UD Trucks. Owner’s Manual (2011-2013)

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VEHICLE OPERATION

To park the vehicle

AFTER PARKING YOUR

IN COLD WEATHER

1.Shift the transmission to the neu-

VEHICLE

tral position (Manual transmission)

Starting the engine in cold

1.Check for oil, water and fluid leaks.

or P (Park) or N (Neutral) position

weather

2.Drain any condensate from the air

(Automatic transmission).

reservoir.

The diesel engine utilizes a com-

2.Apply the parking brake.

3.In cold climates drain water from

pression ignition system and there-

3.Idle the engine for 3 to 5 minutes

the fuel filter. If water remains, it

fore starting the engine in cold

to lower the engine temperature

may freeze resulting in damage to

weather may be difficult compared to

before stopping the engine.

the fuel filter.

a gasoline engine.

4.Perform all necessary service and

In order to facilitate cold weather

starting, adhere to the following pro-

repairs.

CAUTION

cedures.

z Neglecting to idle the engine

Starting method

properly may damage the

engine especially after com-

pleting a high-load or high-

WARNING

speed run.

z Do not use ether to assist with

starting since it is highly toxic

4.Stop the engine and turn all

and flammable and could

switches to OFF.

cause a fire or explosion.

5.Remove the ignition key.

6.Lock the doors.

Fuel

z Use diesel fuel ASTM 1-D in cold

weather.

z Avoid getting water in the fuel sys-

tem. Water in the fuel system will

freeze and make starting the

10 - 36

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VEHICLE OPERATION

engine impossible. At the end of

maintained in the fully-charged

may be faulty and should be

each daily operation, drain water

condition.

repaired.

from the fuel filter.

z Always fill the fuel tank up to its

WARNING

specified level to prevent conden-

sation.

z Do not attempt to jump start a

Failure to drain water could

vehicle having a frozen bat-

cause freezing in the air lines

Oil

tery; the battery may rupture or

and result in serious injury due

explode. If a frozen battery is

to insufficient braking power.

z The lubricating oil thickens as it

suspected or if ice can be seen

gets colder, slowing engine crank-

in each cell, do not attempt to

ing speed. Be sure to use proper

start the vehicle with jumper

lubricating oil in order to offer less

cables.

resistance to the cranking effort of

the engine.

Anti-freeze

See the "Oil viscosity and relation

between viscosity and tempera-

z Check the UDXtra Long Life Diesel

ture:" on page 11-32.

Engine Antifreeze/Coolant to

assure proper winter protection.

Battery

For details, see the "ENGINE

COOLING SYSTEM" on page 11-

z If the battery is not fully charged,

24.

the battery electrolyte may freeze

and the resultant expansion may

Draining air reservoir

damage the battery.

To maintain maximum efficiency,

z At the end of each daily operation,

the battery should be checked reg-

always drain water from the air

ularly, at least once a month, and

reservoir. If a large quantity of

water accumulates, the air dryer

10 - 37

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VEHICLE OPERATION

Cold Weather Operation of Allison

IDLE SHUTDOWN (Optional)

Automatic Transmission

The Idle shutdown function saves

The following chart is the minimum

fuel consumption and reduces emis-

fluid temperature at which the trans-

sion gas when a vehicle is standing

mission may be safely operated in a

still and ignition key is ON position.

forward or reverse range. When

ambient air temperature is below the

This function stops the engine auto-

minimum fluid temperature limit and

matically if a predefined time has

the transmission is cold, warm-up is

elapsed since the entry conditions

required.

are fulfilled when the vehicle is

Run the engine at idling for at least

standing still and the ignition key

20 minutes with the transmission in

position is ON.

neutral before operating in a forward

Coolant heater

The warning period is 30 seconds

or reverse range.

z At temperatures below -4°F

before the engine stops. The dis-

(-20°C), an engine block immer-

played message and audible alarm

CAUTION

sion coolant heater is recom-

warn the driver during this period.

mended to aid cold weather

The warning to the driver continues

z Failure to observe the mini-

starting by keeping the engine

until turn the ignition key to OFF

mum fluid temperature limit

warm. For details, please consult

position.

can result in transmission mal-

function or reduced transmis-

your UD trucks dealer.

sion life.

10 - 38

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VEHICLE OPERATION

z PTO switch is ON.

z DPF is being regenerated.

CAUTION

z Brake pedal is depressed during

the warning period.

z If the vehicle is left as it is after

engine was shut down auto-

z Engine load is over the threshold.

matically by this function, it

z External lever is in use.

results in low battery.

z Any of the entry conditions is not

z It is not easy to operate steer-

fulfilled.

ing because the power steer-

z Just after engine was run at high

ing is not available just after

load.

engine shutdown.

z Any failure occurs in the engine

system.

