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UD Trucks QUESTER Series, Owner'S Manual

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UD Trucks QUESTER Series Owner'S Manual Download Page 180

8.INSPECTION AND MAINTENANCE

8-32

Parking lamp replacement
1.

Apply parking brake.

2.

Turn OFF the ignition switch.

3.

Turn OFF the main switch.

4.

Disconnect the electrical connec-
tor.

5.

Unlock the bulb by rotating it 
clockwise.

6.

Remove the bulb and replace with 
a new bulb.

7.

Secure the bulb by rotating it 
clockwise.

8.

Connect the electrical connector.

 Side indicator lamp replacement

1.

Apply parking brake.

2.

Turn OFF the ignition switch.

3.

Turn OFF the main switch.

4.

Remove the cover (2) by remov-
ing screw (1).

5.

Unlock the bulb and remove.

6.

Replace with a new bulb and lock 
it.

7.

Install the cover.

Summary of Contents for QUESTER Series

Page 1: ...OWNER S MANUAL QUESTER Series Keep with vehicle at all times UD Trucks Corporation...

Page 2: ...ons Ultimately the real winners are the ones who keep on running Like a long distance runner consistently and reliably mile after mile year after year Quester delivers what transport companies around...

Page 3: ...ler to prolong life of the vehicle and reduce maintenance cost In order to retain the safety reliability and long life of the vehicle UD Trucks recommends you to heed our advice regarding the driving...

Page 4: ...he new owner This Quester is equipped with software systems which record various information about the vehicle machine engine and this information is transferred from the vehicle to UD Trucks and used...

Page 5: ...0 1 17 Telematics gateway 1 31 2 GETTING IN AND OUT OF THE CAB 2 1 2 1 When getting into the cab 2 1 2 2 Doors 2 3 2 3 Seats 2 5 2 4 Seat belts 2 11 2 5 Steering wheel adjust 2 12 3 EQUIPMENT DESCRIPT...

Page 6: ...ine oil filter 8 9 8 4 Fuel filter 8 10 8 5 Air bleeding of fuel system 8 16 8 6 Battery 8 17 8 7 Tyres 8 18 8 8 Jack up 8 27 8 9 Lights and fuses 8 30 8 10 Mirror 8 39 8 11 Coolant 8 40 8 12 Brake 8...

Page 7: ...ations and illustrations in this binder are not binding and UD Trucks reserve the right to change them at any point of time without prior information DANGER Indicates a potentially dangerous situation...

Page 8: ...ty of self vehicle and road failing which 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 LH...

Page 9: ...ntroduction This manual provides detailed explanations for working with QUESTER series vehicles as below Please read through and understand the Owner s manual before you drive the truck for the first...

Page 10: ...anagement System SI International System of Units EOL End Of Line TGW Telematics Gateway FRS Function Requirement Specification VIN Vehicle Identification Number GAW Gross Axle Weight GCC Gulf Coopera...

Page 11: ...ive industry Examples are GB 19147 2013 EN590 with nationally adapted cold requirements JIS KK 2204 These fuels perform better exhaust emissions than standard fuels and can therefore be recommended Wa...

Page 12: ...ibed on the equipment itself The driver or user has to familiarise the instructions for handling the fire extinguisher to use it properly in an emergency situation Fire extinguisher is located between...

Page 13: ...compartment box in high roof cab s and in the head console for standard cab s Roof hatch If equipped To open the roof hatch push up the latch handles It can be opened from one side front or rear or bo...

Page 14: ...first step on the right hand side of the truck open the door to view the vehicle identification plate VIN Location VIN number is punched on the chassis frame front on right hand side VIN Plate SEA and...

Page 15: ...ower VIN Plate Tractor China 1 Vehicle model 2 VIN number 3 Engine maximum net power 4 The total mass 5 Maximum allowable takeoff weight 6 Year month 7 Maximum design load 8 Curb weight 9 Engine model...

Page 16: ...in effect up to the date of 7 VIN 8 Category 9 Part number 10 Rear 11 Front Engine identification 1 Decal engine identification 2 Chassis no and serial no 3 Engine system data 4 Engine serial number 5...

Page 17: ...1 INTRODUCTION AND SAFETY 1 9 Axle identification plate location Solo axle Tandem axle Tandem axle Hub reduction Battery plate location 150 Ah 165 Ah and 180 Ah...

Page 18: ...r other areas Do not place items on the instru ment cluster or the dashboard DANGER Opening the door without required care and caution is dangerous and it could lead to an accident WARNING Do not adju...

Page 19: ...o the neutral position and make sure that the parking brake is applied WARNING Do not fasten or remove the seat belt while driving it is very dangerous WARNING Do not place loose objects such as tools...

Page 20: ...d shed or under poor ventilation leading to inhalation of harmful exhaust gases NOTE When starting the vehicle make sure that the area is free from obstacles around the vehicle There are areas that ca...

Page 21: ...imiter Driver information displays Foot brake long term use Avoid using the foot brake continuously for a extended period of time to avoid reduction in braking effect Do not rest the foot on the brake...

Page 22: ...d road CAUTION Do not use the cruise control on wet or snowy roads while raining hilly terrain regions with heavy traffic or on slippery roads turns and bends CAUTION Avoid having auxiliary brake cont...

Page 23: ...and impair visibility Switch to fresh air mode and continue driving after the fog is cleared WARNING If the bed is used while driving the person could be thrown around during a collision or emergency...

Page 24: ...n parking CAUTION Avoid parking the vehicle under trees to avoid bird droppings falling on the vehicle bird droppings are acidic and will cause the paint to wear out Avoid parking under trees which sh...

Page 25: ...e is OFF Use only tow truck to tow the vehicle CAUTION If the vehicle needs to be towed the propeller shaft should be disconnected to avoid damage to transmission DANGER Do not jump start the vehicle...

Page 26: ...the transmission gear lever is in neutral position the parking brake is applied Remove loose and heavy object in the cab and close the glove box and all doors Chock the wheels WARNING Tilt the cab co...

