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UD Trucks. Owner’s Manual (2011-2013) - page 13

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VEHICLE SERVICE AND MAINTENANCE

2.After draining, replace the gasket

Oil refill capacity (Approximately)

Automatic transmission fluid

of the drain plug with a new one.

filter (Allison 1000, 2200 and 2500

Oil capacities

PTO

Reinsert the plug and tighten the

US qt (liters)

series)

plug.

Without

7.2

(6.8)

MLS63

Tightening torque:

With

7.8

(7.3)

WARNING

UD1800 thru UD3300

Without

8.3

(7.8)

MPS63

MLS63

With

8.8

(8.3)

z Do not handle hot filter without

72 to 89 ft·lbf (98 to 120 N·m)

hand protection. Failure to do

(10 to 12 kgf·m)

4.Visually check the oil level and add

so may result in burn injury.

UD2600 and UD3300

oil, if necessary, until it reaches the

MLS63

bottom of the filler plug hole.

To replace the filter

72 to 94 ft·lbf (98 to 130 N·m)

1.Drain the fluid when the transmis-

(10 to 13 kgf·m)

Automatic transmission fluid

sion is at normal operating sump

MPS63

change

temperature 160 to 200°F (71 to

87 to 101 ft·lbf (118 to 137 N·m)

93°C). Hot fluid flows quicker and

(12 to 14 kgf·m)

Have the automatic transmission

drains more completely.

fluid changed by an authorized UD

NOTE:

Trucks dealer or other qualified ser-

vice facility. Use only the transmis-

z The drain plug contains a mag-

sion

fluid

listed

in

the

net. Remove any iron filings on

"RECOMMENDED

LUBRI-

the plug before reinstalling the

CANTS"on page 13-5.

plug.

3.Fill the transmission with fresh oil

through the filler plug hole located

on the side of the transmission.

11 - 57

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VEHICLE SERVICE AND MAINTENANCE

2.Remove the drain plug from the oil

Allison 3000 series

CAUTION

pan and allow the fluid to drain into

A disassembled type of filter is used

a suitable container.

z Turning the filter more than

and incorporated in the oil pan.

3.Using a filter wrench, remove the

ONE FULL TURN after gasket

contact will damage the filter.

control-main filter by rotating it

counterclockwise.

4.Remove the magnet from the filter

10.Reinstall the drain plug and seal-

attachment tube or from the top of

ing washer.

the filter element.

Tightening torque:

22 to 30 ft·lbf (30 to 40 N·m) (3.1

5.Clean any metal debris from the

to 4.1 kgf·m)

magnet. Report any metal pieces

11.After refill, check the fluid level

larger than dust to your mainte-

and add the proper fluid, if neces-

nance personnel.

sary.

6.Reinstall the magnet onto the filter

For the fluid check procedure,

1.Clean the periphery of the filter

attachment tube.

refer to "To check the automatic

cover to prevent dust from entering

7.Lubricate the O-ring on the control-

transmission fluid level

(Allison

at the time of removal of the filter.

main filter with transmission fluid.

1000, 2200 and 2500 series)"on

2.Remove the mounting bolts of the

8.Install, by hand, the control-main

page 11-52.

filter cover and pull out the cover

filter until the O-ring on the control-

12.Start the engine. Check the filter

and filter downward.

main filter touches the converter

and seal for leaks.

3.Replace the filter, O-ring and seal

housing.

with new ones and install to the

9.Turn the filter ONE FULL TURN

cover. When installing, apply a

ONLY by hand, after O-ring con-

light coating of clean oil to the

tact.

entire perimeter of O-ring and seal.

4. Install the cover and filter com-

bined in one unit into the transmis-

sion body.

11 - 58

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VEHICLE SERVICE AND MAINTENANCE

Tightening torque:

DIFFERENTIAL GEAR OIL

CAUTION

37.6 to 45.0 ft·lbf (51 to 61 N·m)

(5.2 to 6.2 kgf·m)

Gear oil

z Before removing the differen-

5.After replacement, be sure to refill

tial filler plug, clean the plug

Inspect the vehicle daily for differen-

and surrounding area to pre-

fluid. After refilling, check the fluid

tial oil leakage. If there is any evi-

vent dirt and debris from enter-

level.

dence of leakage, locate and correct

ing filler hole.

the cause. Check oil level and, if low,

add oil.

WARNING

z Check and/or change the dif-

ferential gear oil only after the

rear axle cools to avoid possi-

ble burn injuries.

