UD Trucks. Owner’s Manual (2011-2013)

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TO THE OWNER

This Owner’s Manual has been prepared to provide you with important oper-

ation, maintenance and safety information relating to your UD Trucks vehi-

cle. 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 opera-

tors with important operation, safety and maintenance information.

The characteristics and functions of this vehicle make its driving and han-

dling 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.

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CLEAN IDLE CERTIFIED

CALIFORNIA PROPOSITION 65

FEDERAL HIGHWAY

LABEL FOR U.S.

WARNING

ADMINISTRATION

Make sure that the following clean

REGULATION

engine idling certified label is affixed

Various regulations relating to vehi-

to the left side of the corner back

WARNING

cle performance, equipment, and

outer. By the CARB regulation listed

safety have been issued by the

Engine exhaust, some of its

below, the label must be affixed

Department of Transportation. These

constituents, and certain vehi-

there to prove that the new vehicle

regulations include, but are not lim-

cle components contain or

with diesel engine manufactured

ited to the Federal Motor Vehicle

emit chemicals known to the

from Jan., 2008 conforms to this reg-

Safety Standards and the Federal

State of California to cause

ulation.

Motor Carrier Safety Regulations.

cancer and birth defects or

Other federal, state and local regula-

other reproductive harm. In

CARB

§ 1956.8. Exhaust

tions may also apply. Final stage

addition, certain fluids con-

Emission Standard and

manufacturers and motor carriers

tained in vehicles and certain

Test Procedure

are responsible for knowing and

products of component wear

(a) (b) Heavy-Duty Diesel

complying with all regulations that

contain or emit chemicals

Engine Idling Requirements

may apply to the vehicle. A finished

known to the State of California

vehicle may also require devices that

to cause cancer and birth

are not specified in the regulations.

defects or other reproductive

Body builders, subsequent stage

harm.

manufacturers and carriers must

determine what safety devices are

necessary for the safe operation of

the vehicle.

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TABLE OF CONTENTS

INTRODUCTION AND SAFETY

1-1

Door Window (Power Window)

5-4

When Reading the Manual

1-1

DRIVING POSITION

6-1

New Vehicles Break-in Period

1-2

Seats

6-1

Keys

1-2

Seat Belts

6-5

Fuel

1-3

Steering Wheel

6-7

Metric Mismatch

1-3

Abbreviation

1-4

INSTRUMENTS AND CONTROLS

7-1

Ignition Key Switch

7-3

IDENTIFICATION

2-1

Meters and Gauges

7-5

Vehicle Identification Number (VIN)