Page 27: ...hot to avoid burns from steam and hot coolant Allow the engine to cool completely before filling the coolant CAUTION Let the engine cool at idling speed before switching off the engine WARNING Do not...

Page 28: ...st away from tank when fueling WARNING Ensure that fuel filter is installed correctly make sure there is no fuel leak from the filter fuel leak can be dangerous and cause a fire if not rectified CAUTI...

Page 29: ...he auto stop does not operate when removing the noz zle temporarily to top up the fuel It is dangerous because the fuel may be spilled in such cases Please observe the precautions posted on the self s...

Page 30: ...e and cause an explosion CAUTION Loose or corroded battery terminals will make it difficult to start the engine and charge the battery which will shorten the life of the battery Connect and secure the...

Page 31: ...ension inspection Ensure care with the drive belt and other rotating parts while engine is running WARNING Make sure that no body parts are extended outside the window while operating the switch Faili...

Page 32: ...osition 2 Disconnect the battery s negative terminal 3 Be sure to ground the welding unit close to the weld contact area 4 When the work is complete check to make sure that all units are functioning n...

Page 33: ...heating that could result in a fire CAUTION Never use a wire in a blown out fuse change a new fuse according to the specified capacity CAUTION Do not remove the fuse from another circuit as a temporar...

Page 34: ...le s undercarriage do not directly apply steam or water from a high pressure washer on the steering shaft joint front axle drag link and tie rod dust covers CAUTION While washing ensure that no water...

Page 35: ...e exhaust gas after treatment The monitoring system will inform the user through warning lamps and fault messages Non erasable fault codes are set Possible derating of the engine depending on type of...

Page 36: ...on as the reason for the power reduction has ceased the power reduction will be deactivated the next time the engine goes to idle Power reduction occurs during any of the following events NOx level ex...

Page 37: ...ina IV engines AdBlue can also be sold and marketed under other names depending on the distributor and can be used as long as ISO standard 22241 is fulfilled AdBlue is not dangerous but should be hand...

Page 38: ...river top up with AdBlue If the tank for AdBlue is empty the following message is shown on the display along with the information lamp and the MIL symbol Fill the tank immediately with AdBlue Monitori...

Page 39: ...The control unit has a slot for a SIM card The GSM antenna is placed on the truck roof combined GSM GPS antenna GPS Satellite positioning 1 Antenna 2 Satellite 3 GPS connector 4 GSM connector 5 Telem...

Page 40: ...THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY...

Page 41: ...dles climb the1st step 3 Place the second foot on the 2nd step 4 Hold upper handle climb the 3rd step 5 Step onto the cab floor with the second foot WARNING Ensure care when getting in and out of the...

Page 42: ...D OUT OF THE CAB 2 2 6 Position comfortable in the driver s seat and release the grasp from the front upper handle 7 Close the door When getting out When getting out use the reverse process followed w...

Page 43: ...the inside pull the handle inner and push the door outwards When closing the door hold the handle and pull the door and close it gen tly There is a lock knob 2 pro vided for locking the door 1 Handle...

Page 44: ...ition 2 Unlock position 3 Insertion position Insert the ignition key and turn it towards the rear to lock the door and turning it towards the front will unlock the door Return the key to the insertion...

Page 45: ...the backrest s position During the adjustment the handle must be held in the lifted position and once the desired backrest position is achieved the handle must be released to lock the backrest The bac...

Page 46: ...ustment When the height adjuster is turned clockwise it stiffens the mechanical spring and when it is turned counterclockwise it softens the mechanical spring This allows the user to adjust the stiffn...

Page 47: ...e released to lock the backrest The backrest locks in steps of 3 The locking range is 36 from vertical to forward and 48 from vertical to rearward backward Seat tilt and height adjustment When the fro...

Page 48: ...lets the user to raise or lower the suspension for height adjustment The suspension can be adjusted up to a 100mm of maximum height possible Longitudinal seat adjustment When the slide rail handle is...

Page 49: ...released to lock the backrest The backrest locks in steps of 3 The locking range is 54 from vertical to backwards The locking range is 15 from vertical to forward and 39 from vertical to rearward back...

Page 50: ...2 GETTING IN AND OUT OF THE CAB 2 10 Centre seat If equipped Center seating position designated for use only when the vehicle is stationary DANGER Center seat should not be used when vehicle is moving...

Page 51: ...evice Precautions for wearing seat belts If the driver tries to drive without wearing the seat belt the warning light will illuminate to warn the driver when the ignition key is turned to ON or START...

Page 52: ...ock position 3 The telescopic adjustment allows the steering wheel to be moved up or down 1 Forward 2 Up 3 Backward 4 Down 4 The tilt adjustment allows the steering wheel to be moved forward or backwa...

Page 53: ...N 3 1 Instrumentation Instrument panel and controls 1 Air outlet 2 Storage box 3 Radio 4 Control panel climate unit 5 Steering wheel 6 Horn 7 Accelerator pedal 8 Brake pedal 9 Clutch pedal 10 Instrume...

Page 54: ...r trailer 10 Right turn indictor tractor rigid 11 Cab tilt 12 Engine fault 13 Fog lamp front 14 Engine pre heat 15 Door open 16 Seat belt reminder 17 Coolant level low 18 Engine oil pressure low 19 Hi...

Page 55: ...0 3000 RPM 2 Green zone 900 1400 RPM The tachometer shows the engine speed in revolutions per minute The green zone indicates economic driving Always keep the indicator within the green zone Speedomet...

Page 56: ...e has a warning lamp indicator Placed on right side where it is marked as H associated with it which is activated when the coolant temperature is high Fuel level gauge The gauge shows the approximate...

Page 57: ...railer Green 7 INFO Low severity White 3 CHECK Medium severity The diagnostic lamps are used with warning messages to indicate the severity of the message Yellow 8 Fog lamp rear Yellow 4 Dipped beam D...

Page 58: ...w 18 Engine oil pressure low Red 13 Fog lamp front Green 19 High beam Blue 14 Engine pre heat Yellow 20 Front and rear position lamp Green 15 Door open Yellow 21 AdBlue level low Blue 16 Seat belt rem...