To check the differential gear oil

level

1.Remove the filler plug and visually

check the oil level. The level

2.Add oil, if necessary.

should reach the bottom of the

3.Replace the gasket of the filler

filler plug hole.

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

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VEHICLE SERVICE AND MAINTENANCE

Oil change

Tightening torque:

STEERING SYSTEM

95 to 108 ft·lbf (128 to 147 N·m)

(13 to 15 kgf·m)

Wheel free play

WARNING

NOTE:

To check for free-play, start and idle

z Check and/or change the dif-

z The drain plug contains a mag-

the engine. Set the front wheels to

ferential gear oil only after the

net. Remove any iron filings on

the straight-ahead position and

rear axle cools to avoid possi-

the plug before reinserting the

lightly rotate the steering wheel to

ble burn injuries.

plug.

the right and left until the front

wheels move. Steering wheel play

3.Fill the differential with fresh oil.

1.Place a container under the differ-

on the circumference of the steering

Check the oil level. Add oil until the

ential drain plug. Remove the drain

wheel should be 0.39 to 1.57 inches

level reaches the bottom of the

plug and drain the oil completely.

(10 to 40 mm) for UD1800, UD2000

filler plug hole.

and UD2300 or 1.18 to 1.97 inches

(30 to

50 mm) for UD2600 and

Oil refill capacity (Approximately)

UD3300. If the play exceeds 1.57

inches

(40 mm) for UD1800,

US measure

Liters

UD2000 and UD2300 or 1.97 inches

UD1800,

(50 mm) for UD2600 and UD3300,

UD2000 and

6.9 qt

6.5

have it corrected by an authorized

UD2300LP

UD Trucks dealer or other qualified

service facility.

UD2300HD

9.5 qt

9

UD2600 and

13.8 qt

13

UD3300

2.After draining, replace the gasket

of the drain plug with a new one.

Install the plug and tighten the

plug.

11 - 60

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VEHICLE SERVICE AND MAINTENANCE

Steering fluid level

CAUTION

If the steering fluid is low or contami-

nated, the power steering may not

z Do not allow dirt or debris to

operate normally which could

enter the fluid reservoir when

adversely affect steering control. If

open. Always clean the fluid

the fluid level is low, check the steer-

reservoir and cap before

ing system for leaks and correct the

removing the cap.

condition before operating the vehi-

z Check for proper fluid level

cle. If the fluid is contaminated, have

before engine start.

it replaced by an authorized UD

Trucks dealer or qualified service

To inspect the steering fluid level

facility.

1.Visually inspect the steering sys-

WARNING

tem for fluid leaks.

z

Do not operate your vehicle

2.The fluid level should be between

with excessive steering wheel

WARNING

the HIGH and LOW lines. If the

free-play. If free-play exists,

fluid level is below the LOW line,

z To avoid possible burn injury,

have the vehicle thoroughly

allow the steering system to

add steering fluid to the HIGH line.

inspected by an authorized UD

cool before checking or chang-

Trucks dealer or qualified ser-

ing the steering fluid.

vice facility.

z Do not operate the vehicle

when the steering fluid is low

or contaminated.

11 - 61

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VEHICLE SERVICE AND MAINTENANCE

Steering fluid and filter change

SERVICE BRAKE SYSTEM

WARNING

Have the steering fluid and filter

Brake fluid level check

changed by an authorized UD

z

Brake fluid loss may indicate a

Trucks dealer or other qualified

Maintain the fluid level in the reser-

leak in the brake system. Have

steering system repair facility.

Use

voir between the HIGH and LOW

the brake system checked

immediately by an authorized

only DEXRON^®II or higher fluid.

marks on the brake fluid reservoir. If

UD Trucks dealer or other

the fluid level is below the LOW mark

qualified brake repair facility.

then add brake fluid.

z

To avoid fire hazard, do not

allow brake fluid to contact the

hot parts of the exhaust sys-

tem.

z

To avoid possible burn injury,

allow the engine and brake

system to cool before check-

ing or changing brake fluid.

z

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 med-

ical attention immediately.

