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UD Trucks Croner Series Manual

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FOREWORD
Congratulations on your wise decision to be the proud owner of Croner, enabling you to drive extra mile. This vehicle
is delivered to you with confidence. It was produced using the latest technology under strict quality control.
Please read through the Owner's manual before driving the vehicle for first time. This will make sure that you are familiar with
the controls and maintenance procedures, and will assist you in operating the vehicle safely, providing room for efficient
driving. However the safety devices installed in the vehicle and the information provided is not a substitute for careful driving.
The driver or user is totally responsible for their own safety, and the safety of the vehicle and other road users, failing which
UD Trucks cannot be held responsible for the failure of the driver to take proper care.
The use of Genuine UD Parts and lubricants are recommended to carry out all scheduled maintenance and repairs. Only
authorised UD Trucks dealers to be used to carry out scheduled maintenance and repairs to reduce maintenance cost and
prolong the life of the vehicle. This will ensure maximum uptime, safety and reliability during vehicle lifetime it is imperative that
recommendations from UD Trucks are adhered to. UD Trucks recommends you to heed our advice about driving and care of
your vehicle. For all your queries on service, maintenance, genuine parts, oils, fluids and procedures, contact your nearest
authorised UD Trucks dealer.
All information, illustrations, operations, maintenance and data provided in this manual are based on the latest model
available during the preparation and printing of this manual. As a part of continuous product optimisation, UD Trucks reserves
the right to change, modify, remove or add features in the vehicles and manuals. Country specific are possible. The truck may
not be equipped with all the functions described. This also applies to safety-related systems and functions. Some of the
equipment described in this manual is optional and may not be included in your vehicle. Therefore the equipment in your truck
may differ from that shown in the descriptions and illustrations. Therefore, you may find some information which does not apply
to your truck model.Please check with the document provided during vehicle hand over for your vehicle details.
Follow the instructions in this manual about the proper operation of your vehicle to avoid truck damage. Damage to your truck
that arises from contraventions against these instructions are not covered by UD Truck warranty. When purchasing this truck
separate warranty manual is provided along with this manual which explains the warranty details of your vehicle. The Owner's
manual and Warranty manual are an integral part of the vehicle. This forms a basic record of your vehicle and should be
maintained and retained in a proper manner with the vehicle at all times.

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Summary of Contents for UD Trucks Croner Series

  • Page 1 This will ensure maximum uptime, safety and reliability during vehicle lifetime it is imperative that recommendations from UD Trucks are adhered to. UD Trucks recommends you to heed our advice about driving and care of your vehicle.
  • Page 2 In the event of the vehicle being sold, please make sure that this manual is kept in the vehicle for the new owner’s reference. Your truck is equipped with software systems which record - temporarily or permanently - various information about the operating state, events and faults of the truck, and can be used to assist in recognising and rectifying faults and defects, analyse or optimize vehicle functions.
  • Page 3 Follow the instructions and advice in this manual, if you have any questions, please consult your nearest authorised UD Trucks dealer. The specifications and illustrations in this manual are not binding and UD Trucks reserve the right to change them at any point in time without prior notification.
  • Page 4 The user is totally responsible for their own safety, the safety of the vehicle and other road users. UD Trucks cannot be held responsible in any manner. This manual covers the feature for both LHD and RHD models. To enhance the understanding of the user, both LHD and RHD illustrations are shown under a single topic.

  • Page 5: Table Of Contents

    TABLE OF CONTENT 2.4 Seat belts ............2-16 2.5 Steering wheel adjust ........2-18 1. INTRODUCTION AND SAFETY ......1-1  1.1 Introduction ............1-1 1.2 Vehicle identification ......... 1-6 3. EQUIPMENT DESCRIPTION AND OPERATION 3-1 1.3 Before driving ..........1-11 3.1 Instruments ...........
  • Page 6  8.16 Washing the vehicle ........8-80 8.17 Handling the exhaust (applicable to  Euro IV, V or equivalent standard) ..8-82 6. DAILY INSPECTION .......... 6-1 8.18 Fifth wheel ............8-86 6.1 Areas to inspect ..........6-1 8.19 Storing the vehicle ........

  • Page 7: Introduction And Safety

    1. INTRODUCTION AND SAFETY 1. INTRODUCTION AND SAFETY 1.1 Introduction This manual provides detailed explanations on working with Croner series vehicles as below: Type Engine Transmission SYNC. MAN. TRANS. 1000 NM, 6 SPEED GH5E (Euro-3 and Euro-4) 6 SPEED ALLISON 2500 SERIES SYNC.
  • Page 8 1. INTRODUCTION AND SAFETY Abbreviations Anti-lock Braking System Malfunction Indicator Lamp Air Conditioning Not Applicable NOx is a generic term for mono-nitrogen oxides NO and After treatment Control Module Nitric oxide and Nitrogen Dioxide Cruise Control On Board Diagnostics Daytime Running Light Program Control Board Electronic Control Unit Powertrain Operating Condition...
  • Page 9 1. INTRODUCTION AND SAFETY For safe operation Weights and measures International standards. These standards minimum The operations and points which This manual uses SI units with their requirements for commercial fuels and require caution when handling the respective metric system equivalents in are often prepared in consultation with vehicle for trouble-free operation are braces.
  • Page 10 C h e c k t h e f i r e e x t i n g u i s h e r these additives have been used. periodically and make sure that It is not UD Trucks policy to use, test or the pressure gauge needle is in evaluate these additives.
  • Page 11 1. INTRODUCTION AND SAFETY Parking brake warning - if equipped Number tag The Horn is activated if the door is opened when parking brake disengaged. Keys A number tag is supplied with the truck keys. Remove the number tag from the bunch of keys so that no unauthorised persons can see the number.

  • Page 12: Vehicle Identification

    1. INTRODUCTION AND SAFETY 1.2 Vehicle identification Vehicle identification plate VIN Location VIN Plate SEA and EMEA Vehicle identification plate is located The VIN number is punched on the 1: Type approval no. for SEA market and above the foot step. For LHD it is on the front of the chassis frame, on right hand chassis no.
  • Page 13 1. INTRODUCTION AND SAFETY VIN Plate - GCC VIN and Data Plate - SAF VIN Plate ISO 1: Name and Country of the manufacturer 1: VIN number 2: Year and month of production 2: Allowable GVW 3: GVW (kg) 3: Allowable front axle weight 4: GAW (kg) ...
  • Page 14 1. INTRODUCTION AND SAFETY Gearbox identification plate -  Engine identification - GH5E Engine identification - GH8E 6 Speed 1. Engine designation and serial number 2. Engine and Chassis serial no. 3. Engine version, power and torque limitation 4. Assembly factory 1.
  • Page 15 1. INTRODUCTION AND SAFETY Gearbox identification plate -  Gearbox identification plate - Battery identification plate 9 Speed APS2500 110 Ah Gearbox identification plate - APS3000...
  • Page 16 1. INTRODUCTION AND SAFETY Rear axle identification plate RSS1132B / RSS1132D  RSS0716 Leaf suspension RSS0918 / RSS0918B Leaf suspension Leaf suspension RSS0716 Air suspension RSS0918 / RSS0918B Air suspension RSS1132B / RSS1132D  Air suspension 1-10...

  • Page 17: Before Driving

    1. INTRODUCTION AND SAFETY 1.3 Before driving When opening the door Keeping the windscreen area clean Wearing and adjusting the seat belt Before opening the doors, watch the WARNING WARNING traffic and ensure that it is safe and the door is free from obstructions. Do not hang accessories or Do not wear the seat belt inside decorations from the windscreen...
  • Page 18 1. INTRODUCTION AND SAFETY Keeping the cabin floor clean Do not carry dangerous goods WARNING Do not carry containers with explosives, flammable goods and other hazardous materials in the vehicle cab. This could cause serious fire hazards. WARNING Do not place loose objects such as tools, cans and bottles etc.

  • Page 19: While Driving

    1. INTRODUCTION AND SAFETY 1.4 While driving Before starting the engine Starting precautions Before starting the engine, shift the NOTE gearshift lever to neutral and make sure that the parking brake is applied. Before driving the vehicle, make sure that the area around the Avoid breathing exhaust fumes vehicle is free of obstacles.

  • Page 20: Vehicle Speed Limit

    Do not ignore the warning lights 2. 90 km/h which light up while driving. Contact the nearest authorised 3. 100 km/h UD Trucks dealer and rectify any 4. 110 km/h malfunction immediately. 3. Without speed limiter Always drive the vehicle in compliance with the road speed limit regulation of the local authorities.
  • Page 21 1. INTRODUCTION AND SAFETY Foot brake long-term use Auxiliary brake Parking brake lever operation Avoid using the foot brake continuously CAUTION DANGER for an extended period of time. This will affect the braking performance and B e c a r e f u l w h e n u s i n g t h e Never exit your vehicle unless the could damage the brake system.
  • Page 22 1. INTRODUCTION AND SAFETY Do not switch OFF the ignition while Air conditioner operation driving Leaving the air conditioner set to “recirculation mode” for a long period DANGER of time will cause the windows to fog up and will impair visibility. Switch to “fresh Do not switch OFF the ignition air mode”...

  • Page 23: Parking

    1. INTRODUCTION AND SAFETY 1.6 Parking When parking Park the vehicle under shade with proper ventilation. CAUTION Do not park the vehicle under the tree or near dried leaves and debris. If the vehicle is parked u n d e r t h e t r e e , t h e b i r d droppings on the vehicle body can damage the paint and the dried leaves can catch fire if...

  • Page 24: When There Is A Problem

    . Contact the nearest authorised CAUTION UD Trucks dealer for assistance. If the vehicle needs to be towed, the propeller shaft should be Refer to “Jump start”...

  • Page 25: Tilting The Cab

    1. INTRODUCTION AND SAFETY 1.8 Tilting the cab Safety WARNING Ti l t t h e c a b c o m p l e t e l y a n d secure it with the lock pin. Do not work underneath the cab while tilting it or when it is half tilted.

  • Page 26: Overheating

    1. INTRODUCTION AND SAFETY 1.9 Overheating When the vehicle overheats Handling the coolant reservoir cap Oil inspection and changes WARNING WARNING Do not fill coolant, when the Do not inspect or change the engine is hot, to avoid burns from e n g i n e o i l , g e a r b o x o i l o r steam and hot coolant.

  • Page 27: Handling The Fuel Filter And Fuel Tank

    1. INTRODUCTION AND SAFETY 1.10 Handling the fuel filter and fuel tank When replacing the fuel filter Draining water from the water sep- Air bleeding the fuel system arator WARNING Ensure that fuel filter is installed correctly and there are no fuel leaks from the filter.
  • Page 28 If there is a spillage. fuel leak, contact nearest authorised • Make sure that the engine is UD Trucks dealer for assistance. switched off. Before opening the fuel filler cap, be sure to touch a metal part to eliminate static electricity.
  • Page 29 1. INTRODUCTION AND SAFETY Dual tanks- if equipped 1. Master tank 2. Slave Tank 3. Shut off valve opening 4. Shut off valve closing Fill both the tanks independently with valve closed. In case if the user needs to fill only 1 tank, then it is mandatory to fill master tank always.

  • Page 30: Handling Of The Battery

    The hydrogen gas generated during charging could ignite and cause an explosion. Contact authorised UD Trucks dealer for battery charging. 1-24...

  • Page 31: Other Precautions

    1. INTRODUCTION AND SAFETY 1.12 Other precautions Drive belt tension inspection When closing the windows WARNING DANGER Make sure that no parts of the Do not inspect the drive belt while body are extended outside the the engine running. w i n d o w w h e n c l o s i n g t h e window.

