Content      ..     12      13      14      15     ..

UD Trucks. Owner’s Manual (2011-2013) - page 14

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

Specific gravity of battery electro-

Cleaning battery terminals

CAUTION

lyte

Periodically inspect the battery

z

Avoid battery acid contact with

The specific gravity of the battery

cables and connectors for corrosion

eyes, skin, wearing materials

electrolyte determines the battery

and tightness. When inspecting the

or painted surfaces. Immedi-

condition. The specific gravity

cables and connections:

ately and thoroughly flush any

decreases as the battery discharges

1.Stop the engine.

contacted area with water. If

and increases as it is charged. The

2.Remove the battery cables and

acid is swallowed or comes

electrolyte temperature also affects

clean contaminated or corroded

into contact with your eyes,

the specific gravity. The specific

terminals. Badly corroded termi-

secure medical help immedi-

gravity of a fully-charged battery is

nals can be cleaned by discon-

ately.

1.280 at

68°F

(20°C). Check the

necting the cables and rubbing

specific gravity of the battery electro-

with a wire brush or sandpaper.

lyte in each cell with a hydrometer. If

CAUTION

Flush any white powder from the

necessary, have the battery checked

terminals with lukewarm water and

z

Do not add water above the

and charged by an authorized UD

specified level. If the battery

Trucks dealer or other qualified ser-

wipe clean.

electrolyte spills, it can cause

vice facility.

damage to the vehicle equip-

ment and body.

WARNING

z

Do not add diluted sulfuric

z When disconnecting the bat-

acid to the battery. This

tery cables, remove the cable

increases the specific gravity

from the negative (-) terminal

of the battery electrolyte and

first. When reconnecting the

shortens the service life of the

cables, attach the cable to the

battery. It also affects specific

negative (-) terminal last.

gravity readings made to

determine battery charge.

11 - 77

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

3.After tightly connecting the cables,

LIGHTS

removal. During this operation, do

apply a thin coat of grease to the

Occasionally it may become neces-

not touch the bulb with bare hands.

terminals to prevent corrosion.

sary to replace a burned out bulb on

your vehicle. When replacing bulbs

with a lens, take care not to over-

tighten lens screws. Overtightening

the screws could damage the lens.

NOTE:

z Use the same number and watt-

age as originally installed.

Refer to "BULBS"on page 13-5.

Headlights

NOTE:

Your vehicle is equipped with halo-

z When the headlight is changed,

Always dispose of automotive batter-

gen headlights.

the light axis must be adjusted.

ies in a responsible manner. Follow

To replace a burned out headlight

If you inevitably replaced it,

your local authorized standard for

bulb:

bring the vehicle for inspection

disposal. Call your local authorized

immediately at the nearest

recycling center to find out more

1.Turn the ignition key and lighting

authorized UD Trucks dealer.

about recycling automotive batteries.

switch to OFF.

2.Tilt the cab.

3.Turn the bulb cover toward OPEN

and remove it.

4.Disconnect the harness connector.

5.While pressing on the set spring,

bring it to the center to take it out.

6.Insert a new bulb into the socket.

Install it in the reverse order of

11 - 78

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

Front turn signal light

3.Turn the socket counterclockwise

Rear combination light

to remove it and replace the bulb

1.Remove the fixing clips (2 loca-

with new one.

tions) from the rubber and turn

over the rubber.

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

Clearance and identification 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 -

Back-up light

Room light

tan; 10 amp - red; 15 amp - blue; 20

amp - yellow; 25 amp - natural and

30 amp - Green; for easy identifica-

tion of current capacity.

Lower portion of main dash

11 - 80

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

CAUTION

z Never connect add-on electri-

cal accessories

(or electrical

circuits) to engine control

fuses or circuits. Doing so

could cause fuses to burn out,

thereby causing a possible

loss of engine and ABS func-

tion.

Inside fusible link box

To replace a blown fuse

2.Install a new fuse with the same

1.Use the fuse puller to remove the

current rating as that specified for

blown fuse.