Page 59: ...pressure high low Red 25 Differential lock between wheels engaged Red 30 ABS fault on Trailer Yellow 26 Differential lock between axles engaged Red 31 ABS fault on Tractor Rigid Yellow 27 Gear shift...

Page 60: ...essages can be active at the same time When a new message is activated the new message is shown instead of the old one if the new one has the same or higher priority If the vehicle message is displaye...

Page 61: ...u is controlled by two sorts of events Driver action events The user can control the display with the push buttons listed below Escape button 1 Down button 2 Up button 3 Enter OK button 4 Software eve...

Page 62: ...EQUIPMENT DESCRIPTION AND OPERATION 3 10 Driving menu The driving menu has the following choices in the following order Note The above diagram describes the different menus Full menu or non driving me...

Page 63: ...ERATION 3 11 When the vehicle is stationary the full or non driving menu can be accessed Note The above diagram describes the different menus The in the figure above indicates that this shall be visib...

Page 64: ...y which gauge it is For E g Fuel Data 1 Leg Fuel The leg fuel trip fuel is the fuel consumption Inst Fuel Instantaneous fuel consumption Leg Fuel DTE Distance to empty Inst fuel 3 Display Display Sett...

Page 65: ...ch also include driving menu Full menu or Non driving menu 6 Diagnostics Self test Telltale Indicator test Gauge test Display test Sound test Part Number EMS IECU ACM Parameter setting EMS IECU ACM Re...

Page 66: ...ter entering pass word Workshop ENTER OLD PASSWORD ENTER NEW PASSWORD Driver ENTER OLD PASSWORD ENTER NEW PASSWORD Note Default password for user is 1234 user can change the password after 9 Maintenan...

Page 67: ...Description 1 DRIVER ID for TGW 10 Beacon light 2 Horn selector 11 Interior light Only for high roof cab 3 Head lamp leveller 12 Front fog lamp 4 Engine PTO 13 Rear fog lamp 5 Transmission PTO 14 Swi...

Page 68: ...or 3 Head lamp leveller switch Head lamp leveling is done by rotating the switch knob based on the load conditions Position the switch in 0 when the vehicle is in unladen condition and adjust to other...

Page 69: ...NT DESCRIPTION AND OPERATION 3 17 6 ADR Switch if equipped 7 Diff lock Interaxles switch 7 Diff lock Interaxles and rear wheel 8 Bogie lift Bogie press switch 9 Working lamp 10 Beacon light switch if...

Page 70: ...3 EQUIPMENT DESCRIPTION AND OPERATION 3 18 11 Interior Light Switch 12 Front fog lamp 13 Rear fog lamp 14 and 18 Switch cover 15 16 17 Bodybuilder switch...

Page 71: ...on the driver side window door control panel NOTE To activate mirror heating function press the button for less than 2 sec this will function for a little time At lower temperatures if fog or snow is...

Page 72: ...3 EQUIPMENT DESCRIPTION AND OPERATION 3 20 Fuse and relays Fuse and relay centre decal is placed inside the dashboard on passenger side of the cab...

Page 73: ...3 EQUIPMENT DESCRIPTION AND OPERATION 3 21...

Page 74: ...ary brake 2 position Without cruise control and auxiliary brake 3 position Auxiliary brake To activate auxiliary brake the combination switch is pushed in downward direction Auxiliary brake with two p...

Page 75: ...ination switch to any one of the following 4 steady positions Wiper momentary active Washer can be controlled through the push button at the end of the combination switch it includes 1 rest position a...

Page 76: ...f return Direction indicator The direction indicator can be controlled by moving the combination switch up and down from neutral position parallel to the steering wheel When the combination switch is...

Page 77: ...ruise control make sure that the following conditions are met 1 Ignition switch should be in ON condition 2 Vehicle speed should be higher than or equal to 30 km h 3 Brake pedal should be in released...

Page 78: ...ressing the accelerator pedal Cruise control can be deactivated when the cruise control set button is pressed when the vehicle in cruise control mode switching the ignition key OFF the clutch is in pr...

Page 79: ...se gear The crawler gear is advised to be used when the vehicle is stuck in sand marshes pits etc It can also be used when starting with a heavy loaded on a hill 12 Speed The 12 speed transmission com...

Page 80: ...ow if the engine is running at a high RPM Refer to the maximum allowable RPM at each shift position in the below table Do not switch the range from High to Low if you are exceeding the maximum RPM whe...

Page 81: ...etc A PTO can be activated and deactivated by the PTO switch on the dashboard when the pre set conditions are met Engine mounted PTO Activate engine PTO 1 Apply the parking brake 2 Switch ON the engi...

Page 82: ...O Switch OFF the engine PTO switch Transmission PTO Activate transmission PTO 12 Speed 1 Apply the parking brake 2 Press down the clutch pedal and shift the gearshift lever to neutral low range NOTE A...

Page 83: ...ch OFF the transmission PTO switch 4 Release the clutch pedal NOTE Make sure parking brake is applied and the gearshift lever engaged in low range The parking brake indicator and the low range indicat...

Page 84: ...and shift the gearshift lever to neutral low range 3 Follow the range selection operation instructions 4 Switch ON the Transmission PTO switch on the dashboard 1 Transmission PTO ON 2 Transmission PT...

Page 85: ...2 Shift the gearshift lever in neutral position 3 Switch OFF the Transmission PTO switch 4 Release the clutch pedal NOTE Warning buzzer alarm sounds unless the parking brake is applied NOTE Make sure...

Page 86: ...SET to increase and hold on to RES SET to decrease the RPM Leave the combination switch to maintain the current engine rpm The RPM control through combination switch will be deactivated by pressing t...

Page 87: ...d in the instrument cluster The system will also help the driver to keep track of the driving behavior and driver s performance over a defined period of time or trips logged which the vehicle owner ca...

Page 88: ...to allow the driver to stay within the sweet spot during most normal operating conditions There may be situations where it is necessary to operate the engine outside the sweet spot especially with tr...