The idle shutdown function starts the

timer to stop the engine if following

1.Turn the ignition key to LOCK

all conditions are fulfilled.

(OFF) position, and a audible

alarm will stop sounding.

AND Engine has been warmed up.

2.Turn the ignition key to the START

AND The engine is running and the

position.

vehicle is standing still.

AND Accelerator pedal is released.

AND Parking brake is applied.

(This condition can be applied

according to the customer

needs.)

The idle shutdown function does not

shutdown the engine if any of follow-

ing conditions is fulfilled.

10 - 39

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VEHICLE SERVICE AND MAINTENANCE

1.When rebuilding an engine, por-

a.In accordance with the original

VEHICLE

tions of an engine, or an engine

engine manufacturer's instruc-

SERVICE AND

system, there must be a reason-

tions; or

able technical basis for knowing

MAINTENANCE

b.Where data or other reasonable

that the resultant engine is equiva-

technical basis exists that such

lent, from an emissions standpoint,

CLEAN AIR ACT

parameter adjustment or design

to a certified configuration (i.e., tol-

element change, when performed

erances, calibrations, specifica-

on the engine or similar engines, is

Heavy-duty engine rebuilding

tions) and the model year(s) of the

not expected to adversely affect in-

practices.

resulting engine configuration

use emissions.

§ 86.004-40

must be identified. A reasonable

The provisions of this section are

basis would exist if:

2.When an engine is being rebuilt

applicable to heavy-duty engines

and remains installed or is rein-

subject to model year 2004 or later

A.Parts installed, whether the parts

stalled in the same vehicle, it must

standards and are applicable to the

are new, used, or rebuilt, are such

be rebuilt to a configuration of the

process of engine rebuilding

(or

that a person familiar with the

same or later model year as the

rebuilding a portion of an engine or

design and function of motor vehi-

original engine. When an engine is

engine system). The process of

cle engines would reasonably

being replaced, the replacement

engine rebuilding generally includes

believe that the parts perform the

engine must be an engine of (or

disassembly, replacement of multiple

same function with respect to

rebuilt to) a configuration of the

parts due to wear, and reassembly,

emissions control as the original

and also may include the removal of

parts; and

same or later model year as the

the engine from the vehicle and

original engine.

other acts associated with rebuilding

B.Any parameter adjustment or

an engine. Any deviation from the

design element change is made

3.At time of rebuild, emissions-

provisions contained in this section

only:

related diagnostic trouble codes

is a prohibited act under section 203

(DTCs) or signals from on-board

(a)

(3) of the Clean Air Act

(42

diagnostic (OBD) monitoring sys-

U.S.C. 7522 (a) (3)).

tems may not be erased or reset

11 - 1

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VEHICLE SERVICE AND MAINTENANCE

without diagnosing and responding

paragraphs 1 through 4 of this sec-

tion that they cannot reasonably

appropriately to the DTCs, regard-

tion. The records shall include at

access.

less of whether the systems are

minimum the mileage and/or hours

C.Parties may keep records of their

installed to satisfy requirements in

at time of rebuild, a listing of work

rebuilding practices for an engine

§ 86.004-25 or for other reasons

performed on the engine and

family rather than on each individ-

and regardless of form or inter-

emissions-related control compo-

ual engine rebuilt in cases where

face. Diagnostic systems must be

nents including a listing of parts

those rebuild practices are fol-

free of all such DTCs when the

and components used, engine

lowed routinely.

rebuilt engine is returned to ser-

parameter adjustments, emis-

vice. Such signals may not be ren-

sions-related DTCs or signals

D.Records must be kept for a mini-

dered inoperative during the

responded to and reset, and work

mum of two years after the engine

rebuilding process.

performed under paragraph 4 of

is rebuilt.

this section.

4.When conducting a rebuild with-

out removing the engine from the

A.Parties may keep records in what-

vehicle, or during the installation of

ever format or system they choose

as long as the records are under-

a rebuilt engine, all critical emis-

standable to an EPA enforcement

sions-related components listed in

officer or can be otherwise pro-

86.004-25

(b) not otherwise

vided to an EPA enforcement offi-

addressed by paragraphs

cer in an understandable format

through 3 of this section must be

when requested.

checked and cleaned, adjusted,

repaired, or replaced as neces-

B.Parties are not required to keep

sary, following manufacturer rec-

records of information that is not

ommended practices.

reasonably available through nor-

mal business practices including

5.Records shall be kept by parties

information on activities not con-

ducted by themselves or informa-

conducting activities included in

11 - 2

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VEHICLE SERVICE AND MAINTENANCE