11 - 62

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VEHICLE SERVICE AND MAINTENANCE

Brake fluid change

Draining air reservoir

CAUTION

Have the brake fluid changed by an

To drain accumulated water from

z

Remove any dirt accumulation

authorized UD Trucks dealer or

the air reservoir

from the brake fluid reservoir

other qualified brake system repair

1.Open the drain cocks.

cap and surrounding area

facility. Use only DOT 3 fluid from a

before removing the reservoir

sealed container.

cap. Do not allow dirt, debris,

water or other foreign materi-

NOTE:

als to enter the reservoir while

z After the brake fluid has been

it is open.

changed, operate the service

z

Use only approved DOT 3 fluid

brakes several times to assure

from a sealed container.

proper operation.

z

Do not add brake fluid above

the HIGH mark.

z

Do not allow brake fluid to con-

CAUTION

tact the painted surfaces of

your vehicle. Brake fluid con-

z

Do not expose the brake fluid

tact may result in paint dam-

2.Allow the water to drain.

to moisture when checking,

age.

3.After draining, release

the

drain

adding or changing the brake

z

Remove the reservoir strainer

cock rings and close

the

drain

fluid. Brake fluid absorbs

and clean any foreign matter

cocks.

from it. If the reservoir con-

moisture. When it does, its

tains sediment, have the reser-

boiling point drops which can

voir inspected and cleaned by

cause vapor lock and corro-

WARNING

an authorized UD Trucks

sion of brake system compo-

dealer or other qualified brake

nents.

z Do not drive vehicle unless

repair facility.

z

Do not add brake fluid which

accumulated water has been

has been exposed to moisture

drained. If not, water could get

to the system. Use fresh DOT 3

into

brake system and

fluid from a sealed container

adversely effect brake func-

only.

tion.

11 - 63

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VEHICLE SERVICE AND MAINTENANCE

Air dryer

have the air dryer repaired by an

CAUTION

authorized UD Trucks dealer or

z

As vehicles are equipped with

other qualified brake system repair

an air dryer, water will nor-

facility.

mally not drain from the air

If the drained liquid contains a large

reservoir when the drain cock

amount of oil, additionally have the

is opened. However, a small

air compressor checked.

amount of water may drain out

under humid conditions. If a

large amount of water is

WARNING

drained, the air dryer may not

To avoid brake failure:

be functioning properly. Check

z

Visually check to be sure that

the air dryer.

water or air is discharged from

bottom drain port.

Visually check to be sure that water

z

Replace desiccant, filters and

drains from the drain port of the air

gasket annually.

dryer. Water will drain when the air

z

Do not allow drain port to clog

pressure governor stops pressuriza-

with foreign material.

tion. The governor stops pressuriza-

tion when the air pressure in the

reservoir reaches the upper level of

the normal operating pressure

range. When the sound of air sup-

plied 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

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VEHICLE SERVICE AND MAINTENANCE

CLUTCH

Adjusting clutch pedal free play

To adjust the outer lever assembly

After adjusting the clutch master cyl-

To adjust the clutch master cylinder

Clutch pedal free play

inder, adjust the clutch booster outer

First adjust the master cylinder

lever assembly located at the left

To check clutch pedal free play,

located on the clutch pedal.

side of the transmission.

depress the clutch pedal by hand

1.Loosen the lock nut on the push

1.Remove the return spring.

until resistance is felt. The play, the

rod.

2.Loosen the push rod lock nut.

distance from the point where the

2.Turn the push rod until it touches

3.Adjust the play of the outer lever to

clutch pedal normally rests and

the piston and there is no play.

0.177 to 0.217 inches (approx. 4.5

where resistance is felt should be

Under this condition, return the

to 5.5 mm) by turning the push rod.

1.18 to 1.97 inches (30 to 50 mm). If

push rod 4/5 turn and make sure

the play is less than 1.18 inches (30

the free play is approximately 0.04

mm) or more than 1.97 inches (50

inches (1 mm).

mm), then adjust the clutch pedal

3.Tighten the lock nut while holding

free play.

the push rod stationary with a

wrench.

MLS63

11 - 65

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VEHICLE SERVICE AND MAINTENANCE

Checking clutch fluid

MPS63

MLS63

4.Tighten the lock nut.

NOTE:

5.Reinstall the return spring.

z DOT 3 brake fluid is used as

clutch fluid. Be sure to handle it

6.Check clutch disc wear with the

carefully. (Refer to "Brake fluid

wear indicator installed near the

level check"on page 11-62.)

left side clutch booster. Clutch disc

wear is within acceptable limits

The clutch fluid level should be

when the pointer at the wear indi-

between the HIGH and LOW marks

cator is between MIN and SET. If

on the fluid reservoir located behind

the pointer goes past MIN, have

the front lid. If the fluid level is low,

the clutch disc replaced by an

add DOT 3 brake fluid until the level

MPS63

authorized UD Trucks dealer or

is between the HIGH and LOW

qualified service facility.

marks. Also check the clutch fluid for

contamination. If the fluid appears

contaminated, have the clutch fluid

changed.