Page 89: ...3 EQUIPMENT DESCRIPTION AND OPERATION 3 37 Sweet spot data logging...

Page 90: ...Also check to see if any of the bolts attaching the fifth wheel to the chassis of the tractor vehicle are loose or missing The trailer and the tractor must be resting on the same flat surface which mu...

Page 91: ...mm behind the fifth wheel bracket pin 1 Use low gear to operate landing gear 2 Fifth wheel tilted position 3 100 150 mm 4 Move the tractor vehicle in slow speed towards the semitrailer keeping them a...

Page 92: ...y meet legal requirements Make sure that the air pressure in the tractor vehicle is correct by reading the pressure gauge on the instrument cluster The tractor vehicle will only be ready to move when...

Page 93: ...the semitrailer does not pull the tractor vehicle Apply the semitrailer brake and the parking brake of the tractor vehicle to chock the semitrailer wheels Lower the lifting device take proper care no...

Page 94: ...Hook the handle notch on unlock pin Disconnect the air hoses and the electric socket by returning them to their holders using safety equipment which is suitable for this operation release the tractor...

Page 95: ...tial lock while driving on a slippery surface the wheel on the slippery surface turns and the vehicle remains stationary 3 While driving on a slippery surface deactivate the differential lock only whe...

Page 96: ...611 The differential lock switch interaxles and rear wheels has three positions 1 OFF 2 Diff lock interaxle ON 3 Diff lock interaxles and rear wheels ON 1st position This deactivates the differential...

Page 97: ...move CAUTION Drive carefully when the differential lock is applied In order to avoid damages to the drive axle and gear never turn or drive on firm surfaces with the differential lock applied NOTE Ap...

Page 98: ...air bellows There are three operating conditions Normal condition Bogie press condition Bogie lift condition Different conditions can be achieved by pressing the bogie lift switch provided on the cab...

Page 99: ...blem of traction driver should press the switch to normal condition again to bring the tag axle to its normal position Bogie lift condition When the vehicle is in unladen or partially laden condition...

Page 100: ...ailer Reverse tractor truck very slowly The drawbar eye must be inserted into the middle of the funnel else the funnel the drawbar eye or the drawbar landing legs might be damaged NOTE The relevant na...

Page 101: ...ol pin in extended condition Move the tractor approximately 1 m and check again if the coupling is secured Closing the coupling manually 1 Release coupling pin with suitable tool 2 Strike hand lever k...

Page 102: ...e steering wheel It can be selected for air or disc horn by operating the horn selector switch on the dashboard Sun visor Sun visors are located on the interior just above the windshield designed with...

Page 103: ...essure Low pressure fuel filter When a monitored component function nears the critical state the driver is warned by caution lamp text and or buzzer The driver warning is activated Driver warnings are...

Page 104: ...e the front panel lock 2 Open the front panel with spring extended Front panel closing 1 Lower the front panel slowly 2 Push the front panel gently until it clicks into place 3 Make sure that the fron...

Page 105: ...4 ACCESSORIES AND AUDIO 4 1 4 ACCESSORIES AND AUDIO 4 1 Accessories Storage box 1 Storage box 2 Card holder 3 Door pocket 4 Ash box 5 Cup holder...

Page 106: ...holder This is used to hold bottle and cup Card holder This can be used to hold toll tickets cards as telephone cards and highway card WARNING Do not overload or place heavy objects in the head conso...

Page 107: ...ovided on the dashboard for mobile charging and others The maximum electric current limit is 5 A and 24 V Ash box Open the lid of the ash box to use it Always close the lid after use To clean ash box...

Page 108: ...ld Auto store 2 1 Preset button 1 tuner RDM MP3 random track on off 7 6 Preset button 6 tuner 12 Aux in 3 2 Preset button 2 tuner RPT MP3 repeat track on off 8 Select previous track MP3 player 13 LCD...

Page 109: ...d hold SET button to enter audio setting mode In audio setting mode press and to switch the audio setting items Turn the volume knob to change the item value After 1 minute without any setting operati...

Page 110: ...band Press and hold AST to activate auto store The unit will give a beep sound and then mute the display will blink When it has finished you will hear a beep sound again and the display will stop blin...

Page 111: ...USB memory device the display will show Audio mode Jazz Pop if selected current playing track number and the play time every 10 seconds Previous next track Press or to select the next previous track T...

Page 112: ...ETUP mode about 1 minute after the last operation OPTION Choice Usage or SETUP Long press of this button enters the SETUP mode REF 05 23 To select the start volume BEEP OFF 1 5 To select the beep soun...

Page 113: ...aerial and its connection RADIO Poor radio reception Check that the antenna is fully extended and properly connected Check that the negative terminal is connected to the earth chassis USB MODE PLAYER...

Page 114: ...THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY...

Page 115: ...position Opening and closing the window driver side If equipped The driver s side power window switch is used to open or close the window when pushed 1 or pulled 2 lightly 1st stage or automatically w...

Page 116: ...s are provided on inside of each door Opening and closing the passen ger s side window The passenger s side power window switch 1 is provided inside the passenger s doors The window moves down when th...

Page 117: ...NG 5 3 5 2 Air conditioner Air vent 1 Air blowing to wind shield 2 Air blowing to upper body 3 Air blowing to foot rest CAUTION Do not switch ON the blower when the engine is switched OFF it could dra...

Page 118: ...lled only AC LHD 4 Mechanical controlled vent unit LHD 5 Mechanical controlled HVAC RHD 6 Mechanical controlled Heater unit RHD 7 Mechanical controlled only AC RHD 8 Mechanical controlled vent unit RH...

Page 119: ...5 AIRCONDITIONING 5 5 Mechanical controlled HVAC RHD Mechanical controlled HVAC LHD 1 Temperature control knob 2 Fresh recirculation switch 3 Blower knob 4 Cooler ON OFF switch 5 Mode knob...

Page 120: ...5 AIRCONDITIONING 5 6 Mechanical controlled only heater unit RHD Mechanical controlled only heater unit LHD 1 Temperature control knob 2 Fresh recirculation switch 3 Blower knob 4 Mode knob...