MAINTENANCE INTERVALS

Abbreviations:

A = Check and adjust if

I = Inspect, clean and correct or

T = Tighten to specified torque

necessary

replace as necessary

L = Lubricate

R = Replace or change

NOTE:

z It is the owner’s responsibility to see that the vehicle receives proper care and maintenance.

z The maintenance or lubrication services shown below are to be performed at the indicated intervals (miles

or months, whichever occurs first).

z 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.

z Items marked with “*” are related to the EMISSION CONTROL SYSTEM MAINTENANCE.

z 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

z 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

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VEHICLE SERVICE AND MAINTENANCE

Engine

First

Every

Miles x 1,000

Months

Reference

Items

(every)

page

Kilometers x1,000

120

BASIC MECHANICAL SYSTEM

♦ Valve clearance

♦*Cylinder compression pressure

♦*Engine mounting

FUEL SYSTEM

♦Low and High idle speed

*Fuel filters (Main and primary fuel filter)

Once for every 2 engine oil and filter replacements

11-39

Fuel hose and pipe

(Fuel filter to supply pump, Fuel tank to

R:36

11-43

fuel filter, Engine to fuel tank)

LUBRICATION

*Engine oil and oil filter:

Type 1

(With UDXtra Engine oil)

Type 2

*Engine oil and oil filter:

Type 1

11-33

(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

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VEHICLE SERVICE AND MAINTENANCE

Engine (Cont’d)

First

Every

Miles x 1,000

Months

Reference

Items

(every)

page

Kilometers x1,000

120

COOLING SYSTEM

*Cooling fan

11-27

Initial inspection at first 6,000 miles (10,000 km)

*Drive belts

11-46

Engine coolant

R: Every 320,000 miles (500,000 km)

11-28

*Radiator and heater hoses and clamps

11-24

INTAKE AND EXHAUST SYSTEM

*Air cleaner element

11-44

Intake air hose and clamps

11-75

*Charge air cooler body

11-27

♦*Charge air cooler hoses

♦ Turbocharger rotor operation

Exhaust pipe and muffler attachment

11-75

loose and damage

♦*DPF

I: Every 155,000 miles (250,000 km) or 4,500 hours

11-70

♦*CCV filter

R: Every 62,000 miles (100,000 km)

11-50

♦*DEF filter

R: Every 150,000 miles (240,000 km) or 7,000 hours

11-48

♦*DPF sensor hose

R: Every 36 months

♦*DPF regeneration system

I: Every 12 months

11-71

11 - 5

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VEHICLE SERVICE AND MAINTENANCE

Chassis

First

Every

Miles x 1,000

Items

Reference page

Kilometers x1,000

120

Months (every)

CLUTCH

Clutch fluid

11-66

Clutch pedal play

11-65

♦ Clutch disc

♦ Clutch piping

MANUAL TRANSMISSION

♦ Breather

Manual transmission gear oil

11-56

AUTOMATIC TRANSMISSION (UD1800 thru UD3300)

Automatic transmission fluid & filter

Refer to 11-12

PROPELLER SHAFT

Sliding shaft

♦ Universal joint

♦ Center bearing

♦ Condition of propeller shaft

DIFFERENTIAL GEAR

Differential gear oil

11-60

11 - 7

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VEHICLE SERVICE AND MAINTENANCE

Chassis (Cont’d)

First

Every

Miles x 1,000

Items

Reference page

Kilometers x1,000

120

Months (every)

STEERING SYSTEM

♦ Gear box

Power steering fluid and filter

11-62

Steering wheel free play

11-60

♦ Steering linkage

♦ Power steering rubber hose

R: Every 24 months

AXLE AND WHEEL

♦ Front axle (I-beam)

♦ Clearance between front axle and

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.)

11-86

NOTE:

1. If the mileage is 2,500 miles (4,000 km) or less in 6 months just before the 6 month inspection, the inspection

can be skipped.

2. Perform maintenance after the first 1,000 miles (1,600 km) of operation. This maintenance procedure also

applies whenever a tire is replaced.

11 - 8

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VEHICLE SERVICE AND MAINTENANCE

Chassis (Cont’d)

First

Every

Miles x 1,000

Items

Reference page

Kilometers x1,000

120

Months (every)

AIR-OVER-HYDRAULIC BRAKE SYSTEM (UD1800 thru UD2600)

♦ Service brake valve

Air dryer

11-64

♦ Air dryer repair kit

R: Every 12 months

♦ Air compressor and air pressure governor (air

dryer integrated model)

♦ Brake piping

♦ Brake hose

R: Every 12 months

♦ Air booster repair kit

R: Every 12 months

Brake fluid

11-62

♦ Wheel cylinder repair kit

R: Every 12 months

♦ Brake lining clearance (Refer to note 1.)

