under hood insulator
Maintenance of noise emission
control system
11 - 74
maintenance at the intervals shown
in the following maintenance chart.
may be equipped with the following
items.
To avoid or minimize the degradation
of noise emission level, it is essential
to perform proper inspection and
12
20
15
25
R = Replace or change
Every
18 20
30 32
24
40
30
48
36
60
A
A
A
Splash shield, under hood
insulation
Check shields and under hood insulation for damage or looseness.
Repair, replace or clean if necessary.
R
T
A
A
50 72 Months
80 120 (every)
12
12
4
12
12
6
12
Cooling fan
 Check the cooling fan for damage,
and replace it when damaged.
 Check the cooling fan mounting
bolts for looseness, and tighten
them if necessary.
VEHICLE SERVICE AND MAINTENANCE
Intake system
 Check the intake system compo-
nents such as ducts, hoses, resonator air cleaner, intake manifold,
clamps and fasteners for damage.
Replace if necessary. Check to be
sure that hose clamps and fasteners are tight.
 Check to be sure that the air
cleaner dust cover is installed
securely.
 Check the rubber gasket in the
dust cover for deterioration.
Replace if necessary.
changed from standard position as
originally received.
To avoid abnormal changes in vehicle sound level, maintenance is necessary at the intervals shown in the
maintenance schedules, and record
on the inspection verification form
provided. Please consult an authorized UD Trucks dealer.
BATTERY
Your UD Trucks vehicle is equipped
with a maintenance-free battery at
the factory.
Below are the specifications for the
two 12 volt batteries installed at the
factory. Their reserved capacity (RC)
and cold cranking amperes (CCA)
are rated at 159 minutes and 622
amperes.
Exhaust system
Check the complete exhaust system.
Check for damage, missing or mispositioned parts, loose connections,
open seams, holes, loose fasteners,
or deformed or plugged outlets.
Replace or tighten if necessary.
Inspect for leaks at various joint connections and tighten clamp. Make
visual inspection for crack or holes in
DPF cleaner and tail pipe. Always
replace with UD Trucks recommended parts. Tail pipe elbow or offset tail pipe orientation must not be
11 - 75
VEHICLE SERVICE AND MAINTENANCE
W
6.81 in (173 mm)
L
12.05 in (306 mm)
H
8.03 in (204 mm)
d
h
Positive (+) terminal:
0.756 - 0.768 in
(19.2 - 19.5 mm)
Negative (–) terminal:
0.693 - 0.705 in
(17.6 - 17.9 mm)
Battery electrolyte level
DANGER
Taper
1/9
0.67 - 0.79 in (17 - 20 mm)
Batteries produce explosive
gases. To minimize risk of serious injury or death:
 Keep sparks and open flame
away from the batteries. Never
smoke when working on or
around the batteries.
 Make sure that adequate ventilation is provided when working on or around the battery in
an enclosed area.
 Do not permit metal tools to
simultaneously contact the
positive battery terminal and
any other metal on either vehicle at the same time.
 Always wear eye protection
when working near batteries.
The battery electrolyte should be
maintained between the upper and
lower levels on the case. If low, add
distilled water to the specified level
and charge the battery for at least 30
minutes with the engine idling.
11 - 76
To add distilled water
1.Remove the cell plugs using a suitable tool.
2.Add distilled water up to the upper
level.
3.Tighten cell plugs.
VEHICLE SERVICE AND MAINTENANCE
CAUTION
 Avoid battery acid contact with
eyes, skin, wearing materials
or painted surfaces. Immediately and thoroughly flush any
contacted area with water. If
acid is swallowed or comes
into contact with your eyes,
secure medical help immediately.
CAUTION
 Do not add water above the
specified level. If the battery
electrolyte spills, it can cause
damage to the vehicle equipment and body.
 Do not add diluted sulfuric
acid to the battery. This
increases the specific gravity
of the battery electrolyte and
shortens the service life of the
battery. It also affects specific
gravity readings made to
determine battery charge.
Specific gravity of battery electrolyte
The specific gravity of the battery
electrolyte determines the battery
condition. The specific gravity
decreases as the battery discharges
and increases as it is charged. The
electrolyte temperature also affects
the specific gravity. The specific
gravity of a fully-charged battery is
1.280 at 68°F (20°C). Check the
specific gravity of the battery electrolyte in each cell with a hydrometer. If
necessary, have the battery checked
and charged by an authorized UD
Trucks dealer or other qualified service facility.
Cleaning battery terminals
Periodically inspect the battery
cables and connectors for corrosion
and tightness. When inspecting the
cables and connections:
1.Stop the engine.
2.Remove the battery cables and
clean contaminated or corroded
terminals. Badly corroded terminals can be cleaned by disconnecting the cables and rubbing
with a wire brush or sandpaper.
Flush any white powder from the
terminals with lukewarm water and
wipe clean.
WARNING
 When disconnecting the bat-
tery cables, remove the cable
from the negative (–) terminal
first. When reconnecting the
cables, attach the cable to the
negative (–) terminal last.
11 - 77
VEHICLE SERVICE AND MAINTENANCE
3.After tightly connecting the cables,
apply a thin coat of grease to the
terminals to prevent corrosion.
LIGHTS
Occasionally it may become necessary to replace a burned out bulb on
your vehicle. When replacing bulbs
with a lens, take care not to overtighten lens screws. Overtightening
the screws could damage the lens.
removal. During this operation, do
not touch the bulb with bare hands.
NOTE:
 Use the same number and watt-
age as originally installed.
Refer to "BULBS"on page 13-5.
Headlights
Always dispose of automotive batteries in a responsible manner. Follow
your local authorized standard for
disposal. Call your local authorized
recycling center to find out more
about recycling automotive batteries.
11 - 78
Your vehicle is equipped with halogen headlights.
To replace a burned out headlight
bulb:
1.Turn the ignition key and lighting
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
NOTE:
 When the headlight is changed,
the light axis must be adjusted.
If you inevitably replaced it,
bring the vehicle for inspection
immediately at the nearest
authorized UD Trucks dealer.
VEHICLE SERVICE AND MAINTENANCE
Front turn signal light
1.Remove the fixing clips (2 locations) from the rubber and turn
over the rubber.
3.Turn the socket counterclockwise
to remove it and replace the bulb
with new one.
Rear combination light
Rear turn signal light
Front side turn signal light
2.Remove the fixing clip from the
lower cover, slide the lower cover
downward and remove it.
11 - 79
VEHICLE SERVICE AND MAINTENANCE
License plate light
Back-up light
Clearance and identification light
Room light
FUSES
The fuse box is located on the lower
portion of main dash and consists of
mini-type fuses.
Also, they are stored in the fusible
link box that is located in front of the
DPF with the muffler installed on the
right side of the chassis.
Open the lid or cover. Labels above
each fuse specify the circuit current
capacity of the fuse to be used in the
circuit.
The fuses are color coded: 5 amp tan; 10 amp - red; 15 amp - blue; 20
amp - yellow; 25 amp - natural and
30 amp - Green; for easy identification of current capacity.
Lower portion of main dash
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 function.
Inside fusible link box
WARNING
 When replacing a fuse, never
use a fuse with a higher current rating than that specified
for the circuit. Heat produced
by currents in excess of circuit
capacity can cause fire.
To replace a blown fuse
1.Use the fuse puller to remove the
blown fuse.
2.Install a new fuse with the same
current rating as that specified for
the circuit.
A new fuse that burns out immediately could indicate other problems
in the electrical system. If this
occurs, have the electrical circuits
checked by an authorized UD Trucks
dealer or other qualified service facility.