  • Page 32: Modifying And Replacing Parts

    Contact nearest authorised UD Trucks When performing electrical welding, the dealer for advice before installing any electric current from the welding accessories.
  • Page 33 1. Fuse OK 2. Blown fuse Contact nearest authorised UD Trucks CAUTION dealer for advice. CAUTION Do not touch the glass portion of the bulbs.

  • Page 34: Washing The Vehicle

    1. INTRODUCTION AND SAFETY 1.14 Washing the vehicle When washing the vehicle CAUTION Use washing facilities which dispose of waste from the washing process in an While washing, ensure that the environmentally compatible manner. water does not seep into the Use environmental friendly cleaning electrical components such as agents as far as possible.
  • Page 35 1. INTRODUCTION AND SAFETY 1.15 OBD (On Board Diagnostics) - SCR technology General The following effects will occur if faults Conditions are detected in the exhaust after UD Trucks uses SCR technology The NOx control monitoring system is treatment: (Selective Catalytic Reduction)
  • Page 36 1. INTRODUCTION AND SAFETY Non-erasable fault codes light, for example. As soon as the Fuel reason for the power reduction has Sulphur-free fuel (<50 ppm) must be Once the new fault code for NOx is ceased, the power reduction will be used in order to ensure that the reported (becomes active), it will be deactivated the next time the engine...
  • Page 37 1. INTRODUCTION AND SAFETY AdBlue (Urea solution) WARNING AdBlue is a safe liquid; It may cause slight irritation for some peo ple. Avoid breathing the fumes, gas, vapour or spray. If spilt onto the body, clothes or g r o u n d , f l u s h t h e a r e a...

  • Page 38: Obd (On Board Diagnostics)

    1. INTRODUCTION AND SAFETY 1.16 Driving trucks with Euro 4, 5 (or equivalent) standard engines If the AdBlue level is less than 10% The truck is equipped with an OBD of the tank, CHECK tell-tale lights up 9:30 ---- system. An MIL (Malfunction Indicator and the engine output is reduced to Lamp) symbol lights up in the event of 12% to 40%, further decrease in...
  • Page 39 1. INTRODUCTION AND SAFETY Emission control monitoring system When a fault occurs in the NOx monitoring system, a message appears on the display together with the yellow warning lamp (CHECK) and the MIL symbol. If the system detects that the fault persists, then the engine's output is reduced by 40% of maximum output.

  • Page 40: Telematics Gateway - If Equipped

    1. INTRODUCTION AND SAFETY 1.17 Telematics gateway - if equipped TGW is a fleet management system TGW is located behind the Instrument GSM Communication panel. Telematics gateway is an on- for truck owners. Telematics gateway has an integrated board unit used for data logging and module data Fleet/truck owner can sit at the comfort...
  • Page 41 1. INTRODUCTION AND SAFETY GPS Satellite positioning location depends on the number of Electrical application satellites that are in contract with the • The TGW can be installed in a number truck unit. The GPS antenna is mounted of different configurations; stand on the truck roof (combined GSM/GPS- alone, in combination with Personal antenna).
  • Page 42 1. INTRODUCTION AND SAFETY The vehicle electrical and electronic system • • • Driver ID Interface - USB Vehicle data readout When a vehicle data read out request is sent to the vehicle by back office, it is received by TGW and sent via Controller Area Network (CAN) to EMS (Engine Management...

  • Page 43: Open Source Software

    1. INTRODUCTION AND SAFETY 1.18 Open source software Your UD Trucks vehicle contains vari- ous software programs. Some of those programs are open source soft- w ar e, w h i c h a m o ng ot he r t hi n g s means that you may have the right to gain access to the source code.

  • Page 44: Biodiesel

    10% biodiesel FAME (Fatty Acid Methyl Esters) Other products which are not FAME, specific service requirements UD Trucks accepts max 10% FAME FAME and/or do not comply with and rebuilds of fuel system must be in diesel fuel (in accordance with t h e s e s t a n d a r d s a r e N O T applied.

  • Page 45: Getting In And Out Of The Cab

    2. GETTING IN AND OUT OF THE CAB 2. GETTING IN AND OUT OF THE CAB 2.1 Doors Opening and closing the doors Opening the door from inside Closing the door from inside from outside • Hold the handle and pull it, till the •...
  • Page 46 2. GETTING IN AND OUT OF THE CAB Locking and unlocking the door Centre lock - if equipped 2. Press the push button and close the door. To lock the doors from inside, push the lock knob. NOTE If the vehicle is equipped with t h e c e n t r e l o c k f e a t u r e , b y operating the driver side lock k n o b y o u c a n a l s o l o c k o r...
  • Page 47 2. GETTING IN AND OUT OF THE CAB Locking and unlocking the door from outside To u n l o c k o r l o c k t h e d o o r f r o m outside, insert the ignition key into t h e k e y h o l e a n d t u r n t h e k e y towards the unlock or lock position accordingly.

  • Page 48: When Getting Into The Cab

    2. GETTING IN AND OUT OF THE CAB 2.2 When getting into the cab 2. Hold the lower handles and climb 4. Step onto the cab floor. WARNING the 1st step. • Be careful when getting in and out of the cab, to avoid slipping or falling.
  • Page 49 2. GETTING IN AND OUT OF THE CAB When getting out When getting out, follow the reverse order of getting in.

  • Page 50: Seats

    2. GETTING IN AND OUT OF THE CAB 2.3 Seats Driver seat - With Air suspension with lower anchorage on seat Lumber adjustment Backrest adjustment Turn the knob on the right side of the When the backrest recliner handle is seat to adjust the fit of the lower seat lifted upwards, it unlocks the recliner b a c k .
  • Page 51 2. GETTING IN AND OUT OF THE CAB Front and rear lifter adjustment Adjustable damper knob Longitudinal seat adjustment W h e n t h e f r o n t h a n d l e i s l i f t e d S u s p e n s i o n h a r d n e s s c a n b e When the slide rail handle is pulled u p w a r d s , t h e f r o n t o f t h e s e a t...
  • Page 52 2. GETTING IN AND OUT OF THE CAB Seat cushion longitudinal adjust- Automatic suspension adjuster Armrest adjustment ment This seat is automatically sets the The armrest can be moved by hand While pushing the slide lever to the initial vertical height based on driver to adjust its angle.First, lower it all right, adjust the seat cushion to the weight.It is equipped with vertical...
  • Page 53 2. GETTING IN AND OUT OF THE CAB Driver seat - Mechanical, Air suspension with lower anchorage on BIW, Fixed seat Note: Your vehicle can be fitted with any one of the following seats. 1. Mechanical adjustment driver seat - with armrest 2.
  • Page 54 2. GETTING IN AND OUT OF THE CAB Backrest adjustment Seat tilt and height adjustment DANGER Do not adjust the seat while driving. NOTE Armrest usage is recommended only for longer/highway drives. 1. Front handle operation When the backrest recliner handle is 2.
  • Page 55 2. GETTING IN AND OUT OF THE CAB Suspension height adjustment - NOTE NOTE Mechanical adjustment driver seat The height of the seat can be D r i v e r m u s t a d j u s t t h e d i a l adjusted by operating both the according to their own body f r o n t...
  • Page 56 2. GETTING IN AND OUT OF THE CAB This allows the user to adjust the Passenger seat -Type 1 Backrest adjustment a m o u n t o f s t i f f n e s s i n t h e a i r When the backrest recliner handle is suspension for comfort.
  • Page 57 2. GETTING IN AND OUT OF THE CAB Cushion flip Passenger seat - Type 2 Headrest adjustment The height of the headrest can be adjusted at 3 levels by moving the headrest by hand.Push the headrest l o c k r e l e a s e b u t t o n t o r e t u r n t h e Lower cushion can be folded by headrest to the standard position.
  • Page 58 2. GETTING IN AND OUT OF THE CAB Backrest fold down Backrest full fold down cushion flip CAUTION D o n o t s i t o r s t a n d o n t h e p a s s e n g e r s e a t i n f o l d e d condition.
  • Page 59 2. GETTING IN AND OUT OF THE CAB Centre seat The centre seat can also be used to store items. In order to access the storage, follow the steps below: NOTE 1. Lift the backrest to unlock. Always keep the centre seat b a c k r e s t i n f o l d e d d o w n 2.

  • Page 60: Seat Belts

    2. GETTING IN AND OUT OF THE CAB 2.4 Seat belts Driver and passenger seats Shoulder strap • Make sure that the seat belt is not twisted when wearing it. Adjust the NOTE seat belt to the user’s comfort. Always wear the seat belt while •...
  • Page 61 2. GETTING IN AND OUT OF THE CAB Three-point seat belt with ELR Precautions for wearing seat belts (Emergency Locking Retractor) The warning light will light up to warn device the driver, if the driver tries to drive without wearing the seat belt, when NOTE t h e i g n i t i o n k e y i s t u r n e d O N o r START....

  • Page 62: Steering Wheel Adjust

    2. GETTING IN AND OUT OF THE CAB 2.5 Steering wheel adjust Method of adjustment 2. Grip the steering wheel and pull 3 . T h e t i l t a d j u s t m e n t a l l o w s t h e the lock lever to release the lock.

  • Page 63: Equipment Description And Operation

    3. EQUIPMENT DESCRIPTION AND OPERATION 3. EQUIPMENT DESCRIPTION AND OPERATION 3.1 Instruments Instrument panel and controls - RHD 1. Air outlet 2. Tachograph (if equipped) 3. Radio 4. Control panel climate unit 5. Instrument cluster 6. Steering wheel 7. Horn pad 8.
  • Page 64 3. EQUIPMENT DESCRIPTION AND OPERATION Instrument panel and controls - LHD 1. Air outlet 2. Tachograph (if equipped) 3. Radio 4. Control panel climate unit 5. Instrument cluster 6. Steering wheel 7. Horn pad 8. Accelerator pedal 9. Brake pedal 10.
  • Page 65 3. EQUIPMENT DESCRIPTION AND OPERATION Instrument cluster (IC) 1. SRS The IC provides the user with information via using gauges, tell-tales and a display. 2. Cab tilt 3. ABS fault on trailer 4. ABS fault on rigid 5. Air pressure, rear brake 14 15 16 17 6.
  • Page 66 3. EQUIPMENT DESCRIPTION AND OPERATION Gauges Tachometer Speedometer The gauges used may be analogue CAUTION or digital. The red zone shows the range of km/h Analogue gauges in the Instrument critical engine speed. Always Cluster: keep the indicator below this •...
  • Page 67 3. EQUIPMENT DESCRIPTION AND OPERATION Coolant temperature gauge When the coolant temperature is high Fuel level gauge STOP tell-tale lights up and engine will start deteriorating, immediately stop the 10:30 12,500km 10:30 12,500km vehicle and contact authorised UD AdBlue AdBlue HIGH HIGH Trip A...
  • Page 68 3. EQUIPMENT DESCRIPTION AND OPERATION Air pressure gauge km/h x100kPa 1. Air pressure, front brake 2. Air pressure, rear brake (System pressure 770-930kPa) This gauge shows the air pressure in the air reservoir. Pressure LED count Pressure LED count (Bar) (Bar) 2.5 - 4 4.5 - 5.5...