WARNING

the circuit.

z

When replacing a fuse, never

A new fuse that burns out immedi-

use a fuse with a higher cur-

ately could indicate other problems

rent rating than that specified

in the electrical system. If this

for the circuit. Heat produced

occurs, have the electrical circuits

by currents in excess of circuit

checked by an authorized UD Trucks

capacity can cause fire.

dealer or other qualified service facil-

ity.

11 - 81

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

BLOWER MOTOR FILTERS

Outside air intake filter

the handle into the hole of the

Air filters for a heater or an air condi-

case.

<Method for removal>

tioner are installed behind the front

1.Hold the upper and lower centers

lid at the right side of the cab front.

Inside air intake filter

of the filter with left hand and bend

the filter toward you.

1.Pull the upper and lower two filters

z The air filters for outside air intake

2.Hold the handle at the right end of

toward you.

and inside air intake may cause

the filter with right hand and pull it

2.After cleaning, insert the filter into

clogging due to dirt or dust. Clean

toward you.

the filter slot of the case until it is

them.

locked.

z The installation and removal of the

air filter is a cartridge type.

z Clean the air filter with water or air.

<Installation method>

1.Hold the handle at the left of the fil-

NOTE:

ter and insert the tab around the

z Clogging of the air filter lowers

air flow, resulting in poor perfor-

handle into the hole of the case.

mance of the heater and the air

2.Hold the upper and lower centers

conditioner.

of the filter and bend the filter

z Clean the air filter every

6

toward you.

months or when performance of

3.Hold the handle at the right end of

the heater or the air conditions

the filter and insert the tab around

is poor.

11 - 82

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

WHEELS AND TIRES

Tires

Note that the size charts on the fol-

lowing 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.)

Current

SI units

Current

SI units

Current

SI units

Current

SI units

Current

SI units

Current

SI units

Current

SI units

Tire size

designation

kPa

660

670

690

720

760

790

830

psi

90

(95)

95

(95)

100

(100)

105

(105)

110

(110)

115

(115)

120

(120)

kgf/cm²

(6.30)

(6.65)

(7.00)

(7.35)

(7.70)

(8.05)

(8.40)

1,550 kg

Dual

-

-

-

-

-

-

-

-

-

-

-

-

-

225/

(3,415 lb)

70R

19.5 (F)

1,650 kg

Single

-

-

-

-

-

-

-

-

-

-

-

-

-

(3,640 lb)

2,650 kg

Dual

-

-

-

-

-

-

-

-

-

-

-

-

-

(5,840 lb)

11R

22.5 (G)

2,800 kg

Single

-

-

-

-

-

-

-

-

-

-

-

-

-

(6,175 lb)

1,950 kg

Dual

-

-

-

-

-

-

-

-

-

-

-

-

-

245/

(4,300 lb)

70R

19.5 (G)

2,060 kg

Single

-

-

-

-

-

-

-

-

-

-

-

-

-

(4,540 lb)

2,120 kg

Dual

-

-

-

-

-

-

-

-

-

-

-

-

-

(4,675 lb)

9R

22.5 (G)

2,240 kg

Single

-

-

-

-

-

-

-

-

-

-

-

-

-

(4,940 lb)

2,300 kg

Dual

-

-

-

-

-

-

-

-

-

-

-

-

-

255/

(5,070 lb)

70R

22.5 (H)

2,500 kg

Single

-

-

-

-

-

-

-

-

-

-

-

-

-

(5,510 lb)

11 - 84

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

Checking the tire pressure and tire

valves when damaged or leaking.