2-1

Multi-display Monitor

7-15

Unit Identification

2-2

Warnings and Indicators

7-26

BEFORE DRIVING YOUR VEHICLE

3-1

Buzzers

7-30

Overloading

3-2

Warnings

7-31

Towing Trailers

3-3

Warning and indicator lights

7-43

Safety Reminders

3-6

Switches and Buttons

7-53

Daily Maintenance

3-6

DPF System

7-69

EGR System Operation

3-11

Levers and Control

7-75

UD Trucks, US2010 Emissions solution

3-11

ACCESSORIES

8-1

Handling of the exhaust emission

control system

3-12

HEATER OR AIR CONDITIONER CONTROL

9-1

Vehicle Labels

3-24

Air Conditioner

9-1

ENTERING AND LEAVING THE CAB

4-1

VEHICLE OPERATION

10-1

Operating Precautions

10-1

DOORS AND WINDOWS

5-1

Break-in Precautions

10-2

Door

5-1

Vehicle Loading

10-2

Keyless Entry System

5-2

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Towing Trailers

10-3

Steering System

11-60

Starting the Engine

10-4

Service Brake System

11-62

Warming up Engine

10-7

Clutch

11-65

Stopping the Engine

10-9

Suspension

11-67

Driving on Grades

10-10

Windshield Washer Fluid

11-68

Driving in Difficult Conditions

10-11

Outside Mirrors

11-69

Operating with Manual Transmission

10-11

Emission Control Systems

11-70

Operating with Automatic Transmission

10-14

Noise Control System

11-73

Brake Operation

10-33

Battery

11-75

Parking your Vehicle

10-35

Lights

11-78

After Parking Your Vehicle

10-36

Fuses

11-80

In Cold Weather

10-36

Blower Motor Filters

11-82

Idle Shutdown

10-38

Wheels and Tires

11-83

Appearance Care

11-89

VEHICLE SERVICE AND MAINTENANCE...11-1

Clean Air Act

11-1

IN CASE OF EMERGENCY/

Maintenance Intervals

11-3

TROUBLESHOOTING

12-1

Grease Lubrication Points

11-16

Engine Overheating

12-1

Before Performing Maintenance

11-19

Jump Starting

12-3

Cab

11-20

Tire Change

12-6

Engine Cooling System

11-24

Towing

12-9

Engine Oil and Oil Filters

11-31

Troubleshooting

12-13

Fuel System

11-37

SERVICE DATA

13-1

Air Cleaner Element

11-44

Maintenance Standard

13-1

Drive Belt

11-46

Tightening Torque

13-3

Aftertreatment DEF Filter

11-48

Bulbs

13-5

CCV Filter

11-50

Recommended Lubricants

13-5

Transmission Gear Oil

11-51

Recommended SAE Viscosity Chart

13-6

Differential Gear Oil

11-59

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INTRODUCTION AND SAFETY

WHEN READING THE MANUAL

INTRODUCTION

AND SAFETY

In this manual, read very carefully those sections which have signs

“DANGER”, “WARNING”, “CAUTION” and “NOTE”. They are particularly

important.

Indicates an imminently hazardous situation which, if not

DANGER

avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not

WARNING

avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not

CAUTION

avoided, could result in minor or moderate injury.

Indicates a situation which, if not avoided, could result in

CAUTION

property damage to the vehicle.

NOTE

Indicates good practice.

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 applica-

ble to your particular vehicle. If you have any questions, consult your UD

Trucks dealer.

1 - 1

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INTRODUCTION AND SAFETY

All information and specifications in

NEW VEHICLES BREAK-IN

KEYS

this manual are based on the prod-

PERIOD

Duplicate keys are provided with

uct information in effect at the time of

For extended service life and reliable

your UD Trucks vehicle. Each key

printing. The right is reserved to dis-

operates the door locks and ignition

performance, your UD Trucks vehi-

continue models, change informa-

cle requires proper handling during

key switch. Record the key number

tion, specifications or design without

stamped on your keys and store in a

the first

600 miles (1,000 km) of

notice and without incurring obliga-

operation. Special instructions for

safe place. Contact your UD Trucks

tion.

dealer if key replacement becomes

this break-in period are described in

We urge you to drive safely, use the

the "BREAK-IN PRECAUTIONS" on

necessary. The key number will

safety equipment provided with your

page 10-2. After this initial break-in

enable the UD Trucks dealer to order

vehicle and observe traffic signs and

period, continued routine inspection

replacement keys.

local laws.

and maintenance as described in

See the “DOORS AND WINDOWS”

Thank you for selecting a UD Trucks

this manual will help assure contin-

section for door operation and Key-

product. We sincerely hope that your

ued dependable operation of your

less Entry System.

UD Trucks experience is safe, satis-

UD Trucks vehicle.

Key number plate

factory and pleasant.

For details, refer to the

“VEHICLE

SERVICE AND MAINTENANCE”

The key number is engraved on the

section.

key number plate so that only the

owner will know the key number.

Remove this from the key you nor-

mally use and store it in a safe place

other than in the vehicle. (The key

number is not engraved on the key.)

1 - 2

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INTRODUCTION AND SAFETY

FUEL

METRIC MISMATCH

Your UD Trucks vehicle is designed

Your vehicle may utilize parts which

to operate on diesel fuel only.

have either metric and/or SAE unit

For details, refer to the "Fuel require-

dimensions. Any fasteners e.g. bolts

ments" on page 11-38.

and nuts, used to replace old ones,

must have the same dimensions and

strength as those removed.