11 - 66

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VEHICLE SERVICE AND MAINTENANCE

Air spring

WINDSHIELD WASHER FLUID

2.If it is low, add more washer fluid

via reservoir cap opening

Check the air bellows for damage,

air leakage, looseness and leveling

valve for proper functioning.

WARNING

Periodically have the U-bolt nut

retightened by an authorized UD

z Do not use cooling system

Trucks dealer or qualified service

solution in the windshield

facility.

washer

reservoir.

When

sprayed on the windshield,

Tightening torque:

cooling system solution can

U- bolt nut

significantly diminish visibility.

406 - 455 ft·lbf

(550 - 617 N·m) (56 - 63 kgf·m)

Open the front lid, and check the

NOTE:

fluid level in the windshield washer

z Do not overfill the windshield

Shock absorber

reservoir daily. If low, add an appro-

washer reservoir.

Check the shock absorber for proper

priate washer fluid solution. Also,

installation, damage or leakage. If

check that fluid is properly sprayed

leakage is present, have the shock

onto the windshield.

absorber checked or replaced by an

In cold weather, use a windshield

authorized UD Trucks dealer or qual-

washer anti-freeze with water at the

ified service facility.

proper mixture ratio. Follow the anti-

freeze manufacturer’s instructions

for the mixture ratio.

Replenishing washer fluid

The windshield washer reservoir

located behind the front lid.

1.Open the front lid, and check the

washer reservoir fluid level.

11 - 68

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VEHICLE SERVICE AND MAINTENANCE

OUTSIDE MIRRORS

Adjusting outside mirrors

To check the mirror heater

1.Set the stay by aligning it with the

(Optional)

matching mark.

2.Adjusting the outside mirror posi-

tion.

z 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.

On a vehicle equipped with a mirror

heater, check the following points.

z Check the heater harness for slack

and twist.

CAUTION

z Do not yank the heater har-

ness by hand or hang on the

Check the outside mirrors daily for

z For vehicles equipped with power

heater harness. The heater

damage, position and visibility. Also

mirror, refer to the "Power mirror

harness may be broken.

check that the mirror mounting bolts

switch (Optional)"on page 7-68.

are properly tightened.

11 - 69

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VEHICLE SERVICE AND MAINTENANCE

CAUTION

z The muffler that is equipped

with the DPF for the PM reduc-

tion device needs to be

cleaned regularly (either every

155,000 miles [250,000 km] or

4,500 hours) even if the DPF

ash level gauge does not reach

“H”.

If not, poor fuel economy and

engine output decrease may

DPF ash level gauge

DPF maintenance warning

occur.

z

The DPF ash level gauge indicates

the accumulation level of the ash

NOTE:

in the filter.

z

Ash is mainly generated from

z

For details on how to display the

the elements included in engine

meter, refer to the

“Multi-display

oil additives. Always use the

monitor” section in “INSTRUMENT

specified engine oil to minimize

AND CONTROLS”.

ash generation.

z

When the level reaches “H”, it indi-

z

The soot collected in the DPF

cates that the filter should be

that is built in the muffler for the

cleaned. The system simultane-

PM reduction device is burned

ously indicates the DPF mainte-

to be regenerated. However, ash

nance warning, warning message

is unburnable during regenera-

and comment to alert the driver of

tion and accumulates in the fil-

cleaning the DPF.

ter. Thus, the filter must be

cleaned regularly.

To keep the DPF efficiency, it

recommend that the manual

11 - 71

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VEHICLE SERVICE AND MAINTENANCE

NOISE CONTROL SYSTEM

Tampering with Noise Control

device or element of design has

System Prohibited

been removed or rendered inopera-

Federal law prohibits the following

tive by any person.

To assure noise control system

acts or the causing thereof:

Among those acts presumed to con-

integrity, the maintenance services

stitute tampering are the acts listed

shown in the following chart must be

(1) The removal or rendering inoper-

below.

performed at the intervals indicated.

ative by any person other than for

When inspecting the exhaust system

purposes of maintenance, repair, or

confirm that all components are

replacement, of any device or ele-

WARNING

intact and securely fitted. Also check

ment of design incorporated into any

all exhaust system components for

z To avoid serious injury from

new vehicle for the purpose of noise

holes, leaks and corrosion. Do not

hot engine and exhaust sys-

control prior to its sale or delivery to

perform any prohibited act to the

tem, perform maintenance

the ultimate purchaser or while it is in

noise control system as described in

after engine has cooled.

use, or

the following chart.

