SB-258-034

SB-10047619-5954
Mr. Gregory Magno, Chief – Defects Assessment
National Highway Traffic Safety Administration
400 Seventh Street, SW
Washington, DC 20590
(202) 366 – 5226
March 4, 2013
Mr. Magno,
In reference to the requirements of 49 CFR Part 579.5 Subparagraph A, this letter serves as
cover for the attached Notices, Bulletins, and Communications that were issued to UD Trucks
North America Sales and Service Dealers in the United States for September 2012.
The Safety Recall Bulletin enclosed is:
NONE
The Technical Bulletin enclosed is:
FSB 238-034 Revised – Engine Hardware and Software Updates – Revised with the
correct sequence when performing software updates.
The Technical Announcements enclosed are:
NONE
The Product Improvement Letters enclosed are:
NONE
The Warranty Letters enclosed are:
NONE
The Service News Letters enclosed are:
NONE
The Warranty Policies & Procedures Manual Revision enclosed is:
NONE
Sincerely,
Les Wells
Senior Manager Service Operations
UD Trucks North America
6012 West Campus Circle Drive Suite 288
Irving, TX 75063
(972) 756-5523
www.udtruckna.com
Trucks
This service bulletin replaces bulletin 258-034 dated 10.12.
Date
Group
No.
2.13
Release
258 034 02
Page
1(24)
Engine Software and Hardware Update
GH7 ENG
2011, 2012 and 2013 MY UD-MD
FSB 258-034, Engine Software and Hardware
Update
(February 2013)
Note: This bulletin has been revised to change the sequence of software updates (see
“Update Software”, page 22 ). It is important to program the MID 233 ACM first, then the MID
128 ECM.
UD Trucks has authorized an engine software update to reduce engine soot and hydrocarbon
buildup. There are three separate operations as part of this update:
•
•
•
Install continuous air purge kit
Inspect and clean aftertreatment system
Update software
Depending on the vehicle, one, two or all three operations may be required.
•
For new in-stock vehicles with less than 1,000 miles, the following operations are required:
•
•
•
“Update Software”, page 22
For in-service vehicles with repeat aftertreatment hydrocarbon doser failures, the following
operations are required:
•
•
•
•
“Continuous Air Purge Kit Installation”, page 3 and
“Continuous Air Purge Kit Installation”, page 3 ,
“Inspect and Clean the Aftertreatment System”, page 14 and
“Update Software”, page 22
For in-service vehicles without repeat aftertreatment hydrocarbon doser failures, the
following operations are required:
•
•
“Inspect and Clean the Aftertreatment System”, page 14 and
“Update Software”, page 22
Service personnel: Please circulate, read and initial
Service
Manager
89092318
Warranty
Administrator
Workshop
Foreman
Service Technicians
USA57929
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Verification Update is Required
1 If the air purge valve shown on pages 11 and 12 has been installed, the update has
already been performed.
2 Verify through the Vehicle Service Notification screen of the UD IntraNETsystem that the
update is required.
Factory and Port Installation
Vehicles produced after the dates listed below or released from the Port after October 1, 2012
have the updated software and continuous air purge system installed.
•
•
UD1800 models produced on or after July 1, 2012, unknown VIN start **
•
•
UD2300 models produced on or after July 1, 2012, unknown VIN start **
•
UD3300 models produced on or after May 28, 2012 and starting with VIN
JNAK510L2DAR20063
UD2000 models produced on or after July 1, 2012 and starting with VIN
JNAL310H9DAE20006
UD2600 models produced on or after May 21, 2012 and starting with VIN
JNAA410H9DAN20088
** At this time there has been no production of these models after the listed date.
Continuous Air Purge Kits
•
•
166000PKPC — Continuous Air Purge Kit for UD2600 and UD3300 models
166000MKLK — Continuous Air Purge Kit for UD1800, UD2000 and UD2300 models
Kits contain all necessary parts.
Note: You must read and understand the precautions and guidelines in Function Group 20,
Engine Safety Practices before performing this procedure. If you are not properly trained and
certified in this procedure, ask your supervisor for training before you perform it.
Note: Information is subject to change without notice. Illustrations are used for reference only
and may differ slightly from the actual vehicle being serviced. However, key components
addressed in this information are represented as accurately as possible.
Page
2(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Continuous Air Purge Kit Installation
WARNING
The fuel system can be pressurised. Remove the first component carefully when working
on a high pressure fuel system.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Check the cab for loose items and secure before tilting the cab. Tilt the cab.