CAUTION

Do not use fuel additives,

agents for removal of water

WARNING

from the fuel, agents for

Mismatched or incorrect

improvement of the fuel effi-

thread fasteners can result in

WARNING

ciency.

thread stripping and/or assem-

This can cause smoke genera-

bly weakness leading to vehi-

Do not leave children alone in

tion or defects from defective

cle damage, malfunction or

the vehicle. If you must leave

sliding of the sliding surfaces

possible serious injury.

the car, be sure to remove the

lubricated by fuel system.

ignition key to avoid an acci-

Do not install devices for

dent.

improvement of the fuel effi-

ciency inside the fuel tank.

Wear particles, fragments from

the installed devices

(after-

CAUTION

market parts) can cause

Only use genuine part ignition

defects of the fuel system.

keys to prevent accidents.

NOTE:

z When leaving the car, be sure

to remove the key and lock the

doors. This will prevent theft.

1 - 3

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INTRODUCTION AND SAFETY

ABBREVIATION

In this manual, the following abbrevi-

ations 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

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IDENTIFICATION

Vehicle lines, series, Chassis, GVWR Class

UNIT IDENTIFICATION

The locations of the stamped chas-

Code

Information

sis serial number, engine serial num-

UD1800 (MKA8F) with MLS63B transmission 4 x 2, Class 5

ber, and each assembly and serial

UD1800 (MKA8F) with 1000RDS transmission 4 x 2, Class 5

number of transmission, differential

UD2000 (MKB8F) with MLS63B transmission 4 x 2, Class 5

carrier, front axle and rear axle are

UD2000 (MKB8F) with 1000RDS transmission 4 x 2, Class 5

shown below:

UD2300DH (LKC8F) with MLS63B transmission 4 x 2, Class 6

Chassis serial number location

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

2 - 2

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BEFORE DRIVING YOUR VEHICLE

BEFORE

DRIVING YOUR

WARNING

VEHICLE

Be sure this vehicle includes required safety features. This vehicle

may be put to many uses, and UD Trucks Corporation cannot antici-

pate all of them. Always consult safety regulations in effect for loca-

tion and type of use of the vehicle. Below are two safety adaptations

required under certain circumstances. Other measures may be

required depending on the type of body built on the chassis and the

uses expected for the final vehicle. Neglecting good safety measures

could cause a serious accident.

REAR IMPACT PROTECTION

Section

393.86 of the Federal Motor Carrier Safety Regulations

requires certain vehicles to be equipped with rear impact protection

guards. Such guards must be installed in accordance with the Federal

Motor Carrier Safety Regulations. Make sure your vehicle has rear

impact protection that meets or exceeds all applicable regulations for

wherever it will be driven and that it is installed correctly.

VISIBILITY DEVICES

Federal Motor Vehicle Safety Standards and Federal Motor Carrier

Safety Regulations require certain vehicles to be equipped with ret-

roreflective sheeting or other devices to insure the vehicle is clearly

visible. Be sure you have visibility devices in compliance with the reg-

ulations and take any other steps necessary to ensure that the vehicle

is sufficiently conspicuous at night or in low lighting conditions.

3 - 1

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BEFORE DRIVING YOUR VEHICLE

OVERLOADING

Model

Tire

GVWR

GAWR-Front

GAWR-Rear

WARNING

Never load your vehicle in

17,995 lb

7,280 lb

13,660 lb

UD1800

225/70R19.5 (F)

excess of the Gross Vehicle

(8,160 kg)

(3,300 kg)

(6,200 kg)

Weight Rating (GVWR) and the

19,500 lb

7,280 lb

13,660 lb

Gross Axle Weight Ratings of

UD2000

225/70R19.5 (F)

(8,845 kg)

(3,300 kg)

(6,200 kg)

the front and rear axle (GAWR).

8,375 lb

15,430 lb

Overloading may cause loss of

UD2300 LP

245/70R19.5 (G)

23,000 lb

(3,800 kg)

(7,000 kg)

vehicle control and result in seri-

(10,435 kg)

8,375 lb

16,535 lb

ous injury or death. It may also

UD2300 DH

9R22.5 (G)

(3,800 kg)

(7,500 kg)

void the new vehicle warranty

11,020 lb

20,280 lb

and shorten vehicle life.