  • Page 69: Indicators

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.2 Indicators The following tell-tales are located on the instrument cluster Tell-tale Tell-tale Sl. no. Description Sl. no. Description Symbols Symbols Engine Oil pressure Gear range high Battery charge Gear range low Door open Engine coolant temp Auxiliary brakes Ad blue Fuel level...
  • Page 70 3. EQUIPMENT DESCRIPTION AND OPERATION Tell-tale Tell-tale Sl. no. Description Sl. no. Description Symbols Symbols Trailer hand brake activation O/D Mode status Road speed limitation Water in fuel Transmission overheat/Malfunction Fuel filter clogging Brake pad wear indication Air filter restriction Transmission service reminder Transmission shift inhibit Maintenance monitoring...
  • Page 71 3. EQUIPMENT DESCRIPTION AND OPERATION Tell-tale Tell-tale Sl. no. Description Sl. no. Description Symbols Symbols Yellow -Engine oil temperature moderate Messages in queue Red -Engine oil temperature critical Regeneration ongoing Engine oil level is low Ad blue level low Regeneration inhibit (Color red AdBlue OBD Ad blue...
  • Page 72 3. EQUIPMENT DESCRIPTION AND OPERATION Instrument, display The layout of the display Control and warning lamps If something occurs which demands the The instrument has warning and control 9:30 ---- driver’s attention, a vehicle message lamps to indicate warning and status. appears on the display.
  • Page 73 3. EQUIPMENT DESCRIPTION AND OPERATION Buzzer Pop up IC tell-tale Message list Vehicle message Popup appears, until ESC button is pressed Tell-tale lights up continuously appears continu- ously Heard continuously Vehicle message until the ESC Stop tell-tale lights up while there is a fault. Tell-tale lights up continuously appears continu- button is pressed...

  • Page 74: Display Menu

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.3 Display menu Software events: Internally generated Default Screen events in the instrument cluster, for example fault message events and Display control interaction timers. CAUTION Do not update the parameters i n t h e I C w h i l e t h e e n g i n e i s running.
  • Page 75 3. EQUIPMENT DESCRIPTION AND OPERATION Favourite Menu 01.Time/Date 03.Speedo Meter Favourite menu is displayed in the centre display screen. We can add and remove some of the menus from favourite menu. 02.Engine Oil 04.Engine Hours Some of the items can be removed and added to the favourite menu based on driver need using ADD/ REMOVE option.
  • Page 76 3. EQUIPMENT DESCRIPTION AND OPERATION 05.D to Empty 07.Driver coaching istance 06.ODD/TRIP 3-14...
  • Page 77 3. EQUIPMENT DESCRIPTION AND OPERATION Main menu By pressing MENU button user can switch from favourite menu to main menu.There are four main menus are available.User can toggle between all m a i n m e n u s u s i n g U P / D O W N button.
  • Page 78 3. EQUIPMENT DESCRIPTION AND OPERATION 01.Escot Eco 02.Escot M 03.Escot Eco OFF 04.Top Gear 01.Engine & gear 05.Within Economy 06.Above Economy 07.Overrev 08.Engine load Driver coaching 01.Fleet overspeed 02.Speed 02.Cruise Control 01.Coasting 03.Anticipation 02.Brake Counter 04.Standstill 01.Idling Deco Notification Enabled/Disabled 05.Deco Notification 01.Deco Notification (Enable/Disable) 06.Deco Illumination...
  • Page 79 3. EQUIPMENT DESCRIPTION AND OPERATION 01.Instant Fuel Instantaneous Fuel (--L/h) Distance to Empty (--km) 02.Distance to empty 01.Fuel Data 03.Leg Fuel Leg Fuel (--L) 04.Average Fuel Average Fuel (--L/100 Km or --km/L) 05.Reset Fuel Data Reset Fuel Data..? (yes Reset Fuel data reset Successful/Failed 01.MODE 1 MODE1 Selected Reset Fuel Data Fuel coaching Data updated...
  • Page 80 3. EQUIPMENT DESCRIPTION AND OPERATION 01.Telltale Test 02.Gauge Test 01.Self Test 03.Display Test 04.Sounfd Test IECU Part Number HARDWARE PART No. XXXXXXXXXXX 01.IECU SOFTWARE PART No. XXXXXXXXXXX Maintenance 01. Diagnostics EMS Part Number HARDWARE PART No. XXXXXXXXXXX 02.Part Number 02.EMS SOFTWARE PART No.
  • Page 81 3. EQUIPMENT DESCRIPTION AND OPERATION TECU ECU FAULTS Occurrence Counter 01.IECU <U0CCC CC Inactive> Last Event EMS FAULTS Occurrence Counter 02.EMS 01.Read Faults <C1006 38 Active> Last Event IC FAULTS Occurrence Counter 03.IC <B1004 1E Inactive> Last Event 04.Vehicle Faults All inactive faults are 01.IECU cleared...
  • Page 82 3. EQUIPMENT DESCRIPTION AND OPERATION 02. View Data Engine hours warning 4674 h Distance warning Engine hours warning DateWarning To Confirm Reset Data Press 00000000 km 000000000.0 h 27/11/2021 03. Reset Data Distance Pre-warning Engine hours Pre warning Date PreWarning Enter Kay Maintenance 00000000 km...
  • Page 83 3. EQUIPMENT DESCRIPTION AND OPERATION 01.Set Time SET TIME<00.00> 02.Set Date SET DATE<11/11/2021> 03.Set Time Format TIME FORMAT <12H/24H> 01. Time & Date 04.Set Date Format Date Format YYYY/MM/DD DD/MM/YYYY Settings MM/DD/YYYY 01.English 02.Spanish 02. Language 03.Bahasa 04.Thai 05.Arabic 03.Brightness 3-21...
  • Page 84 3. EQUIPMENT DESCRIPTION AND OPERATION Workshop PW 01.Workshop PW 0000 Driver PW 02.Driver PW 0000 01.Workshop PW Workshop PW Enter Old Password 0000 04.Password Enter New password 0000 03.Change Password 02.Driver PW Driver PW Settings Enter Old Password 0000 Enter New password 0000 01.Fuel Consumption Fuel Consumption...
  • Page 85 3. EQUIPMENT DESCRIPTION AND OPERATION Activate Drain <YES> 05.Water in fuel <NO> Settings SET RSL 06.RSL Setting Parameter Updated Turn Key OFF to ON Range 0-120 3-23...
  • Page 86 3. EQUIPMENT DESCRIPTION AND OPERATION Driver Coaching(1/3) 3-24...
  • Page 87 3. EQUIPMENT DESCRIPTION AND OPERATION Driver Coaching(2/3) 3-25...
  • Page 88 3. EQUIPMENT DESCRIPTION AND OPERATION Driver Coaching(3/3) 3-26...
  • Page 89 3. EQUIPMENT DESCRIPTION AND OPERATION Monitoring(1/3) 3-27...
  • Page 90 3. EQUIPMENT DESCRIPTION AND OPERATION Monitoring(2/3) 3-28...
  • Page 91 3. EQUIPMENT DESCRIPTION AND OPERATION Monitoring(3/3) 3-29...
  • Page 92 3. EQUIPMENT DESCRIPTION AND OPERATION Maintenance(1/4) 3-30...
  • Page 93 3. EQUIPMENT DESCRIPTION AND OPERATION Maintenance(2/4) 3-31...
  • Page 94 3. EQUIPMENT DESCRIPTION AND OPERATION Maintenance(3/4) 3-32...
  • Page 95 3. EQUIPMENT DESCRIPTION AND OPERATION Maintenance(4/4) 3-33...
  • Page 96 3. EQUIPMENT DESCRIPTION AND OPERATION Settings(1/2) 3-34...
  • Page 97 3. EQUIPMENT DESCRIPTION AND OPERATION Settings(2/2) 3-35...

  • Page 98: Switches

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.4 Switches Switch position Description Switch position Description DRIVER ID for TGW Bodybuilder - 2 Head lamp leveller Bodybuilder - 3 Switch cover ECO OFF mode - Allison 2500 Beacon light Switch cover Front fog lamp Bogie lift Rear fog lamp PTO - Engine...
  • Page 99 3. EQUIPMENT DESCRIPTION AND OPERATION 1. Driver ID for TGW - if equipped 2. Head lamp leveller switch - if 3. Switch cover equipped The USB interface will be available in the trucks with fleet management Head lamp is adjusted by rotating the 4.
  • Page 100 3. EQUIPMENT DESCRIPTION AND OPERATION 5. Front fog lamp switch - if equipped 7. Dump switch/Air suspension height d. After confirming the safety, push control switch (Mechanically the air suspension dump switch, controlled) - if equipped. air is exhausted from the air bellows at the rear axle and the cargo bed is lowered.
  • Page 101 3. EQUIPMENT DESCRIPTION AND OPERATION 9. 10. 11. Bodybuilder switch 13.Switch cover NOTE If the dump switch is accidentally pressed during driving, the cargo bed will not be lowered for safety but a warning buzzer will sound. By pressing the dump switch again, the warning buzzer stops.
  • Page 102 3. EQUIPMENT DESCRIPTION AND OPERATION 15. PTO Switch - Engine - if closer to the allowable maximum equipped limit(6.5T) & the Vehicle is driven in 17. Lift traction switch - If equipped tag axle lifted condition, during some (Electronically controlled) manoeuvres if the drive axle load exceeds 6.5T(due to load transfers), lifted axle is lowered automatically...
  • Page 103 3. EQUIPMENT DESCRIPTION AND OPERATION 18. Prohibit switch - If equipped Mirror heating switch - if equipped NOTE (Electronically controlled) Make sure that the engine is running before activating mirror heating function. The mirror heating switch is located When the switch is pressed, all ECS on the control panel of the driver’s functionalities will be prohibited.
  • Page 104 3. EQUIPMENT DESCRIPTION AND OPERATION Fuses and relays 23815603 HIGH POWER KI-15 KI-R 12V 24V IECU F43 F44 F45 IECU RCIOM TACHO BBEC 10A 10A 20A 30A F51 5A F70 5A F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 TACHO 15A 15A 15A 10A 1 A...
  • Page 105 3. EQUIPMENT DESCRIPTION AND OPERATION Symbol Function Rating Symbol Function Rating Fuse No. Fuse No. Brake Lamp Reverse Lamp Beacon Lamp Ignition Key Alternator Ignition +ve Airbag RCIOM RCIOM Audio + OBD + Park Brake Lamp Free Stalk Switch 1 Power Window Driver Instrument Cluster Battery +ve 12V Power Outlet...
  • Page 106 3. EQUIPMENT DESCRIPTION AND OPERATION Symbol Function Rating Relay No. Symbol Fuse No. Function Type IECU IECU Supply Reverse Lamp Micro-NO Micro-NO/NC Air Valve Unit Wiper On Off Relay Mirror Heating Pre-Heater Micro-NO TACHO Tachograph Horn Relay Micro-NO Dipped Beam RH Free .K26 Main Beam LH...

  • Page 107: Combination Switch

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.5 Combination switch T h e f o l l o w i n g s h o w s t y p e s o f Wiper function combination switch With cruise control and auxiliary brake, Without cruise control and auxiliary brake, Auxiliary brake...
  • Page 108 3. EQUIPMENT DESCRIPTION AND OPERATION 2. Intermittent mode: The wiper Washer function Hazard indicator blades operate at a predetermined time delay between each sweep. This mode is used when the rain or snow conditions are very mild or in drizzle. 3.
  • Page 109 3. EQUIPMENT DESCRIPTION AND OPERATION Light control Flash to pass The DRL (if equipped) is activated when the ignition key is in the ON (3) and the parking brake is released. Combination switch The flasher (to pass) can be controlled Light switch position by moving the combination switch lever...
  • Page 110 3. EQUIPMENT DESCRIPTION AND OPERATION Direction indicator Momentary lane change indicator: Cruise control - if equipped When the lever is moved to the first DANGER position (1 and 3), the direction indicator will flash once and the stalk will spring Do not use cruise control on back to the neutral.
  • Page 111 3. EQUIPMENT DESCRIPTION AND OPERATION Cruise control operation speed). Release when the desired Switching OFF the cruise control cruise speed has been reached. The cruise control is deactivated when NOTE the brake or clutch pedal is pressed or NOTE auxiliary brake is activated or the cruise Make sure that auxiliary brake control momentary switch is pressed.