4 Open all air valves and drain all air tanks.
5 Remove right side fender and mud guard assembly.
6 Remove air cleaner and pipe assembly. Cover the open engine air intake pipe.
7 Disconnect the fuel line from the aftertreatment hydrocarbon doser.
Note: There may be fuel left in the fuel line. Avoid spilling fuel on the diffuser pipe.
C2059918
Page
3(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
8 Remove doser from diffuser pipe.
C2059919
9 Clean the sealing surface on the diffuser pipe.
10 Install the new doser and new gasket provided in the kit on the diffuser pipe. Tighten
fasteners to specification, refer to Function Group 20, Specifications.
C2059920
Page
4(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
11 Push the connection outer ring to remove the air hose from the aftertreatment hydrocarbon
dosing module.
C2059014
12
C2060414
Page
5(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
13
C2059350
14 Clean around the connections between the module and fuel pipes.
15 Before removing the pipes, allow the fuel to drain into a suitable container. Immediately
plug all open ends since the fuel system is very sensitive to dirt.
16
C2059351
Page
6(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
17 Install the new aftertreatment hydrocarbon dosing module provided in the kit. Tighten
fasteners to specification, refer to Function Group 20, Specifications.
Note: Do not reconnect air line to the aftertreatment hydrocarbon dosing module at this
time
C2059352
18 Use new sealing washers and fuel line provided in the kit. Tighten lower line to doser, but
loosely attach upper line to module.
C2059354
Page
7(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
19 Pump hand primer 10 times to flush air out of the upper fuel line. Tighten upper line to
module and pump hand primer until pressure is built up.
20 Tighten fittings to specification, refer to Function Group 20, Specifications.
21
C2059353
22
C2060415
Page
8(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
23 Depending on vehicle model, remove the air line from either port 1 or port 2 on the air
distribution manifold located on the right side frame rail. Confirm that the correct line is
disconnected from the manifold by applying shop air to the line. Air should be felt at the
aftertreatment hydrocarbon dosing module end of the line. If air is not felt, reconnect the air
line and remove the air line from the other port.
W2077032
1. Check this port first for UD2600 and UD3300
2. Check this port first for UD1800, UD2000 and UD2300
Page
9(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
24 Trim the end of the air line tubing square, if necessary, and install a push to connect union
on the end of the tubing.
W2076608
UD2000 Shown
1. Line to Aftertreatment Hydrocarbon Dosing Module
2. Push to Connect Union
25 Connect the air line to the module.
C2059271
Page
10(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
26 Install the air regulator mounting bracket to the rear side of the crossmember behind the
transmission. Secure the bracket with screws and nuts included in the kit. The correct
bracket is included for the specific model kit.
Note: The bracket should not sit on any rivet heads.
W2076605
UD1800, UD2000 and UD2300
1. Port 1
2. Port 2
Page
11(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
W2076606
UD2600 and UD3300 Models
1. Port 1
2. Port 2
3. Plastic Clip
Page
12(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
27 Install the push to connect adapter fittings in the inlet port of the regulator (port 1) and the
outlet port of the regulator (port 2). Fasten the regulator to the mounting bracket and install
the splash shield below the regulator.
28 Measure and cut a sufficient length of 6 mm nylon air brake tubing and corrugated tubing
provided in kit to run from the regulator port 2 to the union that was installed in step 24.
Route the tubing with large bends to avoid kinking and secure with cable ties to existing
harness bundles and the crossmember.
29 Insert the preformed tubing furnished with the kit into the correct port on the air distribution
manifold and push to connect fitting port 1. Secure the tubing to the crossmember and
existing harness bundles with cable ties as necessary.
30 Close air tank drains and lower the cab.
31 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
to 20 ±2 Nm (15 ±1.5 ft-lb).
32 Using Tech Tool, start VCADS Pro and Install the correct accessory kit from list below
based on the vehicle model year. There are three accessory kits that are dependent on
vehicle model year:
Note: Accessory kit must be installed for continuous air purge to function correctly.
Vehicle Model Year
Last Five Digits of VIN
Accessory Kit Part
Number
2011
10001 to 10XXX
85135628
2012
15001 to 15XXX
85135627
2013
20001 to 20XXX
85135626
33 Proceed to “Update Software”, page 22 for MID 233, MID 128 and MID 144
programming.
Note: If MID 128 is not programmed after the accessory kit installation, a mechanical
system error aftertreatment hydrocarbon doser occurs.