UD2600

11R22.5 (G)

25,995 lb

(5,000 kg)

(9,200 kg)

(11,790 kg)

11,020 lb

20,280 lb

UD2600 LP

255/70R22.5 (H)

(5,000 kg)

(9,200 kg)

32,900 lb

11,900 lb

21,000 lb

UD3300

11R22.5 (G)

(14,925 kg)

(5,400 kg)

(9,525 kg)

NOTE:

z UD2300 LP

Tire specification: 245/70R19.5 (G)

z UD2300 DH

Tire specification: 9R22.5 (G)

z UD2600

Tire specification: 11R22.5 (G)

z UD2600 LP

Tire specification: 255/70R22.5 (H)

3 - 2

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BEFORE DRIVING YOUR VEHICLE

TOWING TRAILERS

GVWR of the towing vehicle. The GCW must never

exceed the GCWR.

WARNING

GVWR (Gross Vehicle Weight Rating) — is the maxi-

z Towing trailers beyond the maximum recom-

mum allowable weight of the fully loaded vehicle (includ-

mended trailer weight which exceeds the limit of

ing all options, equipment, passengers, and cargo).

the vehicle’s GCWR, GVWR, GAWR(s) or tire rat-

ings could result in engine damage, transmission

damage, structural damage, loss of vehicle con-

CAUTION

trol, vehicle rollover and personal injury.

z Exceeding the Tire Rating or Simplified Final-

stage Vehicle Certification Label vehicle weight

Definitions:

rating limits could result in substandard vehicle

GAWR (Gross Axle Weight Rating) — is the maximum

handling or performance, engine, transmission

allowable weight that can be carried by a single axle

and/or structural damage, serious damage to the

(front or rear). These numbers are shown on the Simpli-

vehicle, loss of control and personal injury.

fied Final-stage Vehicle Certification Label that can be

found on the inside of the driver’s door or the door frame.

The total load on each axle must never exceed its

GAWR.

GCWR (Gross Combined Weight Rating) — is the maxi-

mum 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 opera-

tion 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

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BEFORE DRIVING YOUR VEHICLE

The following chart indicates the allowable GCWR for your UD Trucks vehicle based on the specific transmission

model and specific rear axle ratio:

Maximum GCWR - Ib. (kg.)

Vehicle Model

Engine Type

Rear Axle Ratio *

MTM

ATM

UD1800

3.90 / 4.11/ 4.33

29,000 (13,154)

26,000 (11,793)**

UD2000

3.90 / 4.11/ 4.33

29,000 (13,154)

26,000 (11,793)**

4.11

33,135 (15,029)

26,000 (11,793)**

UD2300LP

D (245hp)

4.33 / 4.56

34,000 (15,422)

26,000 (11,793)**

UD2300DH

4.88 / 5.29

34,000 (15,422)

26,000 (11,793)**

5.14

34,945 (15,850)

26,000 (11,793)**

5.57

41,000 (18,597)

26,000 (11,793)**

4.63

48,065 (21,800)

N/A

UD2600

4.88

50,715 (23,000)

N/A

E (280hp)

5.57

57,770 (26,200)

57,770 (26,200)**

5.86

N/A

58,430 (26,500)**

6.17

N/A

57,990 (26,300)**

UD2600LP

D (245hp)

4.88

40,225 (18,246)

26,000 (11,793)**

3 - 4

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BEFORE DRIVING YOUR VEHICLE

Vehicle Model

Engine Type

Rear Axle Ratio *

MTM

ATM

4.33

50,490 (22,900)

N/A

4.63

53,800 (24,400)

N/A

UD2600LP

E (280hp)

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)

33,000 (14,968)**

D (245hp)

5.86

43,100 (19,550)

6.83

50,000 (22,680)

N/A

4.88

50,715 (23,000)

N/A

UD3300

5.14

53,580 (24,300)

N/A

5.57

57,770 (26,200)

57,770 (26,200)**

E (280hp)

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

UD Trucks. Owner’s Manual (2011-2013) - page 1