  • Page 112: Gearshift Lever And Push Button

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.6 Gearshift lever and Push button 6 Speed 9 Speed Selector lever - Allison 2500 T h e 6 s p e e d m a n u a l g e a r b o x T h e 9 s p e e d m a n u a l g e a r b o x Allison 2500 Series is a fully automatic comprises six forward gears and one...
  • Page 113 3. EQUIPMENT DESCRIPTION AND OPERATION Selector switch - Allison 3000 Allison 3000 Series is a fully automatic transmission with selector switch has six (6) forward and one (1) reverse gear ranges. 3-51...

  • Page 114: Pto - If Equipped

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.7 PTO - if equipped PTO (Power Take Off) 3. Switch ON the engine PTO switch. NOTE The truck can be equipped with two types of PTO, engine mounted PTO and The PTO is also disengaged gearbox mounted PTO.
  • Page 115 3. EQUIPMENT DESCRIPTION AND OPERATION Activating Gearbox PTO - 6 speed Gearbox PTO NOTE 1. Apply the parking brake. 9 Speed Gearbox PTO Operation M a k e s u r e t h a t t h e d i s p l a y NOTE shows the PTO status icon and that the LED on the PTO switch...
  • Page 116 3. EQUIPMENT DESCRIPTION AND OPERATION Vehicle standstill to Vehicle mobil- NOTE NOTE ity while PTO is ON (9 Speed Gear- box) Make sure that the parking brake Make sure that gearshift lever 1. Press the clutch pedal down fully is applied and gearshift lever is low indicator goes OFF and PTO and move the shift lever to 1st in low range.
  • Page 117 3. EQUIPMENT DESCRIPTION AND OPERATION Vehicle mobility to Vehicle stand- Deactivate 9 Speed Gearbox PTO NOTE s t i l l w h i l e P T O i s O N ( 9 S p e e d Gearbox) 1.
  • Page 118 3. EQUIPMENT DESCRIPTION AND OPERATION Engine speed control using combi- nation switch - vehicle with Cruise control NOTE E n g i n e s p e e d c a n a l s o b e controlled by using combination switch.

  • Page 119: Fuel Coaching System - If Applicable

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.8 Fuel coaching system Sweet spot - fuel consumed in sweet Mode 2: To program that a fuel coaching spot i s res et af t e r e ve ry X am oun t of The fuel coaching system helps the kilometres.

  • Page 120: Fifth Wheel Operation

    UD Trucks The trailer and the tractor must be dealer to get a new copy. resting on the same flat surface. The...
  • Page 121 3. EQUIPMENT DESCRIPTION AND OPERATION 3. With the handle (2) pulled out, Coupling procedure 1 . M o v e t h e t r a c t o r c l o s e t o t h e swing it forwards into position C trailer.
  • Page 122 3. EQUIPMENT DESCRIPTION AND OPERATION Trailer should contact fifth wheel 100- There should be no gap between the 1 5 0 m m b e h i n d t h e f i f t h w h e e l trailer and fifth wheel.
  • Page 123 I f t h e r e a r e a n y c o m p r e s s e d a i r and backward. If the clearance is leaks, find and seal it. excessive, consult nearest authorised UD Trucks dealer. Make sure that the electric socket works perfectly by turning on the WARNING...
  • Page 124 3. EQUIPMENT DESCRIPTION AND OPERATION De-coupling procedure 1. Lift the catch (1). 3. With the handle (2) pulled out, swing it forwards into position C and engage it on the edge of the WARNING plate. The trailer and the tractor must b e r e s t i n g o n t h e s a m e f l a t surface which must not give away under the pressure of the...

  • Page 125: Bogie Control - If Equipped

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.10 Bogie control - if equipped Bogie control Different operating conditions can be Bogie lift switch-OFF s e t b y u s i n g t h e b o g i e l i f t s w i t c h Bogie lift assembly makes it possible Tag axle wheels will always be in provided on the cabin dashboard.
  • Page 126 The height of the cargo bed can be authorized UD Trucks dealer as adjusted to match the platform height soon as possible. by lifting it up and down.
  • Page 127 • Perform height control on a level “Check” tell-tale. When this warning ground. is displayed, contact the nearest • Fill the air tanks with air before authorized UD Trucks dealer. performing height control. No Level Control Possible Visit Workshop • Height control will be canceled...
  • Page 128 3. EQUIPMENT DESCRIPTION AND OPERATION Instructions for filling the air tanks 9:30 ---- CAUTION • Start the engine. • Run the engine at high idling to • Perform cargo bed or coupler fill the air tanks until the air height adjustment with the pressure gauges reach the vehicle stopped (with the specified air pressure.
  • Page 129 3. EQUIPMENT DESCRIPTION AND OPERATION Remote controller Down button 9:30 ---- The cargo bed or coupler lowers while the Down button is pushed, TIME & DATE STOP until the lower limit is reached. You can stop at the desired height at any 9 : 30 time by releasing the button.
  • Page 130 3. EQUIPMENT DESCRIPTION AND OPERATION Up button • Push the neutral button of the NOTE remote controller to return the The cargo bed or coupler rises while cargo bed/coupler height to the • D o n o t l e a v e t h e r e m o t e the Up button is pushed, until the neutral position.

  • Page 131: Air Suspension (Electronically Controlled)

    3. EQUIPMENT DESCRIPTION AND OPERATION Ferry mode • To cancel the ferry mode, with Full Limp home ignition switch • Full limp home can be triggered Precautions for use position, press neutral either due to safety critical faults button/back to drive button on •...

  • Page 132: If Equipped

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.12 SRS Airbag system Seat belt Pretensioners WARNING - if equipped Seat belt pretensioners improves the restraining function of the seat belts. W h e n i n s t a l l i n g a v e h i c l e The SRS (Supplemental Restraint Pretensioners operate during a frontal accessory or when servicing the...
  • Page 133 UD Trucks dealer in order to avoid adverse effect against the SRS airbag system. 3-71...
  • Page 134 Also, you may position or continuously appears burn yourself. the nearest authorized UD Trucks while the ignition switch is in the dealer immediately. ON and the engine is running, • When discarding the vehicle, the...
  • Page 135 UD Trucks dealer. cases that the impact to the cabin is not so hard to function the SRS airbag system.
  • Page 136 3. EQUIPMENT DESCRIPTION AND OPERATION How to wear and release the seat belt Frontal collision with another vehi- WARNING The SRS airbag system is effective when used with the ELR seat belt with • Always wear the seat belts for pretensioner.
  • Page 137 3. EQUIPMENT DESCRIPTION AND OPERATION Depending on the degree of impact, the Falling into a large hole or a ditch Offset collision with a small amount SRS airbag system may function if the of overlap or at a slow collision lower side of the vehicle hits a projecting speed object such as a culvert, bollard, curb,...
  • Page 138 3. EQUIPMENT DESCRIPTION AND OPERATION When the SRS airbag system does Hit by another vehicle from side not function The SRS airbag system does not function even in a frontal collision if the impact is not severe or in the following cases.

  • Page 139: Others

    3. EQUIPMENT DESCRIPTION AND OPERATION 3.13 Others Sun visor Battery cut-off switch Sun visors (Optional for co driver’s side) Horn WARNING are located on the interior just above the windscreen. The sun visors are fitted To sound the horn, push the centre pad Do not turn OFF the battery power with hinged flaps which are adjustable area of the steering wheel.
  • Page 140 3. EQUIPMENT DESCRIPTION AND OPERATION The battery cut-off switch is located on Switch handle installation 3. Secure the rubber bush back in place. the battery box. 1. Pull the rubber bush out and insert the handle into the slot. 1. ON 2.
  • Page 141 3. EQUIPMENT DESCRIPTION AND OPERATION Engine protection 4. Reducing maximum engine speed Propeller shaft catcher- if equipped Engine protection controls the functions 5. Reducing maximum road speed Propeller shaft catcher is intended to u s e d t o p r o t e c t t h e e n g i n e f r o m h o l d t h e p r o p e l l e r s h a f t .
  • Page 142 3. EQUIPMENT DESCRIPTION AND OPERATION Opening the front panel 2. Make sure the front panel is unlocked and is ready to open. The following can be inspected by opening the front panel. • Clutch fluid level • Coolant level • Washer fluid level •...
  • Page 143 3. EQUIPMENT DESCRIPTION AND OPERATION Closing the front panel 3. Make sure the front panel is locked. Resting compartment - if equipped 1. Hold the front panel with one hand, DANGER remove support rod and secure it in the retainer behind the front panel. Do not use the bed while the vehicle is moving.
  • Page 144 3. EQUIPMENT DESCRIPTION AND OPERATION 3-82...

  • Page 145: Accessories And Audio

    4. ACCESSORIES AND AUDIO 4. ACCESSORIES AND AUDIO 4.1 Accessories Storage compartment 1. Card holder 2. Storage compartment 3. Door pocket 4. Ash tray 5. Cup holder...
  • Page 146 4. ACCESSORIES AND AUDIO Overhead storage - if equipped Cup holder Door pocket This is used to hold a bottle or a cup. Door pockets are located in the right WARNING and left doors and can be used for Card holder storing road maps and magazines, etc.
  • Page 147 4. ACCESSORIES AND AUDIO Power outlet 24 V or Power outlet 12 V Ash box Cigarette lighter - if equipped The power outlet provided on the HCV panel will have electrical output of 12 V. WARNING The power outlet/Cigarette lighter outlet provided on the dashboard will •...

  • Page 148: Audio Front Panel - If Equipped

    4. ACCESSORIES AND AUDIO 4.2 Audio front panel - if equipped...
  • Page 149 4. ACCESSORIES AND AUDIO 02.Manual Storing of Stations Main KNOB When SRC is set to Radio mode (RADIO) Press the Main Knob button to switch Once the desired BAND type is the Audio Unit ON Tuning and storing stations selected, Press << button to search -Press the Main Knob once for the station of low frequency or Press BAND button to select the...
  • Page 150 4. ACCESSORIES AND AUDIO When SRC is set to USB/AUX IN Press 3RPT button to play the same Set & Display System Clock mode song/track repeatedly. Press this Press and hold the DISP button for button again to disable the repeat more-than than 2 sec, system time gets To select &...
  • Page 151 4. ACCESSORIES AND AUDIO On non-time display menu Selecting Equalizer Type Frequency Press and hold DISP button and Press SEL button to select one of select any one among the below six five equaliser types options using (◄◄/►►) button. OFF,POP,CLASSIC,ROCK,JAZZ rotating the Volume knob.
  • Page 152 4. ACCESSORIES AND AUDIO USB Function Fuse Insert device into connector and the unit will begin to play automatically.To stop playback of USB device ,push the SRC button to non USB mode and then remove the USB device. 1. USB flash memory 2 in 1 support. 2.
  • Page 153 4. ACCESSORIES AND AUDIO Electrical connection...

  • Page 154: Check Before Requesting Service

    4. ACCESSORIES AND AUDIO 4.3 Check before requesting service The following checklist can help you solve some problems which you may encounter when using the unit. Before consulting it, check the connections and follow the instructions in the user manual. Do not use the unit in abnormal condition, for example without sound, or with smoke or foul smell can cause fire or electric shock, immediately stop using it and call the store where you purchased it Possible cause Solution...