Page 121: ...5 AIRCONDITIONING 5 7 Mechanical controlled only AC unit RHD LHD 1 Mode knob 2 Fresh recirculation switch 3 Blower knob 4 AC on Mode knob...

Page 122: ...contact nearest UD Trucks authorised dealer NOTE Use Freon HFC134a to help protect the environment Only use the specified refrigerant to charge the cooling system To protect the global environment do...

Page 123: ...or abnormal wear out Is the tyre tread groove depth enough Is the engine oil filled to the proper level Is the engine coolant filled to the proper level Has water condensation been removed from the ai...

Page 124: ...tread groove depth is less than 1 6 mm The tyres have 6 equally spaced locations TWI positions that indicate when the tread groove depth is less than 1 6 mm Replace the tyres with new ones when the t...

Page 125: ...on If any of the above conditions are found the vehicle should be placed out of service until the item can be repaired by UD Trucks authorised dealer Engine oil level Pull out the dipstick wipe out th...

Page 126: ...m the air reservoir Open the air reservoir drain cock and drain the water collected Make sure that the drain cock is closed completely after draining If a large amount of water is drained out there co...

Page 127: ...n the cap and check the washer reservoir fluid level If it is low add more washer fluid through the reservoir filler open ing Check to see if the washer fluid sprays out normally If it does not spray...

Page 128: ...r When the temperature drops to 20 C use 1 part of water When oil due to smog is stuck to the windshield use 1 5 parts water Engine starting performance and abnormal sounds Check if the engine starts...

Page 129: ...imilar to value in the table If it does not raise normally there could be a leak in the air system or other issues Contact an authorised UD Trucks authorised dealer immediately Check if the air pressu...

Page 130: ...n indicators are normal if they flash 60 to 120 times per minute Check the light lenses and reflectors are free from dirt and damage 1 Front end outline marker lamp 2 Front position lamp 3 Front direc...

Page 131: ...the driver can see clearly the front and rear side of the vehicle Fasten the seat belt correctly Starting the engine WARNING Do not place loose objects such as tools cans bottles mats etc on the cabin...

Page 132: ...clutch and brake pedals fully Then turn the ignition switch to the START position 1 LOCK 2 ACC 3 ON 4 START Stopping the engine Turn the ignition switch from ON 3 position to the ACC 2 position to st...

Page 133: ...in a safe place and take the required measures Decelerate before entering curves Braking while turning the steering wheel will cause the wheels to lock up and the tyres to slip This will not only resu...

Page 134: ...bove Always maintain the engine rpm in green zone while driving When the engine rpm exceeds the allowable maximum rpm the warning message display will turn on and the overrun warning buzzer sounds to...

Page 135: ...correctly Then always use the auxiliary brake to maintain a safe speed at all times Shifting down to avoid overrunning the engine will also increase the braking force of the auxiliary brake Using the...

Page 136: ...35 meters in front of the planned stopping place At about 5 to 6 meters in front of the planned stopping place gradually allow the pedal to return about 1 3 to 1 2 of the initial pressed amount Press...

Page 137: ...WARNING Keeping the pedal pressed will stop the vehicle in a short distance but this will be accompanied by a strong shock Avoid releasing the brake pedal fully when allowing it to return The air in t...

Page 138: ...designed to prevent the wheels from slipping when braking and will not operate when the wheels slip during accelera tion or when turning In addition when driving on a slippery roads such as on icy roa...

Page 139: ...cularly on surfaces with little traction will ensure that the tractor and trailer remain aligned preventing them from jackknifing The semi trailer brake must also be used when coupling the tractor veh...

Page 140: ...drive the vehicle when the clutch disc is worn out or when the clutch is having problems In addition observe the following to prevent clutch damage Do not drive with resting the foot on clutch pedal...

Page 141: ...he distance is half the number on the speedometer But when driving faster than 60 km h excluding vehicles with speed limiter device maintain an inter vehicular distance greater than the number on the...

Page 142: ...vehicle If the load is unstable it could fall over when braking or turning so fasten it to the truck bed using braces and wires WARNING Fasten down sheets and ropes The heat from the silencer or exhau...

Page 143: ...from extending outside the body as much as possible use a rack and support the load evenly When using racks under the freight ensure care to position them correctly so that the freight is equally supp...

Page 144: ...anel It is advisable to always operate the vehicle within this green band Idling for long time causes fuel wastage Do not run the engine in idling for more than 2 minutes Sudden starting and quick acc...

Page 145: ...aphazardly Such stacking increases air resistance and greatly decreases fuel economy Vehicle maintenance for good fuel efficiency Maintain correct air pressure If the tyre air pressure is low it will...

Page 146: ...ing through snow When driving through snowy or on icy roads attach tyre chains and drive at a low speed Snowy and icy roads are dangerous because they are easy to slip Avoid sharp steering sudden brak...

Page 147: ...aximum level to avoid corrosion in the fuel system Always tighten the fuel tank cap to avoid entry of dust water and snow into the tank When parking When parking for a long time in cold areas choose a...

Page 148: ...THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY...

Page 149: ...rking conditions Use appropriate tools Stop the engine before inspec tion Engage the parking brake lever to the park position Make sure that wheels are secured with wheel chocks to avoid vehicle movem...

Page 150: ...hould be on a flat surface when the cab is tilted Make sure that there is sufficient space while tilting the cab Make sure that there are no loose heavy objects in the cab which could fall forward and...

Page 151: ...struction vehicles the tilt knob is located inside bumper refer below image Cab lowering 1 Turn the selector valve in anticlockwise direction 2 Use the wrench supplied along with the extension bar sup...

Page 152: ...art of the functionality of the air cleaner It is an integral part of the pre cleaning stage on air cleaner Perform visual check and squeeze to make sure the valve is flexible and not inverted Also ch...

Page 153: ...and loose clamps If broken replace it with a new part If the clamps are loose tighten them 7 Replace the air cleaner primary filter CAUTION Take extra care while cleaning the air filter housing Dust...