11 - 81
VEHICLE SERVICE AND MAINTENANCE
BLOWER MOTOR FILTERS
Air filters for a heater or an air conditioner are installed behind the front
lid at the right side of the cab front.
 The air filters for outside air intake
and inside air intake may cause
clogging due to dirt or dust. Clean
them.
 The installation and removal of the
air filter is a cartridge type.
 Clean the air filter with water or air.
Outside air intake filter
<Method for removal>
1.Hold the upper and lower centers
of the filter with left hand and bend
the filter toward you.
2.Hold the handle at the right end of
the filter with right hand and pull it
toward you.
the handle into the hole of the
case.
Inside air intake filter
1.Pull the upper and lower two filters
toward you.
2.After cleaning, insert the filter into
the filter slot of the case until it is
locked.
<Installation method>
1.Hold the handle at the left of the filter and insert the tab around the
handle into the hole of the case.
2.Hold the upper and lower centers
of the filter and bend the filter
toward you.
3.Hold the handle at the right end of
the filter and insert the tab around
11 - 82
NOTE:
 Clogging of the air filter lowers
air flow, resulting in poor performance of the heater and the air
conditioner.
 Clean the air filter every 6
months or when performance of
the heater or the air conditions
is poor.
VEHICLE SERVICE AND MAINTENANCE
WHEELS AND TIRES
Tires
Note that the size charts on the following pages are examples of typical
tire sizes and do not necessarily
apply to your vehicle.
11 - 83
VEHICLE SERVICE AND MAINTENANCE
Load specification
TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES
(The pressure is minimum for the load.)
Tire size
designation
225/
70R
19.5 (F)
Radial Tires
11R
22.5 (G)
245/
70R
19.5 (G)
9R
22.5 (G)
255/
70R
22.5 (H)
11 - 84
Current
SI units
psi
90
(95)
kgf/cm2
(6.30)
kPa
Current
SI units
95
(95)
660
Current
SI units
100
(100)
670
(6.65)
Current
SI units
105
(105)
690
(7.00)
Current
SI units
110
(110)
720
(7.35)
Current
SI units
115
(115)
760
(7.70)
Current
SI units
120
(120)
790
(8.05)
830
(8.40)
Dual
–
1,550 kg
(3,415 lb)
Single
–
1,650 kg
(3,640 lb)
–
–
–
–
–
–
–
–
–
–
–
–
Dual
–
–
–
–
–
–
–
2,650 kg
(5,840 lb)
–
–
–
–
–
–
Single
–
–
–
–
–
–
–
2,800 kg
(6,175 lb)
–
–
–
–
–
–
Dual
–
–
–
–
–
–
–
–
–
1,950 kg
(4,300 lb)
–
–
–
–
Single
–
–
–
–
–
–
–
–
–
2,060 kg
(4,540 lb)
–
–
–
–
Dual
–
–
–
–
–
–
–
–
–
–
–
–
–
2,120 kg
(4,675 lb)
Single
–
–
–
–
–
–
–
–
–
–
–
–
–
2,240 kg
(4,940 lb)
Dual
–
–
–
–
–
–
–
–
–
–
–
–
–
2,300 kg
(5,070 lb)
Single
–
–
–
–
–
–
–
–
–
–
–
–
–
2,500 kg
(5,510 lb)
–
–
–
–
–
–
–
–
–
–
–
–
VEHICLE SERVICE AND MAINTENANCE
Checking the tire pressure and tire
condition
1.Check the pressure of each tire
with a tire gauge daily. For accurate measurement, check the tires
when they are cool. Be sure to
inflate tires to proper pressure
according to the load and inflation
pressure table. Check tire valves
regularly for air leaks. Replace
Condition
valves when damaged or leaking.
Replace missing valve caps.
2.Check the tire sidewall and tread
for cuts, cracks and damage daily.
Remove any foreign objects such
as metal, glass and stones
wedged in the tread grooves and
check for tire damage.
Repair or replace as necessary.
3.Check the tires for uneven or
unusual tread wear. Consult the
table below to determine the cause
of uneven or unusual wear and
corrective action to be taken. Correct the cause of the wear and, if
necessary, replace the tire.
Cause
Cause Correction
Shoulder wear
 Underinflation
 Sharp turning at high speed
 Excessive loading
 Inflate
 Reduce speed
 Reduce loading
Center wear
 Overinflation
 Slippage due to abrupt braking
 Inflate
 Apply brakes slowly
Diagonal wear
 Incorrect toe-in
 Imbalanced braking force
 Adjust toe-in
 Inspect and adjust service brake
Heel/toe wear
 Incorrect toe-in
 Underinflation
 Adjust toe-in or camber
 Inflate
11 - 85
VEHICLE SERVICE AND MAINTENANCE
Each tire has six wear indicators.
Check the tread grooves of each tire
daily. Replace a tire when any of the
tread indicators become visible.
WARNING
 Be sure to confirm that the
wheel has not been damaged
or deformed before putting a
new tire on it. Follow industry
and government safety regulations when assembling and
inflating new tires. Failure to
do so could result in serious
injury or death.
11 - 86
WARNING
Do not operate your vehicle:
 With tires inflated in excess of
the recommendations of the
tire or wheel manufacturer.
 With cut, cracked or damaged
tires.
 When any of the tire tread wear
indicators are visible.
Improperly inflated and damaged tires, and tires with uneven
or excessive wear may cause
blowouts, loss of vehicle control and reduced braking effectiveness. Inspect tires carefully
and make any necessary repairs
or replacements.
<Front wheel alignment>
If abnormal tire wear or ride and handling characteristics such as vehicle
lead or wander are experienced with
properly inflated tires, the front wheel
alignment should be checked.
Checking and retightening the
wheel nuts
Loose wheel stud nuts may cause
shimmy and vibration which can
cause damage to the wheel bearings. Retorque the wheel stud nuts
at the first 1,000 miles (1,600 km) of
operation. Thereafter, check the nuts
for tightness every 6,000 miles
(10,000 km) or two months of operation, whichever occurs first and, if
necessary, retorque to specification.
Using a torque wrench, alternately
tighten wheel nuts. Do not exceed
wheel nut torque specification. Overtightening the wheel nuts will elongate the bolts, deform the wheels
and prevent tightening to the specified torque.
Tightening torque:
UD1800 and UD2000
273 - 310 ft·lbf (370 - 420 N·m)
(38 - 43 kgf·m)
UD2300, UD2600 and UD3300
398 - 435 ft·lbf (540 - 590 N·m)
(55 - 60 kgf·m)
VEHICLE SERVICE AND MAINTENANCE
NOTE:
 The wheel nuts on the right side
of the vehicle have right-handed
threading; the left side wheel
nuts have left-handed threading.
Re-tightening procedures for rear
dual nuts
1.Loosen the outer wheel nuts.
2.Tighten the inner wheel nuts.
3.Tighten the outer wheel nuts.
Tire position rotation
NOTE:
 For removal and mounting of
tires, refer to "TIRE CHANGE"on
page 12-6.
 After rotating the position of the
tires, drive the vehicle a distance of 30 to 60 miles (50 to 100
km) to settle the wheel disc with
hub, and then retighten the
wheel nuts to the specified
torque.
 The wheel must not be overloaded. Pay attention to the total
vehicle load, the weight distribution related to individual axle
loading and the matching of tire
pressures in the case of dual
wheels.
Tire wear differs depending on
where the tire is mounted. Rotate the
tire position to allow more even wear
and extend tire life.
Tire rotation is recommended every
6,000 miles (10,000 km). Shown are
two types of rotation patterns. Use
the one best suited to your needs.