(2) the use of the vehicle after such

Control System

Prohibited Acts

Removal or rendering inoperative air cleaner,

Air Intake System

intake resonator or intake duct, and piping.

Removal of cab shields or acoustical insulation.

Acoustical Shielding

Removal of engine enclosures.

Removal or rendering inoperative fan clutch.

Cooling System

Removal of fan shrouds or radiator side shields.

Removal or rendering engine speed governor

Engine and Drive Line System

inoperative so as to allow engine speed to exceed

manufacturer specifications.

Removal or rendering inoperative exhaust system

Exhaust System

components including muffler, pipe shield or pip-

ing.

11 - 73

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VEHICLE SERVICE AND MAINTENANCE

Noise Control System Maintenance

may be equipped with the following

maintenance at the intervals shown

Schedule

items.

in the following maintenance chart.

In order to comply with federal noise

To avoid or minimize the degradation

regulation, the UD Trucks vehicle

of noise emission level, it is essential

to perform proper inspection and

Abbreviations:

A = Check and adjust if

T = Tighten to specified torque

R = Replace or change

necessary

First

Every

Miles x 1,000

3

6

9

10

12

15

18

20

24

30

36

50

72

Months

Items

Kilometersx1,000

5

10

15

16

20

25

30

32

40

48

60

80

120

(every)

High idling speed

A

12

Cooling fan

A

12

Air intake system hose and clamps

A

4

Air cleaner element

R

12

Exhaust manifolds mounting nuts

T

12

Muffler with catalyst and exhaust pipe clamps

A

6

Splash shields, under hood insulator

A

12

Maintenance of noise emission

Splash shield, under hood

Cooling fan

control system

insulation

z Check the cooling fan for damage,

Check shields and under hood insu-

and replace it when damaged.

lation for damage or looseness.

z Check the cooling fan mounting

Repair, replace or clean if necessary.

bolts for looseness, and tighten

them if necessary.

11 - 74

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VEHICLE SERVICE AND MAINTENANCE

Intake system

changed from standard position as

BATTERY

z Check the intake system compo-

originally received.

nents such as ducts, hoses, reso-

To avoid abnormal changes in vehi-

Your UD Trucks vehicle is equipped

cle sound level, maintenance is nec-

nator air cleaner, intake manifold,

with a maintenance-free battery at

essary at the intervals shown in the

clamps and fasteners for damage.

the factory.

maintenance schedules, and record

Replace if necessary. Check to be

Below are the specifications for the

on the inspection verification form

sure that hose clamps and fasten-

two 12 volt batteries installed at the

provided. Please consult an autho-

factory. Their reserved capacity (RC)

ers are tight.

rized UD Trucks dealer.

and cold cranking amperes (CCA)

z Check to be sure that the air

are rated at 159 minutes and 622

cleaner dust cover is installed

amperes.

securely.

z Check the rubber gasket in the

dust cover for deterioration.

Replace if necessary.

Exhaust system

Check the complete exhaust system.

Check for damage, missing or mis-

positioned parts, loose connections,

open seams, holes, loose fasteners,

or deformed or plugged outlets.

Replace or tighten if necessary.

Inspect for leaks at various joint con-

nections and tighten clamp. Make

visual inspection for crack or holes in

DPF cleaner and tail pipe. Always

replace with UD Trucks recom-

mended parts. Tail pipe elbow or off-

set tail pipe orientation must not be

11 - 75

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VEHICLE SERVICE AND MAINTENANCE

Battery electrolyte level

W

6.81 in (173 mm)

L

12.05 in (306 mm)

H

8.03 in (204 mm)

DANGER

Positive (+) terminal:

Batteries produce explosive

0.756 - 0.768 in

gases. To minimize risk of seri-

(19.2 - 19.5 mm)

Taper

d

ous injury or death:

1/9

Negative (-) terminal:

z

Keep sparks and open flame

0.693 - 0.705 in

away from the batteries. Never

(17.6 - 17.9 mm)

smoke when working on or

h

0.67 - 0.79 in (17 - 20 mm)

around the batteries.

To add distilled water

z

Make sure that adequate venti-

1.Remove the cell plugs using a suit-

lation is provided when work-

able tool.

ing on or around the battery in

2.Add distilled water up to the upper

an enclosed area.

level.

z

Do not permit metal tools to

3.Tighten cell plugs.

simultaneously contact the

positive battery terminal and

any other metal on either vehi-

cle at the same time.

z

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.

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