  • Page 155: Airconditioning

    5. AIRCONDITIONING 5. AIRCONDITIONING 5.1 Ventilation Opening and closing of window- Power window (If equipped) Switches on driver side-Operation of driver Switches driver side-Operation side window. passenger side window. Switches on driver side. The driver’s side door window can The passenger side door window be closed or opened to required can be closed or opened to required The power window switch module...
  • Page 156 5. AIRCONDITIONING Opening and closing of window- Manual (If equipped) Switches on passenger side. The passenger side power window switch is used to open or close the passenger side window by pushing or The window opening/closing levers pulling the switch lightly to position 1 are provided inside of each door.

  • Page 157: Air Conditioner

    5. AIRCONDITIONING 5.2 Air conditioner Air vent 1. Air blown to windscreen 2. Air blown to vent outlets CAUTION 3. Air blown to foot rest Do not switch on the blower when the engine is OFF. Doing so could drain the battery.
  • Page 158 5. AIRCONDITIONING Manual Air-Conditioner NOTE DANGER WARNING W h e n s t a r t i n g t h e A C a f t e r D o n o t s w i t c h O N t h e a i r Do not use air recirculation for a parking for long timed, keep the conditioning system and sleep or...
  • Page 159 5. AIRCONDITIONING Mode knob position details - RHD Mode knob position details - LHD Temperature control knob 1. Bunk mode - Only for LHD vehicles 1. Red - heating 1. Defrost 2. Blue - cooling 2. Feet / Defrost 2. Vent 3.
  • Page 160 5. AIRCONDITIONING Manual controlled air conditioning - RHD 1. Temperature control knob 2. Fresh/recirculation switch 3. Blower knob Manual controlled air conditioning - LHD 4. Cooler ON/OFF switch 5. Mode knob (for LHD, there is an addi- tional bunk mode which is not operational)
  • Page 161 5. AIRCONDITIONING Manual controlled heater unit only - RHD 1. Temperature control knob 2. Fresh/recirculation switch Manual controlled heater unit only - LHD 3. Blower knob 4. Mode knob (for LHD there is additional bunk mode which is not operational)
  • Page 162 5. AIRCONDITIONING Manual controlled air cooling unit only - RHD 1. Fresh/recirculation switch 2. Blower knob 3. AC ON/OFF Manual controlled air cooling unit only - LHD 4. Mode knob (for LHD there is addi- tional bunk mode which is not opera- tional)
  • Page 163 5. AIRCONDITIONING Manual controlled vent only - RHD 1. Mode knob 2. Fresh/recirculation switch Manual controlled vent only - LHD 3. Blower knob...
  • Page 164 5. AIRCONDITIONING If the AC system is not working properly, contact nearest authorised UD Trucks dealer. NOTE Use Freon HFC134a to help protect the environment. Only use the specified refrigerant to charge the cooling system. CAUTION Do not discharge refrigerant to the atmosphere. In order to discharge refrigerant in an environmental friendly manner, please contact your authorised UD Trucks dealer.

  • Page 165: Daily Inspection

    • Carry out the inspection in the following order. The detailed inspection instructions are explained below. • The inspection points shown in bold and * are carried out according to the vehicle's mileage, driving conditions and other factors. • If malfunctions appear, have the vehicle inspected and repaired at authorised UD Trucks dealer.
  • Page 166 6. DAILY INSPECTION 1.Have the previous day's problems been repaired/rectified completely? • Is there any fluid on the ground? • Is there any damage to the body, windscreen and registration plates? • Is the air filter indicator shows red? • Is the engine oil filled to the proper level? * •...
  • Page 167 6. DAILY INSPECTION • Has the parking brake been released properly? 3.Get into the cab • Is the window washer fluid spraying properly? * • Do the wipers wipe properly? * • Does the engine start well? Are there any abnormal sounds? •...

  • Page 168: Inspection Instructions

    6. DAILY INSPECTION 6.2 Inspection instructions Tyre inflation pressure, cracks, damage and abnormal wear R e f e r t y r e m a n u f a c t u r e r s recommendation for the correct DANGER tyre pressure.
  • Page 169 MAX and MIN mark on repaired or corrected by authorised the dipstick. UD Trucks dealer. If the oil level is below MIN, top up the engine oil as necessarily. Refer to “Recommended lubricants and Capacity “in Chapter 11.
  • Page 170 • If a large amount of water is drained out, there could be a problem with the air dryer, so have it inspected at authorised UD Trucks dealer immediately. CAUTION Do not top up reservoir with water.
  • Page 171 6. DAILY INSPECTION Parking brake lever tension Windscreen washer level and spray • If it is low, open the reservoir cap and add washer fluid operation through the reservoir filler opening. WARNING Check if the washer fluid sprays Do not use coolant as washer normally.
  • Page 172 6. DAILY INSPECTION Windscreen washer fluid Access to windscreen Engine starting performance and Always use UD windscreen washer With the windscreen wiper control OFF, abnormal sounds fluid. The windscreen washer fluid is use the grab handle and the steps to Check if the engine starts quickly mixed with water when used.
  • Page 173 6. DAILY INSPECTION Engine performance when run- Check the air pressure of the front and Engine n i n g a t l o w s p e e d s a n d w h e n rear brakes by monitoring the pressure Standard speed Air pressure...
  • Page 174 6. DAILY INSPECTION Brake valve operation Light operation Rear lights Turn ON each light switch and check WARNING that corresponding light lights up or flashes. The turn indicators are normal Always keep the area clean if they flash 60 to 120 times per minute. around the pedals.

  • Page 175: Correct Driving Operation

    CAUTION If the engine does not start, crank the engine at an interval of 30 seconds. If the engine fails to start after three cranks, contact authorised UD Trucks dealer for assistance. 1. LOCK 2. ACC 3. ON 1. Apply the parking brake.
  • Page 176 7. CORRECT DRIVING OPERATION LOCK: This is the position that turns off START: This is the position used to start Stopping the engine the power to the engine. It is also the the engine. The key automatically NOTE position in which the key can be returns to the ON position when inserted and removed and in which the released.
  • Page 177 7. CORRECT DRIVING OPERATION Starting the engine in cold condi- Unloading from an air suspension tion - if equipped with Engine Pre- vehicle heater If a large freight applying heavy load Turn the key to ON, and wait until on the coupler is removed from an the heater element symbol goes OFF air suspension vehicle (for example, and then crank the engine.

  • Page 178: Operation Precautions

    7. CORRECT DRIVING OPERATION 7.2 Operation precautions Handling a new vehicle Precautions while driving turning at crossroads. The rear The service life and performance of a tyres will turn with a smaller truck depend largely on how it is han- radius than the front tyres and WARNING dled during the initial running in...
  • Page 179 7. CORRECT DRIVING OPERATION When traveling downhill or shifting Precaution on engine speed Downhill RSL down The Downhill RSL feature is a function to prevent power line resonances that potentially can occur when the truck is DANGER x100r/min going downhill and protect the engine components from damages due to the Do not engage the auxiliary excessive engine speed.
  • Page 180 UD Trucks CAUTION dealer for assistance.
  • Page 181 Vehicles fitted with consult authorised UD Trucks surfaces which are wet, slippery, ABS may also require longer dealer in advance.
  • Page 182 7. CORRECT DRIVING OPERATION Gearshift lever operation Operating with automatic trans- Inter-vehicular distance mission Your truck may be equipped with an WARNING CAUTION optional automatic transmission. The P l e a s e o b e y a l l l o c a l t r a f f i c Do not apply excessive load to automatic transmission has the flexi- rules and regulations.
  • Page 183 7. CORRECT DRIVING OPERATION When handling freight Driving methods for improving fuel Coasting (rolling) efficiency No fuel is being consumed when the NOTE accelerator pedal is released. When Drive at an economic speed approaching a planned stop, turning S e c u r e a n d c o v e r t h e l o a d The best possible performance and w h e n s l o w i n g...
  • Page 184 7. CORRECT DRIVING OPERATION Reduce the start-off and stopping Clutch operation instructions and frequency precautions Do not drive the vehicle when the A large amount of fuel is required to clutch disc is worn out or when the move the vehicle from a standstill. clutch is having problems.

  • Page 185: Operating With Automatic Transmission

    If icon displays replacement or general transmission Eco mode using the dashboard switch park the vehicle in a safe place and servicing is required. (only for Allison 2500). contact authorised UD Trucks dealer for assistance. ---- 9:30 ---- 9:30...
  • Page 186 OFF after two seconds. If the icon does not illuminate during ignition, or if the icon remains on after ignition, the 1. Requested range (Lever/Switch position) transmission system should 2. Current range (Actual gear) checked immediately. Contact authorised UD Trucks dealer for assistance 7-12...
  • Page 187 7. CORRECT DRIVING OPERATION Allison 2500 (R): Reverse position Shift will not be done if the engine speed is above 1000 RPM. The Allison automatic transmissions This position used to move the vehicle have 6 forward and 1 reverse gear backwards.
  • Page 188 7. CORRECT DRIVING OPERATION (D): Driving position (1): First range WARNING This position can be used during rough This is the position used during normal road conditions, when freeing the driving. Gears will change from 1 - 6 Without applying the service vehicle from mud or deep snow, when when the overdrive (O/D) switch is ON, brake, parking brake:...
  • Page 189 7. CORRECT DRIVING OPERATION • When the ignition key is in the ACC or LOCK position, the selector WARNING CAUTION lever cannot be shifted from N to ( D ) D r i v e a n d o t h e r f o r w a r d Do not idle in R (Reverse) or D another position even if the brake ranges may not be obtained due...
  • Page 190 Contact your nearest authorised • Release the parking brake. Lift pedal depressed with the right foot. UD Trucks dealer for inspection, your foot off of the brake pedal. In this way, there is no need to if this situation occurs.
  • Page 191 7. CORRECT DRIVING OPERATION • When parking the vehicle, first stop 5. Engage the N (Neutral) range by Downshift or reverse inhibitor the vehicle and then shift to N slowly releasing the service The transmission hydraulic system will (Neutral). Then slowly release the brake.
  • Page 192 7. CORRECT DRIVING OPERATION Using the engine to slow the vehicle Parking brake WARNING To use the engine as a braking force, There is no park position in the shift the selector to the next lower transmission shift pattern. Therefore, D o n o t m a k e s h i f t s f r o m N range.
  • Page 193 Allison DOC® For (Transmission Control Module), and PC–Service Tool only. Contact will remain on steady for approximately Authorised UD Trucks dealer for two minutes after the initial selection of assistance. a drive range, until service is performed and the indicator is reset.
  • Page 194 7. CORRECT DRIVING OPERATION Relationship between switch operation Allison 3000 The Range selector switch is used to and digital display shift the gear to the desired driving The Allison automatic transmissions range from among 6 forward ranges have 6 forward and 1 reverse gear Digital display and the reverse range.
  • Page 195 7. CORRECT DRIVING OPERATION (R): Reverse Position (3): Third Range NOTE This position is used when moving the This position is used when strong vehicle backwards. The backup light engine braking is needed while the If the gear shifts up and down comes on and the back buzzer sounds vehicle is descending a slope.
  • Page 196 7. CORRECT DRIVING OPERATION WARNING WARNING WARNING When going downhill if you use Without applying the service D ( D r i v e ) a n d o t h e r f o r w a r d s e r v i c e b r a k e o r i f y o u j u s t brake, parking brake: ranges may not be obtained...
  • Page 197 7. CORRECT DRIVING OPERATION Engine start NOTE CAUTION • Check that the parking brake is applied. You must first stop the vehicle Do not idle in R (Reverse) or D before shifting from a forward • Before starting the engine, make (Drive) for more than 5 minutes.
  • Page 198 “N”, there is shift shock to occur. • To start the vehicle on a level something wrong. Contact the ground, select the “D” range. nearest authorised UD Trucks dealer. • Release parking brake. Avoid attempting to start your Gradually remove the foot from the vehicle by pushing or towing.
  • Page 199 7. CORRECT DRIVING OPERATION SHIFT LIMIT warning message • When stopping for 5 minutes or longer, shift to the N (Neutral) CAUTION selector digital display, position. (selection range) character (can be “R”, If the phenomenon in which • When parking, first stop the vehicle “6”, “5”, “4”, “3”, “2”...
  • Page 200 7. CORRECT DRIVING OPERATION 6. If the operator’s station will be Downshift or reverse inhibitor Using the engine to slow the vehicle unoccupied with the engine feature To use the engine as a braking force, running, chock the wheels and The transmission hydraulic system will shift the selector to the next lower take any other steps necessary...
  • Page 201 7. CORRECT DRIVING OPERATION lower range is selected. It is important • Be careful not to let the engine that you reach the lower range selected overrun while driving (especially WARNING before attempting to accelerate. This when descending slopes). If the wheels are stuck and not will avoid an unexpected downshift turning, do not apply full power Oil life monitor Allison 3000...
  • Page 202 7. CORRECT DRIVING OPERATION Automatic transmission maintenance Reset: indicator will be lit steadily upon each Automatic transmission initialization of the TCM (Traction maintenance indicator can be reset by Control Module), and will remain on either of these methods, steady for approximately two minutes after the initial selection of a drive From Selector range, until service is performed and...