Page 154: ...primary filter NOTE Make sure that the arrow mark on the air cleaner filter is vertical NOTE It is recommended to use UD air cleaner filter Do not use an inferior filter CAUTION If the clips are not f...

Page 155: ...ace and secure it with the clips 8 Lower the cab Refer Cab lowering in Chapter 8 Handling precautions for air cleaner The dust ejector orientation should be within 15 range from the vertical line show...

Page 156: ...ked belts must be replaced There must not be any dirt or grease on the belts or the contact surfaces of the belt pulley Check the automatic belt ten sioner To inspect the compressor belt ten sion Push...

Page 157: ...kgfm 3 Replace the oil filter 2 and the bypass filter 3 at the same time as the oil is changed CAUTION A blocked cartridge could cause unfiltered or contaminated oil to be supplied to the engine compo...

Page 158: ...e decreases Engine output decreases Clogged fuel filter warning and warning messages are displayed CAUTION If the fuel filter is clogged and left unattended the cartridge will be damaged and contamina...

Page 159: ...filter gasket comes in contact with the housing sur face 7 Tighten the filter by additional half or three quarter turn 8 Replace the pre fuel filter at the same time the fuel filter is replaced 9 Dis...

Page 160: ...ir located under the pre fuel filter 1 Level sensor 2 Air blow 12 The drain opening located at the bottom of the water level sensor does not clog 13 Attach a new seal lubricate the seal and then insta...

Page 161: ...er 16 Connect the harness connector 17 Start the engine and perform a leak check 18 Run the engine in idle condition for 3 5 minutes to remove air in the fuel system CAUTION Do not reuse the fuel from...

Page 162: ...ng materials attached on the left side rail if equipped 5 Place a container under the pro file filter 6 Turn the ignition key clockwise to the ACC position 7 Select drain option from menu in instrumen...

Page 163: ...container in a place where the contents will not cause environmental damage 10 The warning status icon will dis appear after the vehicle has started to run for some time after the draining operation N...

Page 164: ...re fuel filter 2 bracket about 100 times until the pressure is felt in the priming pump 1 Air bleeding will be completed do not open the nipple 1 Priming pump 2 Pre fuel filter 7 Start the engine Let...

Page 165: ...t therefore be carried out by a UD Trucks authorised dealer DANGER Battery produces hydrogen gas which is explosive If the battery cables are connected incorrectly a spark could start is sufficient to...

Page 166: ...teering operation If the spare tyre is not used for a long time it may be deformed To maintain even wear of tyres and to extend the life of tyres tyre rotation is recommended Applicable for both LHD a...

Page 167: ...8 INSPECTION AND MAINTENANCE 8 19 Rotation pattern for vehicles equipped with Steer RIB pattern on front axle and drive LUG pattern on Rear axles...

Page 168: ...8 INSPECTION AND MAINTENANCE 8 20 Recommended tyre rotation for trailers wheel carriage...

Page 169: ...ay be turned Do not install tyres of different sizes Replenish new tyres in pairs and install them on the front wheels first When new tyres are installed per form a break in drive Perform break in dri...

Page 170: ...he air valves of the inner tyre and the outer tyre are diagonal in position Inspection Wheel nut hub bolt and disc wheel When replacing a tyre check for any malfunction in the wheel nut hub bolt and d...

Page 171: ...the wheel Front wheel Rear wheel CAUTION When the hub disc wheel and wheel nuts are changed be sure to check for loosening after driving about 50 to 100 km DANGER If any crack or damage is observed on...

Page 172: ...spare wheel is lifted fit the carrier lifting plate 2 tab with the disc wheel in the correct place Be sure to mount the tyre with the convex side of the disc wheel facing upward When the tyre is lift...

Page 173: ...studs that have damaged or distorted threads are broken or bent or are badly corroded Also replace both studs adjacent to the damaged stud If two or more studs have damage replace all the studs in the...

Page 174: ...acked or torn O ring will allow moisture to pass through internal part of the hub which can shorten the life of the hub Therefore the hubcap O ring should be replaced if found damaged DANGER Mismatche...

Page 175: ...e the vehicle is jacked up The jack will dislocate due to engine vibration Do not get underneath the vehicle while it is jacked up If the jack is dislocated it is very dangerous Do not load or unload...

Page 176: ...e jack under the jack up point and set it securely by turning the auxiliary screw Use the jack handle to close the release valve of the jack Set the jack handle and move it up and down for jack up CAU...

Page 177: ...ck handle Lower the jack slowly Change of a tyre Standard wheel CAUTION Do not damage the hub bolt when removing or installing the wheels If the tyre size or brand needs to be changed contact the near...

Page 178: ...gnition switch 3 Turn OFF the main switch 4 Tilt the cab Refer Cab tilting in Chapter 8 5 Disconnect the connector and pull out the rubber boot Sl No Description 1 Front end outline marker lamp 2 Main...

Page 179: ...all the rubber boot 11 Connect the connector 12 Lower the cab Indicator lamp replacement 1 Apply parking brake 2 Turn OFF the ignition switch 3 Turn OFF the main switch 4 Disconnect the electrical con...

Page 180: ...lb by rotating it clockwise 6 Remove the bulb and replace with a new bulb 7 Secure the bulb by rotating it clockwise 8 Connect the electrical connector Side indicator lamp replacement 1 Apply parking...

Page 181: ...rotating it clockwise 5 Unlock the bulb and remove 6 Replace with a new bulb and lock it 7 Install the holder back in place Marker lamp side replacement 1 Apply parking brake 2 Turn OFF the ignition s...

Page 182: ...ch 4 Remove cover by pulling it at the one end 5 Remove the bulb 6 Install the bulb 7 Install the cover back in place Cab reading lamp replacement 1 Apply parking brake 2 Turn OFF the ignition switch...

Page 183: ...F the main switch 4 Disconnect the connector 5 Remove the glass and doom by removing screws 6 Remove the bulb 7 Install the glass and doom back and secure with the screws 8 Connect the electrical conn...