I: Every 2,500 miles (4,000 km) or 1 month

♦ Brake lining

♦ Brake drum

♦ Parking brake system (note 2.)

♦ Parking brake chamber diaphragm (note 2.)

R: Every 24 months

NOTE:

1. During periods of severe service operation or frequent stop-and-go operation, more frequent inspections

of the brake system should be performed.

2. Spring-activated rear wheel parking brake.

11 - 9

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VEHICLE SERVICE AND MAINTENANCE

Chassis (Cont’d)

First

Every

Miles x 1,000

Items

Reference page

Kilometers x1,000

120

Months (every)

AIR BRAKE SYSTEM (UD3300)

♦ Service brake valve

Air dryer

11-64

♦ Air dryer repair kit

R: Every 12 months

♦ Air compressor and air pressure governor

♦ Brake piping

♦ Brake hose

R: Every 12 months

♦ Rear and front brake chamber diaphragm

R: Every 24 months

♦ Brake chamber push rod stroke (Refer to

I: Every 2,500 miles (4,000 km) or 1 month

note 1.)

♦ Rear brake chamber spring cylinder (Refer

R: Every 36 months

to note 2.)

♦ Brake lining

♦ Brake drum

♦ Parking brake system

NOTE:

1. During periods of severe service operation or stop-and-go high volume operation, more frequent inspections of the brake

system should be performed. Always maintain correct push rod stroke and brake adjustment to ensure correct braking.

2. Non-disassembling

11 - 10

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VEHICLE SERVICE AND MAINTENANCE

Chassis (Cont’d)

First

Every

Miles x 1,000

Items

Reference page

Kilometers x1,000

120

Months (every)

SUSPENSION

Leaf spring

11-67

Shock absorber

11-68

♦ U-bolt and nut

Air bellows (Air suspension)

11-68

Leveling valve (Air suspension)

11-68

Air leakage (Air suspension)

11-68

♦ Looseness and damage (Air suspen-

11-68

sion)

Shock absorber (Air suspension)

ELECTRICAL SYSTEM

Battery electrolyte level

11-76

Battery terminal

11-77

Specific gravity of battery electrolyte

11-77

OTHERS

♦ Acoustical shielding

Grease lubrication

L: Every 5,000 miles (8,000 km) or 1 month

11-16

11 - 11

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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)

Vocation

Fluid* (#1)

Control Main**

Internal

Lube/Auxiliary

Change fluid when indi-

Change filter when indi-

Change filter when indicated

cated by controller or 48

General or severe

Overhaul

by controller or 48 months,

months, whichever

whichever 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.

#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

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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 mile-

age 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 transmis-

sion 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 indi-

cate 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

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VEHICLE SERVICE AND MAINTENANCE

UD2600 and UD3300 (Allison 3000 series)

Fluid and Filter Change Interval

High capacity** Main and

Filter Type

Suction Filter Assembly

Fluid Change Intervals

Lube Filter Change Inter-

Change Interval

vals

Whichever is first of the

following:

・If the wrench icon in the selec-

・If the wrench icon in the

tor is illuminated steady for 2

selector is flashing on and

A disassembled

TES 295 Fluids*

minutes after D (Drive) is

off for 2 minutes after D

At time of transmission

type (Incorporated

(includes

selected

(Drive) selected

overhaul

in the oil pan)

TranSynd^®)

・60 calendar months**

・Any time the fluid is

changed

NOTE: Always replace main

・60 calendar months**

and lube filters with the fluid

change**.

TRANSMISSION HEALTH MONITOR (TM)

This prognostic feature determines clutch life status of the transmission’s clutches and alerts you when clutch main-

tenance 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

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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

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VEHICLE SERVICE AND MAINTENANCE

GREASE LUBRICATION POINTS

Lubrication point

No. of points

Lubrication point

No. of points

Rear helper spring

2RL

Steering column

Rear spring pin & shackle pin

3RL

Door hinge

2RL

Propeller shaft journal & yoke

3 to 6

King pin

2RL

Tie rod end (Not applicable to UD1800

Clutch release shaft

1RL

thru UD2300)

Parking brake chamber arm shaft

Clutch release sleeve

1RL

(Not applicable to UD1800 and UD2000)

Cab mounting front torsion bar contact

Rear brake camshaft and slack adjuster

1RL

2RL

seat

(UD3300)

Front brake camshaft and slack adjuster

Front spring pin & shackle pin

3RL

2RL

(UD3300)

Cab mounting main hook & pin

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

UD Trucks. Owner’s Manual (2011-2013) - page 10