  • Page 203: Driving Under Special Conditions

    7. CORRECT DRIVING OPERATION 7.4 Driving under special Driving through snow Fitting tyre chain conditions • When driving on snow covered WARNING or icy roads, attach tyre chains and drive at low speeds. Driving when it is raining • Check the tyre pressures after •...
  • Page 204 P l e a s e c o n s u l t t h e n e a r e s t the tyre with the chain bands authorised UD Trucks dealer for • Always keep the fuel tank filled attached securely.
  • Page 205 7. CORRECT DRIVING OPERATION Fuel tank cap handling 1. Insert the key in key hole and turn the 3. Lift open the cap. 5. Insert the key and turn clockwise to key anticlockwise to unlock. lock. 4. For locking place the filler cap and NOTE 2.
  • Page 206 7. CORRECT DRIVING OPERATION When parking When parking for a long time in cold areas, choose a place where the vehicle will not be snowed on. If an appropriate place is not available, park t h e v e h i c l e s o t h a t t h e e n g i n e compartment is not exposed to the wind.

  • Page 207: Inspection And Maintenance

    8. INSPECTION AND MAINTENANCE 8. INSPECTION AND MAINTENANCE 8.1 Inspection and maintenance Service position Regular inspection and maintenance 3. Move the gear to neutral. can extend the service life of the vehicle 1. Stop the vehicle on a level surface. and promote to safe and comfortable driving.
  • Page 208 8. INSPECTION AND MAINTENANCE Tilting the cab 5. Chock the wheels. NOTE WARNING T h e H o r n i s a c t i v a t e d i f t h e door is opened when parking •...
  • Page 209 8. INSPECTION AND MAINTENANCE 3. Make sure that the cab is free off 7. While holding the grip on the cab, loose and fragile objects. pull-out the “sub hook lever”. 4. Close the doors. 5. Remove the locking pin from the “tilt lock lever”.
  • Page 210 8. INSPECTION AND MAINTENANCE Lowering the cab 1. Remove the locking pin from the pin hole and secure the pin in its storage hole on the “tilt strut”. NOTE If the lock pin is difficult to insert repeat step 2 and 3. 4.
  • Page 211 8. INSPECTION AND MAINTENANCE Cab unlock warning STOP VEHICLE 10:30 12,500km AdBlue HIGH Trip A km/L Cab Tilt Unlocked km/h AdBlue x100r/min Instant MENU HOLD DOWN x100kPa When cab is unlocked and vehicle is moving then driver is warned by buzzer Cab tilt tell-tale sound, stop lamp, cab tilt tell-tale and “STOP VEHICLE”...

  • Page 212: Air Cleaner

    8. INSPECTION AND MAINTENANCE 8.2 Air cleaner Inspection Evacuator valve After the air filter has been replaced, the restriction indicator must be reset The air cleaner is a maintenance by pressing the reset button. free component so cleaning is not recommended.
  • Page 213 8. INSPECTION AND MAINTENANCE Replacement procedure NOTE 1. To access the air cleaner, tilt the CAUTION cab. Refer to “Tilting the cab” in When cleaning, make sure that Take extra care while cleaning Chapter 8. the engine air inlet is blocked the air cleaner housing.
  • Page 214 8. INSPECTION AND MAINTENANCE Precautions when handling air 7. Install the filter. 8. Install the air cleaner cover and cleaner secure it with the clips. • Make sure that the cover and the element are installed correctly. If they are not correctly installed, dust may be sucked into the cylin- der and cause malfunction.
  • Page 215 8. INSPECTION AND MAINTENANCE Air-conditioning filter-nylon mesh 2. Open the front panel and secure it 4. Remove the nylon meshes. with the support rod. 5. Clean the nylon meshes. A nylon mesh is used to filter the incoming air. This nylon mesh is 3.
  • Page 216 8. INSPECTION AND MAINTENANCE Air conditioner belt tension To inspect the belt tension 6. Install the nylon meshes. Push down the belt between the DANGER pulleys with a constant force. Check that the tension pulleys are moving Do not check or adjust the drive at constant speed.

  • Page 217: Engine Oil Filter

    8. INSPECTION AND MAINTENANCE 8.3 Engine oil filter Replacing the oil filter 2. Loosen the oil filler cap. The GH5E engine is fitted with an CAUTION element-type oil filter. We strongly recommend that y o u u s e g e n u i n e U D P a r t s . Using an inferior oil and filter could have a detrimental effect o n e n g i n e o p e r a t i o n a n d...
  • Page 218 8. INSPECTION AND MAINTENANCE 5. Remove the drain plug and drain the 7. Remove the filter assembly. 9. Remove the O-ring. oil. 8. Disassemble the filter. 10. Lubricate the gasket on the new 6. Replace the O-ring and tighten the filter.
  • Page 219 8. INSPECTION AND MAINTENANCE 11. Lubricate the O-ring and assemble. 13. Install the filter assembly. Torque tighten to 40 ±5 Nm (30 ±4 lb ft) 12. Assemble the filter. 8-13...

  • Page 220: Oils

    8. INSPECTION AND MAINTENANCE 8.4 Oils Engine oil recommendations Checking and changing the engine NOTE CAUTION Check or replace whichever WARNING i t e m s c o m e f i r s t o f t h e Do not add any oil additives.
  • Page 221 8. INSPECTION AND MAINTENANCE To check the engine oil level 3 . I f t h e o i l l e v e l i s l o w, a d d o i l CAUTION through the oil filler port. 1 .
  • Page 222 8. INSPECTION AND MAINTENANCE Changing the engine oil To change the engine oil 4.When the oil has been drained 1. Park the vehicle in a service position. c o m p l e t e l y f r o m t h e o i l p a n , WARNING Refer to “Service position”...
  • Page 223 8. INSPECTION AND MAINTENANCE Changing the gearbox oil 3. Place a container under the drain 5. Refill the oil through the filler plug plug. Remove the drain plug and hole, until oil overflows out of the completely drain the oil. CAUTION level plug hole.
  • Page 224 8. INSPECTION AND MAINTENANCE 6.Reinsert the filler plug and level NOTE CAUTION plug and tighten it. O i l d e t e r i o r a t e s t h e For PTO (if equipped) oil change, temperature increases and this d r a i n t h e o i l f r o m t h e m a i n c a u s e s g e a r b o x f a i l u r e .
  • Page 225 8. INSPECTION AND MAINTENANCE To check the automatic transmis- sion fluid level - Allison 2500 Check the fluid while the vehicle is on level ground and the parking brake applied. 1. Start the engine and run for at least one minute at 900 to 1,000 rpm to clear any air in the system.
  • Page 226 8. INSPECTION AND MAINTENANCE Automatic transmission fluid and 1. Operate the transmission in a The safe operating level is any level filter replacement - Allison 2500 drive range for at least 30 minutes within the HOT band on the dipstick. If to get operating temperature.
  • Page 227 8. INSPECTION AND MAINTENANCE 1. Remove the drain plug from the oil 2. Using filter wrench remove the main 7. Install, by hand, the control-main pan and allow the fluid to drain into a filter by rotating it anticlockwise. filter until the O-ring on the control suitable container.
  • Page 228 8. INSPECTION AND MAINTENANCE To check the automatic transmis- COLD Check sion fluid level - Allison 3000 1. Clean around the area near the 1. Park the vehicle on a level ground dipstick. and apply parking brake. 2. Start the engine and run for at least one minute at 900 to 1,000 rpm to clear the system of air.
  • Page 229 8. INSPECTION AND MAINTENANCE 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 Chapter 11. Automatic transmission fluid and Sub Filter 1.
  • Page 230 8. INSPECTION AND MAINTENANCE Oil change procedure 10. After replacement, be sure to refill fluid. After refilling, check the fluid 1. Park the vehicle in a service position. level. Refer to “Service position” in chapter 8. Changing the differential gear oil 2.
  • Page 231 8. INSPECTION AND MAINTENANCE Topping up the power steering oil Oil filter cartridge Check the oil level using the dipstick provided in the reservoir. Replace the oil filter cartridge every WARNING t i m e t h e p o w e r s t e e r i n g o i l i s changed.
  • Page 232 8. INSPECTION AND MAINTENANCE Checking and changing the clutch Precautions when handling clutch • Open the front panel and check fluid fluid the fluid level in the clutch reser- voir. • Since the clutch fluid has a high CAUTION • The fluid level is correct if it is tendency to absorb moisture, it We strongly recommend use UD...
  • Page 233 Vehicle authorised UD Trucks dealer. components such as the engine, • Remove dirt on and around the gearbox and rear axles etc., must...

  • Page 234: Fuel Filter

    8. INSPECTION AND MAINTENANCE 8.5 Fuel filter Replacement procedure 1. Park the vehicle in service position. Inspection and replacement Refer to “Service position” in chap- F u e l m u s t b e f i l t e r e d b e f o r e ter 8 s u p p l y i n g i t t o t h e c o m b u s t i o n chambers.
  • Page 235 8. INSPECTION AND MAINTENANCE 5. Remove the filter assembly. 8. Clean the filter housing with diesel. 10.Lubricate the seal with Diesel. 6. Disassemble the filter and O-ring. 9.Check the flapper valve assembly and drain gasket for damage. 11. Lubricate the O-ring with oil. Replace with new part if damaged.
  • Page 236 8. INSPECTION AND MAINTENANCE 13. Install the filter assembly. 15. Prime the fuel system. Refer to “Fuel system priming” in Chapter 8. 25 Nm (18 lb ft) Tightening torque to 16. Start the engine and check for fuel leaks. NOTE D o n o t i n c r e a s e t h e e n g i n e speed above the idle speed, if you do, any air pockets in the...
  • Page 237 8. INSPECTION AND MAINTENANCE Draining water from the fuel filter Procedure for draining the water Drain the water whenever the red NOTE float ring is floating in the chassis mounted filter. A l w a y s u s e a c o n t a i n e r t o collect the fuel.