Page
13(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Inspect and Clean the Aftertreatment System
WARNING
The fuel system can be pressurised. Remove the first component carefully when working
on a high pressure fuel system.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Check the cab for loose items and secure before tilting the cab. Tilt the cab.
4 Disconnect the EGR pressure sensor connector by pushing up the lock lug.
C2058015
Page
14(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
5 Remove the EGR pressure sensor from the EGR venturi adapter. Remove the EGR
venturi adapter.
C2058708
6 Carefully scrape any carbon buildup from the sensor ports. Remove the separator plate
from the bottom of the venturi adapter and carefully clean carbon from the holes in the
venturi and the adapter using successively larger drill bits and finger pressure. Replace
any O-rings as necessary and reassemble.
CAUTION
Never use compressed air on the sensor. Damage to components can result.
Page
15(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
7 Remove inlet pipe to diesel oxidation catalyst (DOC) and inspect the DOC face with a
borescope. Using the pictures below as a reference, clean the DOC if greater than 25% of
the surface is face plugged. Remove the DOC filter to access the diesel particulate filter
(DPF) and inspect the outlet face of the DPF for soot passing through. If soot pass through
the DPF is found, replace the DPF filter. Refer to TSB EN-47 for details about DPF
condition. Reassemble the aftertreatment system.
W2076607
Good DOC
W2077116
Face-Plugged DOC
Page
16(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
8 Check the engine oil level. If it is overfull, drain to the proper level and notify the operator of
correct oil checking and filling procedures.
9 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
to 20 ±2 Nm (15 ±1.5 ft-lb).
10 Start the vehicle and engage the warm-hold button. Allow the engine to warm to 75° C
(170° F) coolant temperature. For continuous air purge variants, after 5 minutes of idling,
disconnect the line from the aftertreatment hydrocarbon doser and verify the constant air
purge operation by placing a finger over the end of the line with the engine running. After
verification, reconnect the line. If no air is flowing, the system plumbing must be fault
traced.
11 Engage warm hold button to increase DPF intake temp to 250° C (480° F), stop the
engine, turn the ignition key On and record the DPF differential pressure. Start the engine
and increase speed to maximum RPM while monitoring DPF differential pressure, just long
enough for the value to stabilize. Subtract this value from the key On value. If it is greater
than 11 kPa (1.5 PSI), remove DPF and have it professionally cleaned and inspected
locally. Only replace the DPF if it is compromised or damaged. Refer to TSB EN-47 for
details about DPF condition.
12 Perform a parked regeneration while monitoring temperatures with VCADS Pro.
Note: High temperature is caused by air in the aftertreatment hydrocarbon dosing manifold
that will self-bleed at increased engine speed.
a. Monitor the DPF intake temperature at the beginning of the regeneration when dosing
starts. If the temperature rises rapidly above 500° C (930° F), immediately stop the
regeneration and increase engine speed to 2000 RPM to cool the aftertreatment system.
Once the temperatures drop below 300° C (575° F), restart the regeneration.
b. If the engine exhaust temperature does not achieve 250° C (480° F) during the first 15
minutes of the regeneration, replace the EGR valve and restart the regeneration.
Note: A leaking EGR valve will reduce exhaust temperature and decrease regeneration
effectiveness.
c. Continue monitoring the temperatures during the regeneration. During the second 15
minutes of the regeneration, the DPF intake temperature and the DPF outlet temperature
must achieve 450° C (850° F). If it does not reach this level, fuel quality or DOC condition
(if it had not been replaced) is suspect.
13 After the first regeneration has been completed successfully, complete a second
regeneration to insure the system is thoroughly cleaned.
14 Allow the aftertreatment system to cool below 250° C (480° F) after the second
regeneration. Recheck the DPF differential pressure after the regenerations, at maximum
RPM and subtracting the key-on value. The adjusted value must stabilize at or below 4
kPa (0.5 PSI). If not, the DPF must be replaced.
Page
17(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
15 Using VCADS, select 17070–3 Learned Data Reset.
Note: Engine must be running and at operating temperature to perform this procedure.
W2077033
16 Check the current “Fuel Pump Tuning Mode” by selecting the start button in the “Fuel
Pump Tuning Mode” section of the screen. The current “Fuel Pump Tuning Mode” should
display “Off”.
W2077034
Page
18(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
17 Click on the start button in the “$Fuel pump Learning value” section of the screen.
W2077036
18 Click on the start button in the “Reset of fuel pump tuning” section of the screen
W2077037
19 You will need to satisfy all of the conditions for performing the “Reset of fuel pump tuning”.
W2077038
Page
19(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
20 Once the “Fuel Pump Tuning Mode” is initiated, the display will show “Fast”, then “Slow”,
then “Off”.