After rotation, adjust individual tire
pressure as specified in the "Load
specification"on page 11-84. Tighten
wheel stud nuts to the required
torque specification and after 1,000
miles (1,600 km), retorque again to
specification.
When tire tread pattern is identical
all the way around:
When tire tread pattern
between front and rear:
differs
11 - 87
VEHICLE SERVICE AND MAINTENANCE
WARNING
 Never mix different tire size,
construction or patterns on the
same axle.
 If tires of different patterns are
to be used for the front and
rear, the best combination is to
use rib type tires for the front
wheels and traction type tires
for the rear wheels.
 Do not use radial and bias tires
together.
 After mounting dual tires,
ensure that tires do not contact each other under a loaded
condition.
NOTE:
 Mount less worn tires on front
wheels, and it is advisable to
check the front wheels for the
dynamic balance.
 New tires should be used in
pairs and mounted on the front
wheels first.
 The inflation pressure of a new
tire must be adjusted after
break-in operation.
11 - 88
 Replace the hub bolts and nuts
or wheel disc if the threads are
damaged or deformed or the
wheel disc is deformed or
cracked.
 When replacing both dual
wheels, make sure that the inner
wheel nuts are securely tightened before installing the outside wheel.
 When installing the outside
wheel, place the air valve 180°
apart from the inside wheel.
Changing wheel types
WARNING
Use only the same type and style
wheels and mounting hardware
to replace original parts.
Do not use unauthorized wheel
components. Failure to do so
may result in an assembly which
does not fit together properly
resulting in premature wheel or
fastener failures. Mismatched or
incorrect fasteners can result in
the vehicle damage or possible
serious injury.
 Fasteners like bolts and nuts
removed from the vehicle
should be re-used in the same
spot whenever possible.
If not possible, new fasteners
selected must match those
replaced and obtain good
metal-to-metal contact. Do not
attempt to use the fasteners
removed from the vehicle for
the vehicle other than UD1800UD3300.
VEHICLE SERVICE AND MAINTENANCE
APPEARANCE CARE
It is imperative to identify and
use only those fasteners designated for use with the
respective vehicle being serviced.
 Do not attempt to mix ball seat
wheels or fasteners with flange
nut wheels or fasteners.
 The non-domestic wheel components on this vehicle are
similar, but not exactly the
same as domestic wheels. Do
not mix non-domestic and
domestic parts.
 Do not change from steel
wheels to aluminum.
When replacing wheels, consult your
UD Trucks dealer or qualified service
facility before attempting any wheel
or fastener changes.
Neglecting body maintenance can
be a major cause of corrosion, which
not only makes the vehicle unsightly,
but can also bring about weakening
of the vehicle’s body and considerably shorten the vehicle’s life. In
order to prevent corrosion from
occurring and/or spreading, we
would like to suggest the observance
of the points listed below.
If you should notice any abnormalities, such as excessive rusting,
please contact your nearest authorized UD Trucks dealer or other qualified service facility.
Wash away any accumulated dust,
sand, mud, etc., with water, paying
special attention to joints in the sheet
metal, wheel wells and runners, and
edges. After washing, use chamois
or soft cloth to wipe away remaining
water droplets. Waxing the vehicle
surface also promotes corrosion prevention.
We would also like to suggest rinsing
the vehicle with water after driving in
rainy weather or on bad roads.
NOTE:
 Use only soft water for cleaning
the vehicle as the use of hard
water promotes the deterioration of rubber parts and fittings.
 Scrubbing with hard brushes
and the like can scratch the
vehicle’s painted surfaces.
 Avoid getting electrical equipment wet. Also, close all doors
and windows so that water will
not find its way into gaps.
 Carefully wash the vehicle with
water if it has come into contact
with brine, been exposed to seawater for extended periods, or
after traveling salted winter
roads.
 Repair (paint) chips and other
damage to the vehicle’s painted
surfaces resulting from flying
pebbles and such as early as
possible.
 Avoid parking the vehicle in
direct sunlight, as this can also
adversely affect the body finish.
 Do not wipe the vehicle’s finish
with gasoline or alcohol.
11 - 89
VEHICLE SERVICE AND MAINTENANCE
 Be cautious with the use of
garage heaters as their use can
also promote corrosion.
11 - 90
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
IN CASE OF
EMERGENCY/
TROUBLESHOOTING
12 - 1
Proper operation of your vehicle,
together with regular inspection and
maintenance, will provide safe and
dependable service for many years.
Occasionally a problem may arise
which requires operator action to
prevent serious injury, accident and/
or damage to the vehicle. When a
problem arises, consult the following
pages for information to assist you
with the problem.
Hazard Warning Flasher
Use the hazard warning flasher to
warn other drivers when your vehicle
presents a safety hazard. If needed,
use flares, portable reflectors, and
other appropriate warnings.
To activate the hazard warning flashers, pull the switch lever located on
the right side of the steering column.
The flasher will operate with the ignition key in any position. To turn off
the hazard warning flashers, pull the
switch lever again.
ENGINE OVERHEATING
CAUTION
 Do
not suddenly stop the
engine when it has overheated.
Seizure of the engine may
occur, so keep the engine
idling until the engine coolant
temperature drops before turning off the engine.
Engine coolant temperature
gauge
 This gauge indicates the engine
coolant temperature.
 When the engine coolant tempera-
ture becomes high while another
screen is displayed on the multidisplay, a beep will sound and the
display will automatically change
to the engine coolant temperature
gauge (except when warning is
displayed).
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
severe) will appear and at the
same time, a buzzer sounds.
 If the engine coolant tempera-
ture
(ECT)
significantly
increases, an overheat warning
with a 2-phase indication
(amber: moderate, red: severe)
will appear.
Warning message or light
If the temperature gauge indicator is
in the high temperature zone, keep
the engine idling and do not stop the
engine until the indicator falls into
the suitable range.
 When the engine overheats, an
overheat warning with a 2-phase
indication (amber: moderate, red:
CAUTION
 Do not drive while the engine
overheat warning is displayed.
The engine protection function may provide torque derating to prevent the engine from
being damaged, so have it
inspected and serviced by the
nearest authorized UD Trucks
dealer.
the neutral position or P (Park)
position.
2.Operate the engine at a fast idle
with the engine throttle knob
located to the right of the steering
column.
3.Following instructions in this manual tilt the cab to provide ventilation.
4.Stop the engine when the engine
coolant temperature drops to the
normal range on the gauge.
5.After the engine and cooling system have cooled, open the radiator
cap.
If the engine coolant level is below
the bottom of the filler neck, add
coolant and take necessary cares
by following instructions steps 2-4
in the section, "Engine coolant
level warning light" on page 7-45.
1.Immediately stop the vehicle in a
safe place. Apply the parking
brake and shift the transmission to
12 - 2
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
 Be
extremely careful when
opening the radiator filler cap.
Place a thick cloth on the cap
and slowly loosen it to allow a
reduction in pressure in the
cooling system.
WARNING
To avoid serious injury from hot
coolant or steam release:
 Do not open the radiator filler
cap while the engine cooling
system is still hot; wait until it
cools.
If the radiator cap is removed
right after the engine is shut
off, scalding fluid and steam
may blow out under pressure
and cause serious burn injuries.
12 - 3
JUMP STARTING
Emergency Starting
DANGER
Batteries produce explosive
gases. To minimize risk of serious injury or death:
 Keep sparks and open flame
away from the batteries. Never
smoke when working on or
around the batteries.
 Make sure that adequate ventilation is provided when working on or around the battery in
an enclosed area.