3.Check the tires for uneven or

condition

Replace missing valve caps.

unusual tread wear. Consult the

1.Check the pressure of each tire

2.Check the tire sidewall and tread

table below to determine the cause

with a tire gauge daily. For accu-

for cuts, cracks and damage daily.

of uneven or unusual wear and

rate measurement, check the tires

Remove any foreign objects such

corrective action to be taken. Cor-

when they are cool. Be sure to

as metal, glass and stones

rect the cause of the wear and, if

inflate tires to proper pressure

wedged in the tread grooves and

necessary, replace the tire.

according to the load and inflation

check for tire damage.

pressure table. Check tire valves

Repair or replace as necessary.

regularly for air leaks. Replace

Condition

Cause

Cause Correction

Shoulder wear

z Underinflation

z Inflate

z Sharp turning at high speed

z Reduce speed

z Excessive loading

z Reduce loading

Center wear

z Overinflation

z Inflate

z Slippage due to abrupt braking

z Apply brakes slowly

Diagonal wear

z Incorrect toe-in

z Adjust toe-in

z Imbalanced braking force

z Inspect and adjust service brake

Heel/toe wear

z Incorrect toe-in

z Adjust toe-in or camber

z Underinflation

z Inflate

11 - 85

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

Each tire has six wear indicators.

Checking and retightening the

Check the tread grooves of each tire

WARNING

wheel nuts

daily. Replace a tire when any of the

Loose wheel stud nuts may cause

Do not operate your vehicle:

tread indicators become visible.

shimmy and vibration which can

z With tires inflated in excess of

cause damage to the wheel bear-

the recommendations of the

ings. Retorque the wheel stud nuts

tire or wheel manufacturer.

at the first 1,000 miles (1,600 km) of

z With cut, cracked or damaged

operation. Thereafter, check the nuts

tires.

for tightness every

6,000 miles

z When any of the tire tread wear

(10,000 km) or two months of opera-

indicators are visible.

tion, whichever occurs first and, if

necessary, retorque to specification.

Improperly inflated and dam-

aged tires, and tires with uneven

Using a torque wrench, alternately

or excessive wear may cause

tighten wheel nuts. Do not exceed

blowouts, loss of vehicle con-

wheel nut torque specification. Over-

trol and reduced braking effec-

tightening the wheel nuts will elon-

tiveness. Inspect tires carefully

gate the bolts, deform the wheels

WARNING

and make any necessary repairs

and prevent tightening to the speci-

z

Be

sure

to confirm

that

the

or replacements.

fied torque.

wheel has not been damaged

Tightening torque:

or deformed before putting a

<Front wheel alignment>

UD1800 and UD2000

new tire on it. Follow industry

If abnormal tire wear or ride and han-

273 - 310 ft·lbf (370 - 420 N·m)

and government safety regula-

dling characteristics such as vehicle

(38 - 43 kgf·m)

tions when assembling and

lead or wander are experienced with

UD2300, UD2600 and UD3300

inflating new tires. Failure to

properly inflated tires, the front wheel

398 - 435 ft·lbf (540 - 590 N·m)

do so could result in serious

alignment should be checked.

(55 - 60 kgf·m)

injury or death.

11 - 86

-------------------------------------------------------------------------------------------------------------------------------------------------------------

VEHICLE SERVICE AND MAINTENANCE

z After rotating the position of the

When tire tread pattern is identical

NOTE:

tires, drive the vehicle a dis-

all the way around:

z The wheel nuts on the right side

tance of 30 to 60 miles (50 to 100

of the vehicle have right-handed

km) to settle the wheel disc with

threading; the left side wheel

hub, and then retighten the

nuts have left-handed threading.

wheel nuts to the specified

torque.

Re-tightening procedures for

rear

z The wheel must not be over-

dual nuts

loaded. Pay attention to the total

vehicle load, the weight distribu-

tion related to individual axle

loading and the matching of tire

pressures in the case of dual

wheels.

When tire tread pattern

differs

Tire wear differs depending on

between front and rear:

where the tire is mounted. Rotate the

tire position to allow more even wear

and extend tire life.

1.Loosen the outer wheel nuts.

Tire rotation is recommended every

2.Tighten the inner wheel nuts.

6,000 miles (10,000 km). Shown are

two types of rotation patterns. Use

3.Tighten the outer wheel nuts.

the one best suited to your needs.