W2077470
21 Once the “Fuel Pump Tuning Mode” displays “Off” switch your display to “Job Card View”
by clicking on the job card icon.
W2077039
Page
20(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
22 Select the “Results” tab. Next, select “Learned Data Reset” in the “Completed Operations”
menu. Then, click on the time and date stamp in the sub operations menu.
W2077040
23 The final “$Current learned value” of the pump should be between 50,000 and -450,000.
Page
21(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Update Software
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Using Tech Tool, start VCADS Pro and perform MID 233, ACM, programming.
3 When MID 233 programming is complete, perform MID 128, ECM. programming.
4 When MID 128 programming is complete, perform MID 144, VECU, programming.
5 Clear diagnostic trouble codes (DTC).
Page
22(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Job Card
1 Send Job Card directly to UDT.
2 Sending addresses are: attn; [email protected], cc; akihiro.kawano@udtrucks.
co.jp / [email protected].
3 Make sure to show VIN.
4 XML file is too big, use ZIP or LZH compressed files.
Page
23(24)
UD Trucks
Date
2.13
Group
No.
Release
258
034
02
Reimbursement
Warranty Code
K744
Trouble Code
12500379
Failed Part Number
5221323765
Failed Part Name
EECU
Labor Rate
Continuous Air Purge Kit Installation and Update Software
3 hours/unit
Inspect and Clean the Aftertreatment System and Update Software
4 hours/unit
Continuous Air Purge Kit Installation, Inspect and Clean the Aftertreatment System and Update
Software
5 hours/unit
Operation Code
999X
Parts Disposition
Dispose of removed parts following local regulations
UD Trucks North America engages in a comprehensive program of testing and evaluating to
provide the best possible product. UD Trucks North America however, is not committed to, or
liable for updating existing vehicles.
Page
24(24)

SB-10047619-4601
Tr u c k s
U D Tr u c k s
Ageo, Japan
Date
10.12
Group
No.
Release
258 034 01
Page
1(23)
Engine Software and Hardware Update
GH7 ENG
2011, 2012 and 2013 MY UD-MD
FSB 258-034, Engine Software and Hardware
Update
(Octo ber 2012 )
UD Trucks has authorized an engine software update to reduce engine soot and hydrocarbon
buildup. There are three separate operations as part of this update:
•
•
•
Install continuous air purge kit
Inspect and clean aftertreatment system
Update software
Depending on the vehicle, one, two or all three operations may be required.
•
For new in-stock vehicles with less than 1,000 miles, the following operations are required:
•
•
•
“Update Software”, page 18
For in-service vehicles with repeat aftertreatment hydrocarbon doser failures, the following
operations are required:
•
•
•
•
“Continuous Air Purge Kit Installation”, page 3 and
“Continuous Air Purge Kit Installation”, page 3 ,
“Inspect and Clean the Aftertreatment System”, page 14 and
“Update Software”, page 18
For in-service vehicles without repeat aftertreatment hydrocarbon doser failures, the
following operations are required:
•
•
“Inspect and Clean the Aftertreatment System”, page 14 and
“Update Software”, page 18
Service personnel: Please circulate, read and initial
Service
Manager
89078425
Wa r r a n t y
Admini strator
Wo r k s h o p
Foreman
S e r v i c e Te c h n i c i a n s
USA56094
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
Ve r i f i c a t i o n U p d a t e i s R e q u i r e d
1 If the air purge valve shown on pages 11 and 12 has been installed, the update has
already been performed.
2 Verify through the Vehicle Service Notification screen of the UD IntraNETsystem that the
update is required.
Fac tory and P o rt Ins tal l a ti on
Vehicles produced after the dates listed below or released from the Port after October 1, 2012
have the updated software and continuous air purge system installed.
•
•
UD1800 models produced on or after July 1, 2012, unknown VIN start **
•
•
UD2300 models produced on or after July 1, 2012, unknown VIN start **
•
UD3300 models produced on or after May 28, 2012 and starting with VIN
JNAK510L2DAR20063
UD2000 models produced on or after July 1, 2012 and starting with VIN
JNAL310H9DAE20006
UD2600 models produced on or after May 21, 2012 and starting with VIN
JNAA410H9DAN20088
** At this time there has been no production of these models after the listed date.
Continuous Air Purge K its
•
•
166000PKPC — Continuous Air Purge Kit for UD2600 and UD3300 models
166000MKLK — Continuous Air Purge Kit for UD1800, UD2000 and UD2300 models
Kits contain all necessary parts.