 Do not permit metal tools to
simultaneously contact the
positive battery terminal and
any other metal on either vehicle at the same time.
 Always wear eye protection
when working near batteries.
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
WARNING
 Do not use ether or other start-
ing aids which are flammable.
 The engine should never be
started by pushing or towing
the vehicle. Since with the
engine stopped the effectiveness of the service brake system is seriously reduced and
the power steering requires
greater effort than in normal
conditions.
CAUTION
 Do not hold the ignition key at
the START position continuously for more than 15 seconds. Extended cranking will
shorten the life of the battery
and damage the starting system. If the engine cannot be
started on the first try, wait 30
seconds and try again.
ness. Tighten the connectors and
remove corrosion as necessary.
Turn off all electrically operated
equipment and accessories and
attempt to start the engine.
When the engine still cannot be
started because of a discharged battery, use the following procedure to
jump start the vehicle with the discharged battery.
WARNING
 Do not attempt to jump start a
vehicle having a frozen battery; the battery may rupture or
explode.
 Route the jumper cables to
avoid parts such as fans and
belts which will move when the
engines are started.
 Your vehicle has a 12-volt negative ground electrical system
(two 12 volt batteries connected in parallel). Make sure
that the other vehicle also has
a 12-volt negative ground electrical system. Do not attempt
to jump start either vehicle if
you are unsure of the other
vehicle’s voltage or grounding
system.
 Do not use jumper cables
which have been damaged or
are not properly insulated.
Before attempting to jump start a
vehicle, check the battery cables and
connections for corrosion and tight12 - 4
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
<To jump start a vehicle>
1.Position the vehicles so that the
jumper cables can be attached. Do
not allow the vehicles to come into
contact with one another.
2.Turn off the ignitions of both vehicles and apply the parking brakes.
3.Connect one end of one jumper
cable to the red positive (+) terminal 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 discharged battery at a location as
distant from the battery as possible. 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
5.Start the engine of the vehicle with
the good battery. After increasing
to a moderate engine speed, start
the vehicle with the discharged
battery.
6.After your engine is started,
remove the jumper cables in the
reverse order of connection.
7.Charge the discharged battery at
an authorized UD Trucks dealer or
other qualified service facility.
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
TIRE CHANGE
Damaged tire
WARNING
 Avoid full or panic braking if
you have a flat tire while driving since this may cause loss
of vehicle control.
Cautiously pull your vehicle off
the road while paying attention
to other traffic. Hold the steering wheel firmly and park the
vehicle in a level and safe
place. Apply the parking brake
firmly, turn on the hazard warning flasher switch and stop the
engine.
 If the vehicle is operated continuously with a flat tire, it may
become hot, causing the tire to
ignite or burst. This is very
dangerous.
 An inflated tire contains air
under high pressure. An
inflated tire and wheel can be
dangerous if misused, and can
result in serious injury and/or
property damage.
The maintenance of a damaged tire and wheel requires
the use of proper tools, safe
equipment, and tire service
expertise.
To replace a tire, refer to the following instructions.
Jack operating instructions
Follow the jacking instructions in this
manual as well as the instructions of
the jack manufacturer.
WARNING
To avoid serious injury when
jacking up your vehicle:
 Never start the engine or get
under your vehicle while it is
supported by a jack.
 Select a flat, hard surface
when using a jack.
 Place chocks at both the front
and back of the tire diagonally
opposite
the
tire
being
replaced.
 While jacking up the vehicle,
do not load or unload cargo.
The jack might come off by
vibration and shifting of the
center of gravity.
 When lowering the vehicle, do
not open the release valve fully
at one time. The vehicle might
drop rapidly, causing the jack
to come off.
12 - 6
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
CAUTION
 Do not allow any person to
stay in the vehicle while it is on
the jack.
 Remove oil and grease, if any,
before using the jack.
 Place the jack directly under
the jack-up point.
 If leaving the vehicle jacked up
for a considerable time, support the vehicle with wooden
blocks or stands for safety.
Jacking up the vehicle with air suspension
<Before jacking up>
While the engine stops, operate the
air suspension dump switch repeat12 - 7
edly to discharge air from the tank
and air spring till the vehicle height
cannot be returned to the normal
position.
After that, turn the ignition key to the
OFF position and start the jack-up
operation.
CAUTION
 If the jack-up operation is con-
ducted without discharging air,
the vehicle height may change
during the operation. It is dangerous.
Changing tires
<Removing a tire>
1.Park on a level ground. Stop the
engine and set the parking brake.
Turn on the hazard warning
flasher.
2.Place chocks at both the front and
back of the tire diagonally opposite
the tire to be replaced.
3.Place the jack(s) directly beneath
the axle or other main structured
members. Do not attempt to raise
the vehicle by the bumper.
4.Using the wheel nut wrench,
loosen but do not remove the
wheel nuts (or the outer wheel nuts
if working on a dual wheel) of the
wheel to be removed.
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
not use molybdenum grease for
this purpose.
 Make sure that the nut spherical
surface faces the wheel disc.
NOTE:
 The wheel nuts on the right side
of the vehicle have right-handed
threading; the left side wheel
nuts have left-handed threading.
5.Raise the vehicle to the height
where an inflated tire will just clear
the surface.
6.Remove the wheel nuts (or the
outer wheel nuts) and wheel. If
replacing an inside dual wheel:
a) Lower the axle and loosen the
inner wheel nuts.
b) Raise the vehicle again to the
height where an inflated tire will
clear the surface.
c) Remove the inner wheel nuts
and inner wheel.
<Installing a tire>
NOTE:
 Replace the hub bolts and nuts
or wheel disc if the threads are
damaged or deformed or the
wheel disc is deformed or
cracked.
 Clean the wheel mounting surfaces with a wire brush and
clean waste cloth. Dirty mounting surfaces may cause the
wheel nut to loosen.
 Before reinstalling the wheel,
apply a small amount of engine
oil or grease to the threaded
portions of the hub bolts and
wheel nuts and the spherical
surfaces of the ball seats. Do
1.Using a lever, raise and fit the
wheel to the hub by aligning the
wheel disc bolt holes to the hub
bolts.
2.Position the wheel so that the hub
bolts are in the middle of the bolt
holes, and then tighten the wheel
nuts temporarily.
3.Loosen the jack and lower the
wheels slowly.
4.Tighten the wheel nuts a little at a
time in the numerical sequence
shown below to the specified
torque.
UD1800 and UD2000
273 to 310 ft·lb (370 to 420
N·m) (38 to 43 kgf·m)
UD2300, UD2600 and UD3300
398 to 435 ft·lb (540 to 590
N·m) (55 to 60 kgf·m)
12 - 8
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
(UD1800 and UD2000)
(UD2600 and UD3300)
TOWING
WARNING
 When
towing your vehicle,
observe all state and local laws
and regulations.
NOTE:
 Turn signals do not work when
(UD2300)
NOTE:
 When
replacing both dual
wheels, make sure that the inner
wheel nuts are securely tightened before installing the outside wheel.
 When installing the outside
wheel, place its air valve 180°
apart from the inside wheel.
 After changing the wheels, drive
the vehicle a distance of 30 to 60
miles (50 to 100 km) to settle the
wheel disc with hub, and then
retighten the wheel nuts to the
specified torque.
12 - 9
the hazard warning
switch is operating.
flasher
Towing the vehicle
If there is a need to tow your vehicle:
1.Unload your vehicle.
2.Turn the ignition key to the OFF
position.
3.Release the parking brake.
4.Shift the transmission to the NEUTRAL position.