  • Page 238: Priming The Fuel System

    Priming option is available on main filter only. DANGER After starting the engine, check for fuel leakages from any of the components of the fuel system. If leaks are found, stop the engine and contact the nearest authorised UD Trucks dealer. 8-32...

  • Page 239: Battery

    This procedure must therefore be carried out by a authorised UD Trucks dealer. Some of the vehicle are fitted with maintenance free batteries, if you have any clarification please contact authorised UD Trucks dealer for assistance.. 8-33...

  • Page 240: Tyres

    8. INSPECTION AND MAINTENANCE 8.8 Tyres Rotating the tyre position Ty r e r o t a t i o n f o r n e w t y r e s o f same size and tread T h e t y r e w e a r d e p e n d s o n r o a d conditions, the cargo and the way brakes and steering are used.
  • Page 241 8. INSPECTION AND MAINTENANCE Rotation pattern for vehicles equipped with steer (RIB) pattern on the front axle and drive (LUG) pattern on rear axles For 4x2 For 6x2 8-35...
  • Page 242 8. INSPECTION AND MAINTENANCE Recommended tyre rotation for trailers - “wheel carriage”. 8-36...
  • Page 243 8. INSPECTION AND MAINTENANCE Precaution when rotating the tyre position Specified range of differences in the outer diameter of multiple tyres Do not install the tyres with different outer diameters beyond the specified Within 12 mm r a n g e o n m u l t i p l e w h e e l s ( r e a r wheels).
  • Page 244 Contact the nearest • Check for deformation on the authorised UD Trucks dealer. wheel for any damage. If damage screw portion of the bolts and is found, replace the part immedi- Check whether wheel nuts have wheel nuts.
  • Page 245 8. INSPECTION AND MAINTENANCE JIS front wheel nut assembly for LHS JIS rear wheel nut assembly LHS NOTE The JIS wheel nuts for the right side of the vehicle has a right hand thread type and the letter “R” is stamped on the hub bolt. The wheel nuts for left side of the vehicle vary between left hand thread and right hand...
  • Page 246 8. INSPECTION AND MAINTENANCE Removing wheel Front wheel - ISO Type • Park the vehicle in a service position. Refer to “Service position” in chapter 8. • Loosen the nuts with a wheel nut spanner. Loosen the nuts until they can be turned by hand.
  • Page 247 8. INSPECTION AND MAINTENANCE Rear wheel - ISO Type Wheel Installation Using the tyre lever, attach the wheel disc by aligning its bolt holes with the hub bolts. Apply a light coating of engine oil to the wheel nut thread (only for JIS type), threads of the inner nuts and hub bolts.
  • Page 248 8. INSPECTION AND MAINTENANCE Position the wheels so that the hub bolts are in the centre of the bolt hole and then pre-tighten the wheel nuts. Loosen the jack and lower the tyres slowly. Start tightening the wheel nuts by 3 turns in a diagonal sequence and finally tighten them to the specified torque.
  • Page 249 In loose during driving. Make sure that that case, have the problem rectified the chain is not twisted. Turn the at authorised UD Trucks dealer. crank handle to the right (clockwise) for lifting. • After lifting, fix the wheel by tight- ening with the crank handle.
  • Page 250 8. INSPECTION AND MAINTENANCE Apply a force of more than 294 Wheel end assembly Nm {30 kgf} at handle edge when The front wheel bearing uses oil as a WARNING tightening. An adult turning the l u b r i c a n t . A l w a y s u s e t h e U D handle with one hand at full force •...
  • Page 251 8. INSPECTION AND MAINTENANCE Wheel studs/bolts R e p l a c e t h e s t u d s w h i c h a r e adjacent (both sides) to the damaged s t u d . I f t w o o r m o r e s t u d s a r e damaged, replace all the studs in the hub.

  • Page 252: Using The Jack

    8. INSPECTION AND MAINTENANCE 8.9 Using the jack Jacking points Rear wheel Jacking procedures Front wheel WARNING • Place the jack under the front axle • Place the jack under the rear axle • Do not start the engine while as shown below.
  • Page 253 8. INSPECTION AND MAINTENANCE If vehicle is to be jacked up at the • Place the jack under the jacking CAUTION r o a d s i d e b e c a u s e o f a f l a t t y r e , point and fix it securely by turning select a safe location where traffic is the auxiliary screw.
  • Page 254 If the tyre size or brand needs to be changed, contact authorised UD Trucks dealer. NOTE S w i t c h O F F t h e i g n i t i o n b e f o r e changing the tyres if the vehicle has ABS.

  • Page 255: Lights And Fuses

    8. INSPECTION AND MAINTENANCE 8.10 Lights and fuses Front lamps Rear lamps 1. Position lamp 1. Turn indicator/Hazard lamp 2. Low beam 2. Stop lamp 3. High beam (and DRL if equipped) 3. Rear position lamp 4. Turn indicator/Hazard lamp 4.
  • Page 256 8. INSPECTION AND MAINTENANCE Replacing the head light low beam 3. Open the cover. 5. Remove the bulb from the socket. bulb 1. Park the vehicle in a service position. Refer to “Service position” in chapter 8. 2. Tilt the cab. Refer to “Tilting the cab”...
  • Page 257 8. INSPECTION AND MAINTENANCE Replacing the head light high 7. Install the socket by pushing into 3. Open the cover. beam bulb the bulb holder. 1. Park the vehicle in a service position. Refer to “Service position” in chapter 8. 2.
  • Page 258 8. INSPECTION AND MAINTENANCE 5. Take out the bulb. 8. Make sure that bulb is fixed firmly. 6. Insert the new bulb. 9. Install the cover. 7. Rotate the bulb clockwise. 10. Lower the cab. Refer to “Lowering the cab” in Chapter 8 8-52...
  • Page 259 8. INSPECTION AND MAINTENANCE Replacing the position lamp 1. Park the vehicle in a service position. 4. Remove the bulb. 6. Insert and rotate the bulb assembly Refer to “Service position” in clockwise direction . chapter 8. 2. Tilt the cab. Refer to “Tilting the cab”...
  • Page 260 8. INSPECTION AND MAINTENANCE Replacing the indicator lamp bulb 3. Rotate the socket in anti-clockwise 5. Remove the bulb. direction. 1. Park the vehicle in a service position. Refer to “Service position” in chapter 8 2. Tilt the cab. Refer to “Tilting the cab”...
  • Page 261 8. INSPECTION AND MAINTENANCE Replacement of fog lamp - if 7. Insert the bulb and the socket. 4. Disconnect the cable. equipped 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 262 8. INSPECTION AND MAINTENANCE Replacing the side indicator lamp 6. Replace the bulb. 8. Secure the cover. 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 263 8. INSPECTION AND MAINTENANCE 5. Replace the bulb. 7. Install the cover. 3. Remove the bulb assembly from the cover. Replacing the front end outline 6. Install the bulb assembly and lock marker lamp 4. Replace the bulb. 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 264 8. INSPECTION AND MAINTENANCE Front end outline marker lamp Replacing the cab living room replacement lamp - if equipped 1. Apply parking brake. 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 265 8. INSPECTION AND MAINTENANCE 4. Remove the lamp assembly by 6. Remove the screws. 8. Install the new lamp. moving it forward and disassemble the lamp connector. 7. Remove the lamp housing. 9. Fix the connector and position the lamp assembly with hooks. 5.
  • Page 266 8. INSPECTION AND MAINTENANCE Replacing the cab reading lamp 10. Install the screws. 4. Replace the bulb. 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 267 8. INSPECTION AND MAINTENANCE Replacing the tail lamp bulbs 3. Replace the bulb. 4. Install the cover and secure with screws. 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n .
  • Page 268 8. INSPECTION AND MAINTENANCE Replacing the number plate lamp (If equipped) 1 . P a r k t h e v e h i c l e i n a s e r v i c e p o s i t i o n . R e f e r t o “ S e r v i c e position”...
  • Page 269 8. INSPECTION AND MAINTENANCE Replacing the side marker lamp 3. Replace the bulb. 3. Remove the nuts (1). 1 . P a r k t h e v e h i c l e i n a s e r v i c e 4.
  • Page 270 8. INSPECTION AND MAINTENANCE 7. Remove the gasket. 9. Install the lamp (4). 13. Connect the connector. 10. Install the washers (3). 11. Install the spring washers (2). 12. Install the nuts (1). 8. Install the new gasket. NOTE Make sure that the sealing gasket is properly aligned and secured in the channel housing.
  • Page 271 1. Fuse OK authorised UD Trucks dealer. 2. Burned Fuse Replacing the relay S o m e f u s e s m a y n o t b e u s e d ,...

  • Page 272: Mirror

    8. INSPECTION AND MAINTENANCE 8.11 Mirror Mirror JPY (Japanese) Mirror class 2 and 4 - RHD Image on mirror • Make sure that the side and rear of the vehicle can be seen in the main mirror. The right side, left s i d e a n d r e a r o f t h e v e h i c l e should be visible in the wide angle mirror.
  • Page 273 8. INSPECTION AND MAINTENANCE Rear view mirror - if equipped Mirror arm drive position Mirror electrical adjustment - if JPY Mirror equipped The main arm will be marked with Adjust the mirror with the switch letter L (Wide arm) or M (Medium provided on the centre console.

  • Page 274: Coolant

    UD Trucks dealer. 8-68...
  • Page 275 8. INSPECTION AND MAINTENANCE Replenishing the coolant Checking and cleaning the radiator Cooling fan and fan shroud 1. Stop the engine. To maintain the efficiency of the C h e c k t h e c o o l i n g f a n a n d f a n cooling system and keep the engine s h r o u d t o m a k e s u r e t h e y a r e 2 .
  • Page 276 8. INSPECTION AND MAINTENANCE DANGER Keep your hand away from the fan when the engine is running. 8-70...

  • Page 277: Brake

    8. INSPECTION AND MAINTENANCE 8.13 Brake Brake pedal play and braking per- formance WARNING Inspection interval: Daily • Make sure that brake pedal area is free of foreign objects such as • Press the pedal gently to check empty cans and gravel etc. the play.
  • Page 278 If damage is found, con- brakes are applied.If you can hear tact the nearest the noises, the rivet securing the authorised UD Trucks dealer and brake lining may be loose. Contact have the vehicle inspected. the nearest authorised UD Trucks...
  • Page 279 8. INSPECTION AND MAINTENANCE Performance of the parking brake NOTE NOTE Inspection interval: Every month Stop the vehicle on a dry slope (not T h e H o r n i s a c t i v a t e d i f t h e Be aware of the traffic conditions exceeding 18% slope), apply the door is opened when parking...
  • Page 280 8. INSPECTION AND MAINTENANCE Air actuated type Checking the axle shaft bolt Condition of reflector and license plate Inspection interval: Every 3 months • Check for dirt or damage on the Tighten the axle shaft bolt to the reflector and license plate. s p e c i f i e d t o r q u e u s i n g a t o r q u e wrench.
  • Page 281 8. INSPECTION AND MAINTENANCE Air cleaner Inspection period NOTE If the air cleaner filter is clogged, it Inspection interval: Every year. In Euro-4 and Euro-5 vehicles will produce black smoke from the Inspection procedures some white smoke is visible exhaust. Check and replace the filter sometimes in the starting, this is on a regular basis.
  • Page 282 NOTE be serviced at the nearest authorised UD Trucks dealer. with water. W h e n u s i n g a h i g h p r e s s u r e...
  • Page 283 8. INSPECTION AND MAINTENANCE Air dryer CAUTION Failing to replace the air dryer at the recommended intervals will result in consequential damage to the pneumatic systems and components. CAUTION Do not step/stand on the cooling coil. 1. Air dryer 2. Silencer Check if air is being exhausted from the air dryer silencer.