Page 184: ...stall the cover back in place 9 Connect the electrical connector Fog lamp replacement 1 Apply parking brake 2 Turn OFF the ignition switch 3 Turn OFF the main switch 4 Remove electrical connector 5 Un...

Page 185: ...k box that is located in front of the muffler installed on the right side of the chassis Replacement of fuses Set the ignition switch to the OFF position Pull out the assistant lower panel from the to...

Page 186: ...me current rating as that specified for the circuit DANGER Be sure to use a fuse with the specified capacity A fuse beyond the specified capacity can overheat or create fire NOTE If the replaced fuse...

Page 187: ...front left wheel should be visible in the close proximity mirror Check that the images in the mir rors are good and mirrors are clean 1 Wide angle mirror driver side 2 Main mirror driver side 3 Front...

Page 188: ...Contact nearest UD Trucks authorised dealer for coolant replacement CAUTION Using non UD coolant can result in severe consequential damages that will not be covered by warranty CAUTION Continuous use...

Page 189: ...of the radiator which is used to cool the heated intake air charged by the turbocharger When mud or debris is attached to the front of the core the passage of cooling air is impaired So it is recomme...

Page 190: ...body Using water will impair cooling due to corrosion When driving on a road near the sea or on the road where deicing agent is applied wash it completely DANGER To prevent hand injury never insert t...

Page 191: ...ance for effect and pulling to one side Insufficient braking or pulling to one side is dangerous In this case contact the nearest UD Trucks authorised dealer Brake pedal free play 12 3 mm WARNING Ther...

Page 192: ...mechanism is provided adjustment during operation is not required Check the brakes of each wheel in the same way Wear check Remove the rubber plug from the inspection hole and check for wear of the b...

Page 193: ...air brake Apply the parking brake and ensure smooth and complete operation of the spring brake actuator push rod Axle shaft bolt checking Inspection time Every 3 months Tighten the axle shaft bolt to...

Page 194: ...se are specified in the safety standard noise and emission regulation The regulation values must be satisfied This section describes the simple check and service for emission control and noise control...

Page 195: ...increase of fuel consumption increase of oil consumption and reduction of power If a failure is found ask for service at the nearest UD Trucks authorised dealer Treatment of parts related to exter nal...

Page 196: ...ged from the air dryer outlet The amount of exhausted air will be more at beginning NOTE When maintaining the vehicle or washing with a high pressure device ensure care to avoid damage to the noise ab...

Page 197: ...CTION AND MAINTENANCE 8 49 8 13 Tools General tools required for the daily check and service are placed in the vehicle 1 Tool bag 2 Extension bar 3 Towing brace 4 Socket wrench 5 Decal hand tool appli...

Page 198: ...rucks authorised dealer During inspection and service observe the following items Be sure to prepare the drain oil container Perform the work in a location where an oil disposal unit is avail able Alw...

Page 199: ...e dipstick 1 Oil filler cap 4 After adding oil wait at least for 10 minutes then recheck the oil level 5 After checking insert the engine oil dipstick Replacement of engine oil Oil capacity Refer Capa...

Page 200: ...w washer each time the drain plug is removed Tightening torque 54 59 Nm 5 5 6 0 kgfm 5 Replace the oil filter 6 Add UD oil through the oil filler port 7 After refilling the engine oil wait for at leas...

Page 201: ...drain the transmission oil 2 Reinsert the drain plug and tighten 3 Refill the oil through the filler plug hole until oil overflows the level plug hole 4 CAUTION Using non UD lubricants can result in s...

Page 202: ...n oil from main transmission but also from PTO as shown in below picture CAUTION Oil is deteriorated with increase in the temperature which in turn causes failure of the transmission Oil in vehicles o...

Page 203: ...case through the filler plug hole Tightening torque Drain and filler plug 80 16 Nm 8 15 1 63 kgfm 3 When refilling ensure care to avoid dirt or dust from entering the filler plug hole CAUTION Using no...

Page 204: ...e at the joints in the steering line 1 MAX 2 MIN WARNING Allow the steering system to cool down before carrying out an oil check or replacement If there is insufficient oil or it is dirty the power st...

Page 205: ...tween the HIGH and LOW marks on the reservoir If it is lower than the LOW mark add UD clutch fluid till the HIGH mark CAUTION It is strongly recommended to use UD lubricants in order to avoid severe c...

Page 206: ...is low it is necessary to check if there is any leakage in the clutch system Have it inspected at the nearest UD Trucks authorised dealer Remove dirt in and around the cap before removing the cap of t...

Page 207: ...ual for maintenance intervals Lubricate lower funnel bearing 2 with recommended grease After cleaning re lubricate cou pling pin and support ring with recommended grease Please note the following when...

Page 208: ...oupling pin may be used until diameter of crowned section has worn to less than 36 5 mm after which it must be replaced Vertical play in coupling pin should not exceed 2 mm Lower bush Check wear for i...

Page 209: ...ment Check funnel lock Push the funnel along the side Move hand lever in locking direc tion up Release funnel The funnel must swing back to central position and should be locked again If not contact n...

Page 210: ...lied 2 Chock the wheels 3 Pull the wiper arm 4 Press and pull the lock 5 Replace the wiper blade and lock it 6 Place back the wiper arm on wind screen 7 Check for wiper blade function NOTE Keep the wi...

Page 211: ...ions while washing around the silencer When washing around the silencer perform the following procedures High pressure washing Spray 1 5 meters away from the silencer Removing mud or snow Use only a s...

Page 212: ...tions below when clean the vehicle lights When performing a high pressure wash Follow the instructions below when clean the vehicle lights Spray from a distance of at least 1 5 m from the lights Furth...

Page 213: ...wait for at least 120 seconds before disconnecting the battery cable or electrical system connectors when servicing the vehicle Handling of the silencer The silencer is specially integrated with a cat...

Page 214: ...hold the urea water solution AdBlue General containers containers that have been used for other applications and dirty containers will not maintain the quality of the urea water solution AdBlue So ma...