5.Use a qualified towing service with
a suitable lift and towing equipment.
6.When possible, tow the vehicle
from the front.
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
CAUTION
CAUTION
 Do not raise the vehicle by its
 Do not attempt to secure the
bumpers. Always use towing
chains or jacks. When using
towing chains, attach the
chains to a main structural
member. When using a jack or
jacks, place directly under a
main structural member.
 When towing the automatic
transmission model, raise the
rear wheels or remove the
drive shaft.
tow chains to the bumper. Lifting or towing by the bumper
could result in the vehicle
breaking loose and vehicle
runaway. Attach the chains to
the main structural members
of the vehicle and use a bumper protector bar.
Towing with front axle off ground or
with all wheels on ground.
To tow the vehicle from the front,
remove either the propeller shaft or
the rear axle shafts. If the rear axle
shafts are removed, drain lubricant
to prevent it from leaking from the
rear axle housing. Cover both ends
of the rear axle housing to keep out
dirt. Attach the chains to or place a
jack or jacks directly under the main
structural members of the vehicle.
be removed or the rear wheels must
be raised.
Releasing parking brake
(With spring-activated rear wheel
parking brake vehicles)
In case of an emergency when the
air pressure cannot be restored and
the vehicle must be towed the parking brakes must be released manually as follows:
WARNING
Towing with rear axle off ground
To tow the vehicle from the rear,
secure the steering wheel so that the
front wheels are straight. If this cannot be done, do not tow the vehicle
from the rear. If the vehicle is
equipped with the manual transmission, drain about 1.1 US pt (0.5 liter)
of oil from the transmission so that it
does not enter the clutch housing.
Attach the chains to or place a jack
or jacks directly under the main
structural member of the vehicle.
To tow a vehicle with an inoperative
rear axle, it is necessary to raise the
rear wheels. If the transmission is
inoperative, the propeller shaft must
 To
avoid serious injury or
property damage, be sure to
block the wheels so that the
vehicle cannot move when the
brakes are manually released.
For towing, make sure the
vehicle is securely connected
to the tow vehicle before
releasing the parking brakes.
 Do not operate the vehicle
when the parking brake activates automatically.
Have
the
brake
system
checked and repaired by an
authorized UD Trucks dealer or
a qualified brake repair facility.
12 - 10
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
NOTE:
 If the air pressure drops to
approximately 40 psi (275 kPa)
(2.8 kgf/cm2) in both front and
rear brake system, the parking
brake will automatically be
applied.
[UD1800 and UD2000]
Manual Release Procedure
1.Block the wheels to prevent the
vehicle from moving.
2.Loosen the lock nuts. (See figure
below.)
3.Turn the turnbuckle to extend the
push rod until the brake shoes are
released from the drum.
CAUTION
 Do not apply excessive force
to the clevis. Doing so may
damage the wheel cylinder.
[UD2300 and UD2600]
Manual Release Procedure
1.Block the wheels to prevent the
vehicle from moving.
2.Loosen the lock nut. (See figure
below.)
3.Turn the release nut to extend the
push rod until the brake shoes are
released from the drum.
UD2300
12 - 11
UD2600
[UD3300]
Manual Release Procedure
1.Block the wheels to prevent the
vehicle from moving.
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
2.Release the release nut by turning
it counterclockwise by the specified release amount (Do not use
impact wrench).
3.To ensure the compression spring
is fully caged, the stud length
should be approximately 2.95 in
(75 mm).
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 cannot 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.
Engine starting problems
Problem
Starter does
not turn, or
turns at low
speed
Engine does
not turn
Starter turns,
but engine
does not start
Possible Cause
Battery discharged
Battery terminals disconnected, loose, or corroded
Ground is disconnected
Improper viscosity engine oil used
No fuel
Insufficient preheating time
Fuel filter is clogged
Fuel is frozen
Air in fuel system
Air cleaner is clogged
Cause Correction
Charge or replace
Connect securely and remove corrosion
Secure ground connection
Replace with proper engine oil
Add fuel
Operate intake air heater until light goes out
Replace fuel filter element
Warm fuel line with hot water
Bleed air from fuel system
Replace air cleaner element
Possible Cause
Low idling speed
No fuel
Fuel filter clogged
Air cleaner clogged
Cause Correction
Adjust with throttle control knob
Add fuel
Replace fuel filter element
Replace air cleaner element
Warm-up
Problem
Engine stops immediately
after starting
12 - 13
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation
Problem
Possible Cause
Parking brake is not completely released
Engine lacks power
Fuel filter clogged
Air cleaner clogged
Brakes are dragging
Clutch slipping
Fan clutch malfunctioning
Engine overheats
Radiator front is clogged with insects and debris
Radiator is clogged with scale
Insufficient coolant solution
Drive belt loose
Defective thermostat
Cause Correction
Release parking brake completely if problem persists, consult an authorized UD Trucks dealer or
other qualified service facility
Replace fuel filter element
Replace air cleaner element
Have brakes checked and adjusted by an authorized UD Trucks dealer or other qualified service
facility
Have clutch checked and adjusted by an authorized UD Trucks dealer or other qualified service
facility
Replace at an authorized UD Trucks dealer or
other qualified service facility
Clean
Clean
Add coolant solution
Adjust belt tension or replace belts
Check at an authorized UD Trucks dealer or other
qualified service facility
12 - 14
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem
Possible Cause
Fuel leaks
Air cleaner clogged
Tire air pressure low
Excessive fuel consumption
Brakes are dragging
Clutch slipping
Excessive engine oil consumption
Steering wheel does not
return smoothly
Steering wheel is heavy
Excessive steering wheel
vibration
Improper grade or viscosity engine oil used
Too much engine oil
Oil leaks
Insufficient lubrication of steering system
Lubricate steering system
Tire air pressure low
Lack of power steering fluid
Wheel nuts loose
Tire air pressure low or uneven
Tires partially worn
Adjust the air pressure
Add fluid up to normal level
Tighten to specified torque
Adjust to normal air pressure
Replace tires
Check and adjust at an authorized UD Trucks
dealer or other qualified service facility
Check and adjust at an authorized UD Trucks
dealer or other qualified service facility
Improperly adjusted wheel balance
Excessive steering wheel play
12 - 15
Cause Correction
Check fuel system and tighten connections if
loose
Replace air cleaner element
Adjust to proper pressure
Have brakes checked and adjusted by an authorized UD Trucks dealer or other qualified service
facility
Have clutch checked and adjusted by an authorized UD Trucks dealer or other qualified service
facility
Replace with proper engine oil
Adjust engine oil level properly
Check lubrication system and tighten connections
as necessary
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem
Possible Cause
Bolts and nuts connecting propeller shafts loose
Excessive propeller shaft deflection
Vehicle vibrates excessively
Wheel balance out of adjustment
Loose propeller shaft universal joints
Air in brake system
Poor braking action
Worn linings
Incorrect shoe clearance
Brake system leaks air or fluid
Brakes on one side operate
more than on other
Uneven tire pressure
Tires partially worn
Incorrect shoe clearance
Incorrect shoe clearance
Brakes drag
Wheel cylinder returns improperly. Broken return
spring
Cause Correction
Tighten
Check at an authorized UD Trucks dealer or other
qualified service facility
Check and adjust at an authorized UD Trucks
dealer or other qualified service facility
Replace at an authorized UD Trucks dealer or
other qualified service facility
Bleed air from brake system at an authorized UD
Trucks dealer or other qualified brake service
facility
Adjust or replace at an authorized UD Trucks
dealer or other qualified brake service facility
Tighten loose connections. If still leaking, check
and repair at an authorized UD Trucks dealer or
other qualified brake service facility
Adjust air pressure
Replace tires
Adjust at an authorized UD Trucks dealer or other
qualified brake service facility
Adjust at an authorized UD Trucks dealer or other
qualified brake service facility
Check at an authorized UD Trucks dealer or other
qualified brake service facility
12 - 16
IN CASE OF EMERGENCY/TROUBLE-SHOOTING
Operation (Cont’d)
Problem
Loss of brake fluid
Battery runs down
Possible Cause
Cause Correction
Tighten loose connections. If still leaking, check
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 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
Lights do not come on
12 - 17
Possible Cause
Bulb burned out
Fuse blown
Loose connection at system ground
Cause Correction
Replace bulb
Replace fuse
Clean and tighten ground terminal
SERVICE DATA
SERVICE DATA
MAINTENANCE STANDARD
Items
Valve clearance
Engine
Intake
Exhaust
Drive belt tension
Engine low idling speed
Engine high idling speed
Steering wheel free play
Toe-in
Chassis
Wheel alignment
Camber
Caster
Brake pedal play
Clearance between service brake
drum and lining
Maintenance Standard
0.012 - 0.016 in (0.30 - 0.40 mm)
0.018 - 0.020in (0.45 - 0.50 mm)
Auto adjusting
See page 11-47.