After rotation, adjust individual tire

Tire position rotation

pressure as specified in the "Load

specification"on page 11-84. Tighten

NOTE:

wheel stud nuts to the required

z For removal and mounting

of

torque specification and after 1,000

tires, refer to "TIRE CHANGE"on

miles (1,600 km), retorque again to

page 12-6.

specification.

11 - 87

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IN CASE OF EMERGENCY/TROUBLE-SHOOTING

severe) will appear and at

the

the neutral position or P

(Park)

same time, a buzzer sounds.

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 man-

ual tilt the cab to provide ventila-

tion.

4.Stop the engine when the engine

coolant temperature drops to the

z

If the engine coolant tempera-

normal range on the gauge.

ture

(ECT)

significantly

5.After the engine and cooling sys-

increases, an overheat warning

tem have cooled, open the radiator

with a

2-phase indication

CAUTION

cap.

(amber: moderate, red: severe)

z

Do not drive while the engine

If the engine coolant level is below

will appear.

overheat warning is displayed.

the bottom of the filler neck, add

The engine protection func-

coolant and take necessary cares

Warning message or light

tion may provide torque derat-

by following instructions steps 2-4

If the temperature gauge indicator is

ing to prevent the engine from

in the section, "Engine coolant

in the high temperature zone, keep

being damaged, so have it

level warning light" on page 7-45.

the engine idling and do not stop the

inspected and serviced by the

engine until the indicator falls into

nearest authorized UD Trucks

the suitable range.

dealer.

z When the engine overheats, an

overheat warning with a 2-phase

1.Immediately stop the vehicle in a

indication (amber: moderate, red:

safe place. Apply the parking

brake and shift the transmission to

12 - 2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IN CASE OF EMERGENCY/TROUBLE-SHOOTING

JUMP STARTING

z

Be extremely careful when

opening the radiator filler cap.

Place a thick cloth on the cap

Emergency Starting

and slowly loosen it to allow a

reduction in pressure

in

the

cooling system.

DANGER

Batteries produce explosive

gases. To minimize risk of seri-

ous injury or death:

z

Keep sparks and open flame

away from the batteries. Never

smoke when working on or

WARNING

around the batteries.

z

Make sure that adequate venti-

To avoid serious injury from hot

lation is provided when work-

coolant or steam release:

ing on or around the battery in

z Do not open the radiator filler

an enclosed area.

cap while the engine cooling

z

Do not permit metal tools to

system is still hot; wait until it

simultaneously contact the

cools.

positive battery terminal and

If the radiator cap is removed

any other metal on either vehi-

right after the engine is shut

cle at the same time.

off, scalding fluid and steam

z

Always wear eye protection

may blow out under pressure

when working near batteries.

and cause serious burn inju-

ries.

12 - 3

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IN CASE OF EMERGENCY/TROUBLE-SHOOTING

<To jump start a vehicle>

5.Start the engine of the vehicle with

6.After your engine is started,

the good battery. After increasing

remove the jumper cables in the

1.Position the vehicles so that the

to a moderate engine speed, start

reverse order of connection.

jumper cables can be attached. Do

the vehicle

with

the

discharged

7.Charge the discharged battery at

not allow the vehicles to come into

battery.

an authorized UD Trucks dealer or

contact with one another.

other qualified service facility.

2.Turn off the ignitions of both vehi-

cles and apply the parking brakes.

3.Connect one end of one jumper

cable to the red positive (+) termi-

nal of the discharged battery and

the other end to the red positive

terminal of the good battery.

4.Connect one end of the second

jumper cable to the grounded

black negative (-) terminal of the

good battery. Connect the other

end of the second cable to the

frame of the vehicle with the dis-

charged battery at a location as

distant from the battery as possi-

ble. Confirm that the cables are

routed such that they will not come

into contact with fans, belts, or

other moving parts when the

engines are started.

12 - 5

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Content      ..     12      13      14      15     ..