Page 215: ...e cap Remove the key while it is in this position When fire or leak occurs Urea water solution AdBlue is non flammable but quickly move it to a safe location if there is a fire If urea water solution...

Page 216: ...20 tonne 1 Bracket supports 2 Trailer contact surface 1 Lock jaws and front lock wear ring king pin contact area 28 tonne 1 Trailer contact surface 1 Lock plunger wedge and front lock WARNING All main...

Page 217: ...NTENANCE 8 69 1 Bracket contact surface Inspection and lubrication Tighten the loose bolts and fasteners Replace the missing are damaged parts CAUTION To adjust the fifth wheel contact nearest UD Truc...

Page 218: ...ndscreen Apply lubrication and grease on all the required points Close all the openings in the vehicle such as exhaust air inlet etc to avoid entry of air and dust Clean and remove the rust in the bod...

Page 219: ...71 8 21 Greasing Greasing should be performed periodically Wipe all dust and dirt from the grease nipples with a cloth and then apply grease After greasing wipe off any excess grease 8 4 1 Spring pin...

Page 220: ...8 INSPECTION AND MAINTENANCE 8 72 6 2 and 6 4 1 Spring pin 2 Spring pin and Shackle pins...

Page 221: ...8 INSPECTION AND MAINTENANCE 8 73 4 2 1 Spring pin 2 Spring pin and Shackle pins...

Page 222: ...THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY...

Page 223: ...Extended low speed operation Frequent stop and go operation Any replacement parts used for required maintenance service or repairs should be UD Genuine Parts A maintenance programme is provided with...

Page 224: ...ls Items First Torque tightening intervals Remarks Kilometers x 1000 5 10 15 20 25 30 35 40 45 50 55 60 Months 1 2 3 4 5 6 7 8 9 10 11 12 SUSPENSION FRONT U bolt and nut T T SUSPENSION REAR U bolt and...

Page 225: ...ENANCE SCHEDULE 9 3 Grease lubrication For complete lubrication points and intervals refer to maintenance programme provided with the purchase of the truck or contact your nearest UD Trucks authorised...

Page 226: ...THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY...

Page 227: ...signs around the vehicle to indicate the breakdown If not subsequent vehicles may collide into the rear Be sure to put signs of vehicle breakdown according to the methods below Stop indicator Switch o...

Page 228: ...vehicle stops with the spring brake failure of the brake system may be possible Have it inspected by the nearest UD Trucks authorised dealer CAUTION The release nut is secured on the release bolt with...

Page 229: ...Do s Always chock the wheels before releasing parking brake Disconnect propeller shaft before towing Always use tow hook and tow rod for towing the truck Lift the bogie axle up if provided before tow...

Page 230: ...urn on the hazard light to alert subsequent vehicles and stop the vehicle in a safe location for changing the tyre For changing a tyre Refer Chapter 8 DANGER Do not drive with a flat tyre the flat tyr...

Page 231: ...start the engine of the vehicle with the discharged battery If it is difficult to start the engine in a cold region start the engine of the vehicle that supplies the battery power and wait for several...

Page 232: ...icle switch OFF the engine of that vehicle and ensure that the two vehicles are not in contact with each other Pay attention to the connection order when drawing power from a vehicle with a normal bat...

Page 233: ...tem Maintenance standard Remarks Chassis Wheel alignment Toe in 1 mm at axle free condition Camber 0 42 Caster 3 30 Turning angle inside X Outside 49 X 34 5 FAA 10 44 5 X 33 FAA 20 Tyre pressure Refer...

Page 234: ...Oil Mega Multi 4 SAE 15W 40 Gear oil Transmission API GL 4 UD Genuine Gear Oil GL 4 80W 90 Axle oil Single reduction API GL 5 UD Genuine Rear Axle Oil GL 5 85W 140 Hub reduction Power steering fluid A...

Page 235: ...r liters Oil volume between dipstick Max Min liters Remarks Engine oil GH11E 37 5 5 Title Engine Capacity liters Remarks Engine coolant GH11E 49 5 Only a guide line as this varies dependent on vehicle...

Page 236: ...with PTO and oil cooler oil volume liters Transmission 6 Speed ST1306 F6S13T 11 5 11 6 12 5 12 6 ST1006 F6S10T 11 5 11 6 12 5 12 6 9 Speed STO2009 F9R20A 14 14 8 15 15 8 ST1509 F9R15T 13 13 1 14 14 1...

Page 237: ...11 SERVICE DATA 11 5 Recommended SAE viscosity number Use oil with the right viscosity value that suits the climatic condition of the area being operated Engine oil Gearbox oil...

Page 238: ...grease should be lithium or lithium complex type The grease should contain EP and anti rust additives The grease must have a consistency equivalent to NLGI no 2 The grease should not contain any soli...

Page 239: ...nationally adapted cold requirements JIS KK 2204 Most of the fuel sulphur is converted into sulphur dioxide SO2 in the combustion process this SO2 is later transformed into sulphuric acid in the atmos...

Page 240: ...trailer and is used as the basis for horizontal loads in the dynamic tests Variant Fifth wheel Model No D value King pin size Max vertical load Fifth wheel height H KPSIZE50 FW20 150 150 kN 50 mm 20...

Page 241: ...00 Nm 950 1400 rpm 1800 Nm 1000 1400 rpm 1800 Nm 950 1400 rpm 2000 Nm 1000 1400 rpm 2000 Nm 950 1400 rpm No of cylinders 6 6 6 Diameter of cylinder 123 mm 123 mm 123 mm Stroke 152 mm 152 mm 152 mm Pis...

Page 242: ...W 6 Bulb Side marker lamp with tail lamp R5W 5W 7 Bulb Side marker lamp without tail lamp W5W 5W 8 Bulb Side direction indicator lamp P21W 21W 9 Bulb Rear position lamp P21 5W 21 5W 10 Bulb Stop lamp...

Page 243: ......

Page 244: ...Pub No 22336671 UD Trucks Corporation 1 1 Ageo shi Saitama 362 8523 Japan...

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