550 rpm
2,750 rpm
0.39 - 1.57 in (10 - 40 mm)
1.18 - 1.97 in (30 - 50 mm)
0 - 0.08 in (0 - 2 mm)
0 in (0 mm)
1.5°
1°
Remarks
While cold
Fan belt deflection
Air conditioner belt tension
UD1800, UD2000 and UD2300
UD2600 and UD3300
UD1800, UD2000 and UD2300
UD2600 and UD3300
UD1800, UD2000 and UD2300
UD2600 and UD3300
3°20′
0.12 - 0.28 in (3 - 7 mm)
Auto adjusting
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 correct. 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.
MAINTENANCE STANDARD (CONT’D)
Items
Tire tread groove depth
Chassis Clutch pedal free play
Clutch outer lever free play
13 - 2
Maintenance Standard
More than 0.063 in (1.6 mm)
1.18 - 1.97 in (30 - 50 mm)
0.177 - 0.217 in (4.5 - 5.5 mm)
Remarks
SERVICE DATA
TIGHTENING TORQUE
Items
Oil pan drain plug
Oil filter drain plug
Valve
clearance
adjust
screw nut
Maintenance
Standard
ft·lbf (N·m) (kgf·m)
40 - 44
(54 - 59) (5.5 - 6.0)
9.4 - 16.7
(12.8 - 22.6)
(1.3 - 2.3)
Rocker
arm
18 (25) (2.5)
Crosshead
18 (25) (2.5)
Valve cover mounting bolt
Engine Fuel filter case
Primary fuel filter
case
Primary fuel filter
fuel inlet plug
Air conditioner compressor tension pulley lock nut
DEF filter cover
Crankcase ventilation pipe mounting
bolt
8.6 - 10.1
(11.7 - 13.7)
(1.2 - 1.4)
26 - 29
(35 - 40) (3.6 - 4.1)
26 - 29
(35 - 40) (3.6 - 4.1)
1.7 - 2.5
(2.3 - 3.4)
(0.2 - 0.3)
22.4 - 28.9
(30.4 - 39.2)
(3.1 - 4.0)
15 - 18
(20 - 25) (2.0 - 2.5)
8.6 - 10.1
(11.7 - 13.7)
(1.2 - 1.4)
Items
Remarks
Engine
Air compressor inlet
pipe mounting bolt
Maintenance
Standard
ft·lbf (N·m) (kgf·m)
8.6 - 10.1
(11.7 - 13.7)
(1.2 - 1.4)
Remarks
UD1800,
155 - 170
UD2000 and
(210
230)
(21
24)
Steering gear body
UD2300
mounting bolt
251 - 288
UD2600 and
(340 - 390) (35 - 40) UD3300
Differential drain and
95 - 108
filler plug
(128 - 147) (13 - 15)
UD1800,
103 - 111
UD2000 and
Chassis
Axle shaft mounting (140 - 150) (14 - 15) UD2300
bolt
111 - 118
UD2600 and
(150 - 160) (15 - 16) UD3300
273 - 310
UD1800 and
(370 - 420) (38 - 43) UD2000
Wheel nut
UD2300,
398 - 435
UD2600 and
(540 - 590) (55 - 60)
UD3300
13 - 3
SERVICE DATA
TIGHTENING TORQUE (Cont’d)
Items
Maintenance
Standard
ft·lbf (N·m) (kgf·m)
Items
Remarks
UD1800,
174 - 203
UD2000 and
(235 - 275) (24 - 28)
UD2300
Front
362 - 398
UD2600 and
(490 - 539) (50 - 55) UD3300
UD1800,
Chassis
195 - 239
UD2000 and
spring U(265 - 324) (27 - 33)
UD2300
bolt nut
362 - 398
UD2600 and
Rear
(490 - 539) (50 - 55) UD3300
UD2600 and
406 - 455
UD3300 with
(550 - 617) (56 - 63)
air suspension
Chassis
UD1800,
35 - 53
UD2000 and
(47 - 72) (4.8 - 7.3)
Front spring cenUD2300
ter bolt
80 - 94
UD2600 and
(108 - 127) (11 - 13) UD3300
Rear spring center
80 - 94
bolt
(108 - 127) (11 - 13)
MLS63
72 - 89
UD1800 thru
(98
120)
(10
12)
Manual transmisUD3300
sion drain and filler
MPS63
plug
87 - 101
UD2600 and
(118 - 137) (12- 14)
UD3300
13 - 4
Maintenance
Standard
ft·lbf (N·m) (kgf·m)
Remarks
Allison 1000,
2200 and 2500
22 - 30
series
(30 - 40) (3.1 - 4.1)
UD1800 thru
Automatic transUD3300
mission drain plug
Allison 3000
series
18.5 - 23.6
(25 - 32) (2.5 - 3.3) UD2600 and
UD3300
Allison 3000
Automatic transseries
37.6 - 45.0
mission filter cover
(51 - 61) (5.2 - 6.2) UD2600 and
mounting bolt
UD3300
Chassis
UD1800
65 - 80
UD2000 and
(88 - 108) (9 - 11)
UD2300
Propeller shaft
mounting bolt
156 - 177
UD2600 and
(211 - 240)
UD3300
(21.5 - 24.5)
Fuel tank drain
36 - 51
plug
(49 - 69) (5 - 7)
25 - 33
UD1800 and
(34 - 45) (3.5 - 4.6) UD2000
Actuator lock nut
90 - 105
UD2300 and
(122 - 142)
UD2600
(12.4 - 14.5)
SERVICE DATA
BULBS
RECOMMENDED LUBRICANTS
Items
Headlight (Halogen)
Front turn signal light
Front side turn signal light
Front clearance light
Front identification light
Rear combination light Tail & stop light
Rear turn signal light
License plate light
Back-up light
Room light
Wattage Trade
(W)
No.
60/55
HB2
21
21
5
168
5
168
8/27
1157
27
1156
8
67
27
1156
10
-
Lubricant/Fluid
Engine oil
Gear
oil
Manual
transmission
Differential
Specifications
VDS-4
Remarks
See page 11-31
API :GL-4
#80W/90
Refer to "RECOMMENDED SAE VISMIL- COSITY CHART" on
L2105B page 13-6.
