TO THE OWNER This Owner’s Manual has been prepared to provide you with important oper- ation, maintenance and safety information relating to your UD Trucks vehi- cle. We urge you and others operating the vehicle to carefully read this manual and follow the recommendations for operation, maintenance, and safety. Failure to follow these recommendations could result in serious injury or death to those riding in this vehicle or bystanders. This manual should be considered a permanent part of the vehicle and must be kept with the vehicle at all times. This Owner’s Manual should accompany the vehicle when sold to provide future owners and opera- tors with important operation, safety and maintenance information. The characteristics and functions of this vehicle make its driving and han- dling different from that of a car. Before operating your vehicle, familiarize yourself and others operating the vehicle with these differences. The Warranty and Service Booklet provided with each vehicle contains important information about warranty and service matters. Keep it with your vehicle at all times and present it to your authorized UD Trucks dealer or other service facility when service is required. When service or other assistance is required, consult your UD Trucks dealer. If you have a problem that has not been handled to your satisfaction, contact UD Trucks North America, Inc., 7900 National Service Road Greensboro, NC 27409. 1206-20710-K1 All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not per- mitted without written authorization from UD Trucks Corporation. UD Trucks may change the contents without notice and without incurring obligation. © 2012 UD Trucks Corporation i CLEAN IDLE CERTIFIED CALIFORNIA PROPOSITION 65 FEDERAL HIGHWAY LABEL FOR U.S. WARNING ADMINISTRATION Make sure that the following clean REGULATION engine idling certified label is affixed Various regulations relating to vehi- to the left side of the corner back WARNING cle performance, equipment, and outer. By the CARB regulation listed Engine exhaust, some of its safety have been issued by the below, the label must be affixed constituents, and certain vehi- Department of Transportation. These there to prove that the new vehicle cle components contain or regulations include, but are not lim- with diesel engine manufactured emit chemicals known to the ited to the Federal Motor Vehicle from Jan., 2008 conforms to this reg- State of California to cause Safety Standards and the Federal ulation. cancer and birth defects or Motor Carrier Safety Regulations. other reproductive harm. In Other federal, state and local regula- CARB § 1956.8. Exhaust addition, certain fluids con- tions may also apply. Final stage Emission Standard and tained in vehicles and certain manufacturers and motor carriers Test Procedure products of component wear are responsible for knowing and (a) (b) Heavy-Duty Diesel contain or emit chemicals complying with all regulations that Engine Idling Requirements known to the State of California may apply to the vehicle. A finished to cause cancer and birth vehicle may also require devices that defects or other reproductive are not specified in the regulations. harm. Body builders, subsequent stage manufacturers and carriers must determine what safety devices are necessary for the safe operation of the vehicle. ii WARNING Making modifications to vari- ous parts, components and systems of the vehicle, such as brake and steering system can adversely affect the qual- ity, reliability and operation of your vehicle and could result in property damage, serious injury or death. Such modifica- tions must be avoided. iii iv TABLE OF CONTENTS INTRODUCTION AND SAFETY..................... 1-1 Door Window (Power Window) .......................... 5-4 When Reading the Manual................................. 1-1 DRIVING POSITION........................................6-1 New Vehicles Break-in Period............................ 1-2 Seats .................................................................. 6-1 Keys ................................................................... 1-2 Seat Belts ........................................................... 6-5 Fuel .................................................................... 1-3 Steering Wheel................................................... 6-7 Metric Mismatch ................................................. 1-3 Abbreviation ....................................................... 1-4 INSTRUMENTS AND CONTROLS .................7-1 Ignition Key Switch............................................. 7-3 IDENTIFICATION............................................ 2-1 Meters and Gauges............................................ 7-5 Vehicle Identification Number (VIN) ................... 2-1 Multi-display Monitor ........................................ 7-15 Unit Identification................................................ 2-2 Warnings and Indicators................................... 7-26 BEFORE DRIVING YOUR VEHICLE ............. 3-1 Buzzers ............................................................ 7-30 Overloading........................................................ 3-2 Warnings .......................................................... 7-31 Towing Trailers ................................................... 3-3 Warning and indicator lights ............................. 7-43 Safety Reminders............................................... 3-6 Switches and Buttons....................................... 7-53 Daily Maintenance.............................................. 3-6 DPF System ..................................................... 7-69 EGR System Operation.....................................3-11 Levers and Control........................................... 7-75 UD Trucks, US2010 Emissions solution............3-11 ACCESSORIES...............................................8-1 Handling of the exhaust emission control system .................................................. 3-12 HEATER OR AIR CONDITIONER CONTROL.........9-1 Vehicle Labels.................................................. 3-24 Air Conditioner.................................................... 9-1 ENTERING AND LEAVING THE CAB ........... 4-1 VEHICLE OPERATION .................................10-1 Operating Precautions...................................... 10-1 DOORS AND WINDOWS ............................... 5-1 Break-in Precautions........................................ 10-2 Door ................................................................... 5-1 Vehicle Loading................................................ 10-2 Keyless Entry System ........................................ 5-2 v Towing Trailers ................................................. 10-3 Steering System ............................................. 11-60 Starting the Engine........................................... 10-4 Service Brake System.................................... 11-62 Warming up Engine.......................................... 10-7 Clutch ............................................................. 11-65 Stopping the Engine......................................... 10-9 Suspension..................................................... 11-67 Driving on Grades .......................................... 10-10 Windshield Washer Fluid................................ 11-68 Driving in Difficult Conditions ..........................10-11 Outside Mirrors............................................... 11-69 Operating with Manual Transmission..............10-11 Emission Control Systems ............................. 11-70 Operating with Automatic Transmission......... 10-14 Noise Control System..................................... 11-73 Brake Operation ............................................. 10-33 Battery............................................................ 11-75 Parking your Vehicle ...................................... 10-35 Lights.............................................................. 11-78 After Parking Your Vehicle.............................. 10-36 Fuses.............................................................. 11-80 In Cold Weather ............................................. 10-36 Blower Motor Filters ....................................... 11-82 Idle Shutdown ................................................ 10-38 Wheels and Tires ........................................... 11-83 Appearance Care ........................................... 11-89 VEHICLE SERVICE AND MAINTENANCE...11-1 Clean Air Act .....................................................11-1 IN CASE OF EMERGENCY/ Maintenance Intervals .......................................11-3 TROUBLESHOOTING............................................12-1 Grease Lubrication Points...............................11-16 Engine Overheating.......................................... 12-1 Before Performing Maintenance .....................11-19 Jump Starting ................................................... 12-3 Cab..................................................................11-20 Tire Change...................................................... 12-6 Engine Cooling System...................................11-24 Towing .............................................................. 12-9 Engine Oil and Oil Filters ................................11-31 Troubleshooting.............................................. 12-13 Fuel System ....................................................11-37