  • Page 284: Tools

    8. INSPECTION AND MAINTENANCE 8.14 Tools Storage box - if equipped Basic tool kit - if equipped Complete tool kit - if equipped 1. Socket wrench 1. Decal The storage box mounted on the 2. Extension bar 2. Pliers 3. Screwdriver chassis can be used for storing The tool kit provided is stored behind 4.

  • Page 285: Wiper Blade

    8. INSPECTION AND MAINTENANCE 8.15 Wiper blade Replacement procedure 4. Press the lock and remove the wiper. 5. Replace the wiper blade and lock 1. Park the vehicle in a service p o s i t i o n . R e f e r t o “ S e r v i c e position”...

  • Page 286: Washing The Vehicle

    8. INSPECTION AND MAINTENANCE 8.16 Washing the vehicle Precautions when washing the High pressure washing vehicle CAUTION High pressure wash shall not be directed on electrical components ie. Prevent water from coming into head lamps and lamp connectors, c o n t a c t w i t h t h e e l e c t r i c a l electrical connections components, Failure to comply...
  • Page 287 8. INSPECTION AND MAINTENANCE Precautions when washing the underbody When washing the underbody, do not d i r e c t t h e j e t o f w a t e r f r o m a pressure washer on to the steering shaft joint, sector shaft joint or rubber boots of the drag link and tie rod.

  • Page 288: Handling The Exhaust

    8. INSPECTION AND MAINTENANCE 8.17 Handling the exhaust (applicable to Euro IV, V or equivalent standard) Do not kick or strike the silencer the ignition is turned OFF. Therefore, NOTE wait for at least 120 seconds before CAUTION disconnecting the battery cable or Not applicable to Euro III or electrical system connectors when Do not climb onto, stand on or...
  • Page 289 8. INSPECTION AND MAINTENANCE Do not modify the tail pipe Only use the urea water solution (AdBlue) specified by UD Trucks which complies with ISO 22241-1. CAUTION • The specified urea water solution Do not modify the tail pipe, it will...
  • Page 290 8. INSPECTION AND MAINTENANCE Handling filler cap Attaching the cap CAUTION • Turn the cap to the right until it locks. Do not drive the vehicle when the AdBlue tank is empty. • Insert the AdBlue tank key and turn it 90° to the right to lock the cap.
  • Page 291 8. INSPECTION AND MAINTENANCE In the event of a fire or leak • Urea water solution (AdBlue) is non-flammable. Move it to safe location if there is a fire. • If urea water solution (AdBlue) is spilled, wash it off with water. It can be disposed of by diluting it with a large amount of water and then pouring it into the drain.

  • Page 292: Fifth Wheel

    8. INSPECTION AND MAINTENANCE 8.18 Fifth wheel Inspection and lubrication WARNING It is recommended to carry all the maintenance to be per- formed by a authorised UD Trucks dealer. All maintenance must be performed when the tractor is uncoupled from the trailer.

  • Page 293: Storing The Vehicle

    • Clean the vehicle thoroughly. • Apply lubricant and grease to all UD Trucks dealer for assistance. • C h e c k t h e o i l a n d o t h e r f l u i d the points requiring it.

  • Page 294: Lubrication With Grease

    8. INSPECTION AND MAINTENANCE 8.20 Lubrication with grease The vehicle should be lubricated with grease periodically. Use a cloth to wipe all dust and dirt from the grease nipples, and then apply the grease. After applying the grease wipe off any excess grease. For intervals for greasing lubrication refer to “Maintenance schedule”...
  • Page 295 8. INSPECTION AND MAINTENANCE For 6x2 RIGID 1. Front panel lock x 2 2. Front king pin x 2 3. Steering column x 1 4. Clutch release bearing x 1 5. Brake shaft rear x 8 6. Front suspension x 6 7.
  • Page 296 8. INSPECTION AND MAINTENANCE For 4x2 TRACTOR 1. Front panel lock x 2 2. Front king pin x 2 3. Steering column x 1 4.Clutch release bearing x 1 5. Brake shaft rear x 4 6. Front suspension x 6 7.

  • Page 297: Maintenance Schedule

    • Frequent stop and starting UD Genuine Parts, should be used for any maintenance, service or repair work. Please contact your authorised UD Trucks dealer for complete information on the lubrication points, oils and fluids, service intervals and service contract.
  • Page 298 9. MAINTENANCE SCHEDULE Torque tightening intervals Contact your nearest authorised UD Trucks dealer for a complete list of torque tightening points and intervals. First Torque tightening intervals Items Kilometres x 1000 100 120 140 160 180 200 220 Remarks Months...
  • Page 299 9. MAINTENANCE SCHEDULE Grease lubrication Contact your nearest authorised UD Trucks dealer for a complete list of lubrication points and intervals. Grease lubrication intervals Items Kilometres x 1000 100 120 140 160 180 200 220 Remarks Months Steering column Front king pin...
  • Page 300 9. MAINTENANCE SCHEDULE...

  • Page 301: Emergency Procedures

    10. EMERGENCY PROCEDURES 10. EMERGENCY PROCEDURES 10.1 When there is problem Precautions in the event of a break- • Place the warning signs around • For repairs involving the use of down t h e v e h i c l e t o i n d i c a t e t h e a jack on the road, the vehicle breakdown.
  • Page 302 12.0 to 14 T 15.0 to 17 T 18.0 to 19 T NOTE 25.0 to 26 T* *For 6x2 If the vehicle doesn't move even after releasing the parking brake manually, have it inspected by the nearest authorised UD Trucks dealer. 10-2...
  • Page 303 10. EMERGENCY PROCEDURES Towing Using a tow brace Rear towing brace is designed for e m e r g e n c y s i t u a t i o n t o p u l l t h e Use a rigid towrope.
  • Page 304 10. EMERGENCY PROCEDURES Precautions when towing If you have a flat tyre or tyre burst NOTE while you are driving Do’s The maximum pulling capacity of • Always use front tow brace to tow DANGER the towing hook is 2.5 ton, do not the vehicle.
  • Page 305 10. EMERGENCY PROCEDURES If there is a problem with the air suspension CAUTION Do not drive the laden vehicle if t h e r e i s p r o b l e m w i t h a i r suspension.

  • Page 306: Jump Start

    Always use a heavy duty jumper engine in a cold region, start the explode. Charge the battery cable for a large vehicle. Ask the after the fluid has been topped nearest authorised UD Trucks dealer for the correct jumper cable. 10-6...
  • Page 307 10. EMERGENCY PROCEDURES engine of the vehicle supplying the battery power and wait for several minutes before starting the engine of the vehicle with the discharged battery. • After the engine has started, disconnect the jumper cables in t h e r e v e r s e o r d e r u s e d f o r connection.
  • Page 308 10. EMERGENCY PROCEDURES 10-8...

  • Page 309: Service Data

    11. SERVICE DATA 11. SERVICE DATA 11.1 Maintenance standard For more information on the items below, contact your authorised UD Trucks dealer. Item Maintenance standard Remarks 1.8 ± 1 mm at axle unladen condition FAL 4.2 Toe-in 3.8 ± 1 mm at axle unladen condition FAL 5.0...
  • Page 310 11. SERVICE DATA 6 Stud 8 Stud 10 Stud Disc wheel ISO 670 ± 30 Nm Wheel nuts torque 405 ± 25 Nm 575 ± 25 Nm 275 ± 45 Nm Front suspension 540 ± 70 Nm FAL 6.5 Suspension bolt torque Rear leaf suspension 540 ±...
  • Page 311 1) The right viscosity number of oils according to the climatic condition is referred to Recommended SAE viscosity number”, page 11-5 and 11-6 2) For oil refill contact authorised UD Trucks dealer. 3) 40% dilution for temperatures below -25 ˚...
  • Page 312 11. SERVICE DATA Capacities (approximately) Total engine oil volume Oil volume between dipstick Title Engine including approximate vol- Remarks Max - Min (litres) ume for oil filter (litres) GH5E 13.5 Engine oil 20.5 GH8E Title Engine Climate unit Capacity (litres) Remarks CU-MCC4,ST1006 22.5...
  • Page 313 11. SERVICE DATA Variant Gearbox Standard oil Gear box with PTO oil Title Remarks (Model) volume (litres) volume (liters) ST1306 11.5 12.5 (F6S13T) 6 Speed ST1006 11.5 12.5 (F6S10T) ST1109 9 Speed Gearbox ST1199 Allison 2500 AL256 For oil refill contact authorised UD Trucks dealer.
  • Page 314 11. SERVICE DATA Recommended SAE viscosity number Use oil with the correct viscosity value for the climatic condition of the area in which the vehicle is used. Engine oil Gearbox oil 11-6...
  • Page 315 11. SERVICE DATA Grease quality The requirements for lubricating grease are as follows. • High grade wheel-bearing grease should be used. • The grease should be mineral-oil based. • The grease should be lithium or lithium complex type. • The grease should contain EP and anti-rust additives. •...
  • Page 316 11. SERVICE DATA Diesel fuel Fuel composition plays an important role in engine function, service life and emission pattern. In order to achieve the specified power output and fuel economy and meet the emission requirements stipulated by the authorities, you must only use fuels which comply with legal requirements and national and international standards.
  • Page 317 11. SERVICE DATA Fifth wheel Variant Fifth wheel Model No. D-value King pin size Max vertical load Fifth wheel height KPSIZE50 FW20-185 150 kN 50 mm 20 tonne 185 mm The D value is the theoretical reference value for the horizontal forces in the towing vehicle and the trailer and D value is used as the basis for horizontal loads in the dynamic tests 11-9...
  • Page 318 11. SERVICE DATA Engine specification GH5E GH5E210 EU3 GH5E180 EU3 Designation GH5E240 EU4 GH5E210 EU4 Power, net 180 hp (2200 rpm) 210 hp (2200 rpm) 240 hp (2200 rpm) Torque, net 750 Nm (1200 - 1600 rpm) 825 Nm (1200 - 1600 rpm) 900 Nm (1300 - 1600 rpm) No.
  • Page 319 11. SERVICE DATA Engine specification GH8E GH8E280 EU3 GH8E250 EU3 GH8E280 EU4 Designation GH8E250 EU4 GH8E280 EU5 GH8C250 EU5 GH8C280 EU5 Power, net 250 hp 280 hp 950 Nm (1100 - 1700 rpm) 1050 Nm (1100 - 1700 rpm) Torque, net 950 Nm (1000 - 1800 rpm) 1050 Nm (1100 - 1800 rpm) No.
  • Page 320 11. SERVICE DATA Electrical system - 24 Volts Battery (Quantity 2 nos.) Parameter Specification Voltage 12.5 V C20 capacity (for ref only) 110 Ah CCA at -18° 600 CCA Recommended testing specific gravity volume (20°C) 1.280 ± 0.005 g/cm³ Filled weight 29.2 ±1.6 kg Weight without acid 20.1 kg...
  • Page 321 11. SERVICE DATA SI. No. Description Category Specification Bulb - Head light, High beam and DRL 24V 60/20W Bulb - Head light, Low beam 24V 70W Bulb - Head Light, Front position lamp 24V 5W Bulb - Front fog lamp 24V 70W Bulb - Front turn indicator PY21W...

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Croner rigid 4 x 2Croner rigid 6 x 2Croner tractor 4 x 2

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