API
GL-5
See the Allison
Automatic transmission fluid
Power steering fluid
Apply grease
Grease Lubricate with a
grease gun
Brake and clutch fluid
Antifreeze
automatic
transmission
fluid recommendations next
page.
UD1800 thru UD3300
DEXRON® II or GM ATF type
higher grade
NLGI No. 1
NLGI No. 2 or
NLGI No. 3
DOT 3
-
Lithium soap base
US FMVSS
No. 116
(1)
Remarks:
(1) UDXtra Long Life Diesel Engine Antifreeze/Coolant
13 - 5
SERVICE DATA
Allison automatic transmission fluid recommendations
Hydraulic fluids used in the transmission are important
influences on transmission reliability and durability.
Allison TranSynd fluids or TES-295 approved fluids are
recommended.
This vehicle is factory filled with TranSynd fluid.
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 contamination 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
RECOMMENDED SAE VISCOSITY CHART
SERVICE DATA
(Cont’d)
REFILL CAPACITIES
US
measure
Item
Engine oil
With oil filter
18.4 qt
17.4
Without oil
filter
18.0 qt
17.0
5.9 qt
5.5
Without
PTO
7.2 qt
6.8
With PTO
7.8 qt
7.3
Without
PTO
8.3 qt
7.8
With PTO
8.8 qt
8.3
16.3 qt
Allison
1000,
15.4 2200 and
2500
series
Windshield washer fluid
Allison
29.9 3000
series
Cooling system solution
Power steering fluid
UD1800
thru
UD3300
Manual
transmission gear
UD2600
oil
and
UD3300
Automatic transmission fluid (system total)
Item
Liter Remarks
UD1800 thru
UD3300
UD2600 and
UD3300
31.6 qt
Differential gear oil
MLS63
MPS63
Fuel tank
US
measure
Liter
Remarks
6.9 qt
6.5
UD1800, UD2000
and UD2300LP
9.5 qt
9
UD2300DH
13.8 qt
13
UD2600 and
UD3300
32.8 gal
124
UD1800 and
UD2000
32.8 gal
124 UD2300
48.9 gal
185
Optional for
UD2300DH only
48.9 gal
185
UD2600 and
UD3300
4.3 qt
4
6.9 gal
26
With manual
transmission
6.6 gal
25
With Allison 1000,
2200 and 2500
series
7.9 gal
30
With Allison 3000
series
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.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You
can also obtain other information about motor vehicle
safety from the Hotline.
14 - 1
A-C
Fluid temperature warning... 7-41
Maintenance .......................11-12
Maintenance information
light ...................................... 7-50
Operation........................... 10-14
Power mode indicator light .. 7-52
Selector lever....................... 7-76
Selector switch .................... 7-76
Shift limit warning
light ........................... 7-49, 10-30
System warning ................... 7-42
INDEX
A
Abbreviation ................................1-4
ABS .........................................10-34
ABS warning light ......................7-44
Accelerate and Resume
switch ........................................7-61
Accessories .................................8-1
Air cleaner element ................. 11-44
Air conditioner .............................9-1
Air vent ...................................9-1
Heating...................................9-5
Operation panel......................9-2
Air dryer................................... 11-64
Air pressure gauge ......................7-8
Air pressure warning light..........7-43
Air spring ................................. 11-68
Air suspension dump switch......7-66
Allison ATM fluid........................13-6
Antifreeze ........... 10-37, 11-24, 13-5
Appearance care ..................... 11-89
Ashtray ........................................8-2
Automatic transmission
Fluid change....................... 11-57
Fluid filter...................... 11-57, 58
Fluid refill capacity................13-7
15 - 1
B
Battery
Electrolyte level ..................11-76
Gravity ................................11-77
Jump start............................ 12-3
Specifications......................11-75
Block immersion heater .......... 10-38
Blower motor filter....................11-82
Brake
Air dryer ..............................11-64
Air reservoir ........................11-63
Drum and lining clearance... 13-1
Fluid..................................... 13-5
Fluid level ...........................11-62
Maintenance .........................11-9
Operation........................... 10-33
Pedal play ............................13-1
Break-in............................. 1-2, 10-2
Bulbs .............................. 11-78, 13-5
Buzzers ..................................... 7-30
C
Cab
Accessories............................8-1
Air conditioner ....................... 9-1
Doors & windows ...................5-1
Driving position ......................6-1
Entering & leaving cab ...........4-1
Front lid .............................. 11-20
Instruments & controls ...........7-1
Lower the cab .................... 11-23
Tilting the cab..................... 11-21
Calendar..............................7-18, 24
Camber ..................................... 13-1
Card holder .................................8-4
Caster........................................13-1
CCV filter................................. 11-50
Chassis grease ............. 11-16, 13-5
Child restraint ..............................6-6
Cigarette lighter...........................8-1
Circuit breaker...........................7-56
Clean air act .............................. 11-1
Clock ...................................7-18, 24
Clutch
Fluid ................................... 11-66
D-F
Free play ............................ 11-65
Clutch fluid ................................13-5
Clutch pedal free play ...............13-2
Cold weather ...........................10-36
Console box ................................8-5
Controls.......................................7-1
Conversion factors ....................13-8
Coolant
Antifreeze................. 11-24, 13-5
Level warning light ...............7-45
Reservoir tank .................... 11-25
Temperature gauge ................7-9
Coolant heater.........................10-38
Cooling system
Drive belts .......................... 11-46
Fan and fan shroud ............ 11-27
Radiator ............................. 11-26
Cruise Control
Accelerate and Resume
switch ...................................7-61
Indicator light........................7-60
Main switch ..........................7-60
Operation .............................7-60
Set and Coast button ...........7-60
Cup holder...................................8-3
D
Daily maintenance.......................3-6
DEF filter..................................11-48
DEF gauge ............................... 7-10
DEF tank.......................... 3-17, 7-10
Defrost ........................................ 9-8
Differential gear oil........ 11-59, 13-5
Dilution water...........................11-26
Dimmer switch .......................... 7-57
Door pocket ................................ 8-5
Doors .......................................... 5-1
Double-clutch.......................... 10-13
DPF ash level gauge ................ 7-14
DPF regeneration system......... 3-20
DPF soot level gauge ...... 7-14, 7-70
DPF system .............................. 7-69
Drive belt tension.......... 11-47, 13-1
Drive belts................................11-46
Driver seat .................................. 6-1
Driving in difficult conditions ....10-11
Driving on grades ................... 10-10
Driving position ........................... 6-1
E
EGR...........................................3-11
ELR............................................. 6-5
Emergency starting................... 12-3
Emission control systems
maintenance ............................11-70
Engine control warning light ..... 7-43
Engine idling
speed ..................... 7-53, 10-7, 13-1
Engine oil ...................... 11-31, 13-5
Engine oil filter ........................ 11-36
Engine oil pressure gauge ........ 7-12
Engine oil refill capacity ............ 13-7
Engine oil temperature gauge... 7-13
Engine overheating ................... 12-1
Engine overspeed ................... 10-10
Engine throttle control
knob ................................7-53 , 10-7
Engine warm-up switch....7-54, 10-8
Exhaust brake indicator light..... 7-51
Exhaust brake switch ................ 7-55
Exhaust system....................... 11-75
F
Fan and fan shroud................ 11-27
Fan drive belt .......................... 11-46
Front lid ................................... 11-20
Front wheel alignment............... 13-1
Fuel ................................. 1-3, 11-38
Fuel gauge ................................ 7-12
Fuel system
Fuel cap ............................. 11-39
Fuel filling........................... 11-39
Fuel tank ............................ 11-37
Main fuel filter..................... 11-40
Primary fuel filter ................ 11-41
15 - 2
G-M
Purging air from fuel
system................................ 11-43
Fuel requirements ................... 11-38
Fuses ...................................... 11-80
Fusible link box ....................... 11-80
G
Gauges........................................7-5
GAWR .........................................3-2
GCWR .........................................3-3
Gear oil refill capacities .............13-5
Gear shift lever ..........................7-75
Grease ......................................13-5
Greasing points ....................... 11-16
GVWR .........................................3-2
H
Hazard warning flasher switch ..7-59
Headlights ............................... 11-78
Headrest......................................6-3
Heater .........................................9-5
Heater or air conditioner
blower motor filters .................. 11-82
Horn ..........................................7-68
Hotline .......................................14-1
Hour meter ..................................7-7
I
Identification number (VIN) ......... 2-1
Idle shut down ........................ 10-38
Idling speed ........... 7-53, 10-7, 13-1
Ignition key switch ...................... 7-3
Illumination control rheostat...... 7-64
Immersion heater.................... 10-38
In cold weather ....................... 10-36
Indicator lights
ATM maintenance................ 7-50
ATM O/D OFF...................... 7-52
ATM power mode ................ 7-52
Cruise Control ON ............... 7-60
Cruise Control SET.............. 7-60
Exhaust brake...................... 7-51
Exhaust gas high
temperature ......................... 7-50
Hazard ................................. 7-51
High beam ........................... 7-52
Intake air heater................... 7-51
Transmission PTO ............... 7-64
Turn signal ........................... 7-51
Instruments ................................. 7-1
Intake air heater
indicator light ............................ 7-51
J
Jack operation .......................... 12-6
15 - 3
Jump start .................................12-3
K
Keyless entry system ..................5-2
Battery....................................5-3
Keys ............................ 1-2, 5-1, 7-3
L
Labels........................................3-24
Language setting.......................7-25
Leaf spring .............................. 11-67
Lighting switch...........................7-57
Lights....................................... 11-78
Lining clearance ........................ 13-1
Loading .................................... 10-2
Long life coolant ............ 11-24, 13-5
Lower the cab.......................... 11-23
Lubricants..................................13-5
Lumber support ...........................6-2
M
Maintenance
Chassis ................................ 11-7
Engine.................................. 11-4
Intervals ............................... 11-3
Noise emission control
system................................ 11-73
N-T
Precautions ........................ 11-19
Standard...............................13-1
Maintenance and inspection
display .......................................7-20
Meters .........................................7-5
Metric ................................ 1-3, 13-8
Mirror....................................... 11-69
Mirror heater............................ 11-69
Mirror heater switch...................7-67
Multi-display ..............................7-15
N
New vehicle break-in
period ................................ 1-2, 10-2
NHTSA ......................................14-1
Noise control system............... 11-73
O
Odometer ....................................7-6
Operating precautions...............10-1
Outside mirrors........................ 11-69
Overhead box..............................8-3
Overheating...............................12-1
Overloading....................... 3-2, 10-2
Overspeed...............................10-10
P
Parking brake valve....... 7-76, 10-35
Parking brake warning light ...... 7-47
Passenger seat........................... 6-2
Passing switch.......................... 7-57
Power mirror switch .................. 7-68
Power mode switch .................. 7-65
Power socket .............................. 8-2
Power steering system
Fluid......................... 11-61, 13-5
Refill capacities.................... 13-7
Power window ............................ 5-4
Pregnant woman restraint .......... 6-6
Primary fuel filter......................11-41
PTO ............................... 7-64, 10-22
PTO switch ............................... 7-64
R
Radiator
Changing coolant ...............11-28
Cleaning .............................11-26
Engine coolant level 7-45, 11-25
Recommended lubricants......... 13-5
Refill capacities......................... 13-7
Refrigerant.................................. 9-9
Regeneration switch ........ 3-20, 7-70
Remote control ........................... 5-2
Reporting safety defects........... 14-1
Rheostat ................................... 7-64
Room light .................................. 8-4
S
SAE viscosity chart ................... 13-6
Safety reminders......................... 3-6
Seat adjustment .......................... 6-1
Seat belts .................................... 6-5
Serial number.............................. 2-2
Set and Coast button ................ 7-60
Shift limit ........................... 10-15, 30
Shift lock ................................. 10-17
Shock absorber....................... 11-68
Speedometer............................... 7-6
Spring-activated parking
brake ....................................... 12-10
Starter switch .............................. 7-3
Starting the engine .................... 10-4
Starting the engine
(In cold weather) .................... 10-36
Steering fluid ........................... 11-61
Steering fluid filter ................... 11-62
Steering wheel ............................ 6-7
Steering wheel free play............ 13-1
Stopping engine ........................ 10-9
T
Tachometer ................................. 7-7
Throttle control knob ................. 7-53
Tightening torque ...................... 13-3
Tilting and telescoping
steering wheel............................. 6-7
15 - 4
U-W
Tilting the cab ......................... 11-21
Tire
Change.................................12-6
Condition ............................ 11-85
Inflation pressure................ 11-84
Load specification .............. 11-84
Position rotation ................. 11-87
Size .................................... 11-83
Tire tread groove depth .............13-2
Toe-in ........................................13-1
Towing .......................................12-9
Towing trailers ................... 3-3, 10-3
Transmission
Automatic transmission
operation ............................10-14
Gear oil..................... 11-51, 13-5
Manual transmission
operation ............................ 10-11
Oil refill capacity ...................13-7
PTO switch...........................7-64
Trip hour meter............................7-7
Trip meter ....................................7-7
Troubleshooting...................12-1, 13
Turn signal and hazard
indicator light .............................7-51
Turn signal switch......................7-57
15 - 5
U
Unit identification ........................ 2-2
V
Valve clearance ........................ 13-1
Vehicle identification number ...... 2-1
Vehicle loading ................. 3-2, 10-2
Vehicle operation ...................... 10-1
VIN.............................................. 2-1
Viscosity chart........................... 13-6
Volt meter ................................. 7-13
W
Warming up engine................... 10-7
Warning lights ........................... 7-43
ABS ..................................... 7-44
Air pressure ......................... 7-43
Automatic transmission
shift limit.............. 7-49, 10-15, 30
Brake ................................... 7-47
DEF low level....................... 7-10
DPF clogging .............. 3-20, 7-70
Engine control...................... 7-43
Engine coolant level ............ 7-45
Parking brake ...................... 7-47
Seat belt ................................ 6-6
Tilt lock................................. 7-48
Warnings................................... 7-31
ATM fluid temperature..........7-41
ATM system .........................7-42
Charge .................................7-32
DEF low level .......................7-33
DPF maintenance ..... 3-24, 11-71
DPF regenerating........3-21, 7-72
DPF regeneration
restriction .............................7-73
DPF system .........................3-22
Engine communication
malfunction...........................7-40
Engine oil pressure ..............7-32
Engine oil temperature.........7-37
Engine overrun.....................7-31
Engine system .....................7-38
Meter communication
malfunction...........................7-39
Overheat .......................7-9, 12-1
PTO engine start interrupt....10-5
Starter overheat ...................10-5
Vehicle electrical system
communication malfunction .7-40
Vehicle electrical system
malfunction...........................7-39
Wheel alignment .......................13-1
Wheels, tires and nuts.... 11-86, 12-7
Window lock switch .....................5-5
W-W
Windshield
Washer fluid ............... 11-68,13-7
Washer reservoir................ 11-68
Wiper, washer and
exhaust brake switch ...........7-55
15 - 6