N o t e : You must read and understand the precautions and guidelines in Function Group 20,
Engine Safety Practices before performing this procedure. If you are not properly trained and
certified in this procedure, ask your supervisor for training before you perform it.
N o t e : Information is subject to change without notice. Illustrations are used for reference only
and may differ slightly from the actual vehicle being serviced. However, key components
addressed in this information are represented as accurately as possible.
Page
2(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
Continuous Air Purge K it Installation
WA R N I N G
The fuel system can be pressurised. Remove the first component carefully when working
on a high pressure fuel system.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Check the cab for loose items and secure before tilting the cab. Tilt the cab.
4 Open all air valves and drain all air tanks.
5 Remove right side fender and mud guard assembly.
6 Remove air cleaner and pipe assembly. Cover the open engine air intake pipe.
7 Disconnect the fuel line from the aftertreatment hydrocarbon doser.
N o t e : There may be fuel left in the fuel line. Avoid spilling fuel on the diffuser pipe.
C2059918
Page
3(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
8 Remove doser from diffuser pipe.
C2059919
9 Clean the sealing surface on the diffuser pipe.
10 Install the new doser and new gasket provided in the kit on the diffuser pipe. Tighten
fasteners to specification, refer to Function Group 20, Specifications.
C2059920
Page
4(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
11 Push the connection outer ring to remove the air hose from the aftertreatment hydrocarbon
dosing module.
C2059014
12
C2060414
Page
5(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
13
C2059350
14 Clean around the connections between the module and fuel pipes.
15 Before removing the pipes, allow the fuel to drain into a suitable container. Immediately
plug all open ends since the fuel system is very sensitive to dirt.
16
C2059351
Page
6(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
17 Install the new aftertreatment hydrocarbon dosing module provided in the kit. Tighten
fasteners to specification, refer to Function Group 20, Specifications.
N o t e : Do not reconnect air line to the aftertreatment hydrocarbon dosing module at this
time
C2059352
18 Use new sealing washers and fuel line provided in the kit. Tighten lower line to doser, but
loosely attach upper line to module.
C2059354
Page
7(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
19 Pump hand primer 10 times to flush air out of the upper fuel line. Tighten upper line to
module and pump hand primer until pressure is built up.
20 Tighten fittings to specification, refer to Function Group 20, Specifications.
21
C2059353
22
C2060415
Page
8(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
23 Depending on vehicle model, remove the air line from either port 1 or port 2 on the air
distribution manifold located on the right side frame rail. Confirm that the correct line is
disconnected from the manifold by applying shop air to the line. Air should be felt at the
aftertreatment hydrocarbon dosing module end of the line. If air is not felt, reconnect the air
line and remove the air line from the other port.
W2077032
1. Check this port first for UD2600 and UD3300
2. Check this port first for UD1800, UD2000 and UD2300
Page
9(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
24 Trim the end of the air line tubing square, if necessary, and install a push to connect union
on the end of the tubing.
W2076608
UD2000 Shown
1. Line to Aftertreatment Hydrocarbon Dosing Module
2. Push to Connect Union
25 Connect the air line to the module.
C2059271
Page
10(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
26 Install the air regulator mounting bracket to the rear side of the crossmember behind the
transmission. Secure the bracket with screws and nuts included in the kit. The correct
bracket is included for the specific model kit.
N o t e : The bracket should not sit on any rivet heads.
W2076605
UD1800, UD2000 and UD2300
1. Port 1
2. Port 2
Page
11(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
W2076606
UD2600 and UD3300 Models
1. Port 1
2. Port 2
3. Plastic Clip
Page
12(23)
U D Tr u c k s
Date
10.12
Group
No.
Release
258
034
01
27 Install the push to connect adapter fittings in the inlet port of the regulator (port 1) and the
outlet port of the regulator (port 2). Fasten the regulator to the mounting bracket and install
the splash shield below the regulator.
28 Measure and cut a sufficient length of 6 mm nylon air brake tubing and corrugated tubing
provided in kit to run from the regulator port 2 to the union that was installed in step 24.
Route the tubing with large bends to avoid kinking and secure with cable ties to existing
harness bundles and the crossmember.
29 Insert the preformed tubing furnished with the kit into the correct port on the air distribution
manifold and push to connect fitting port 1. Secure the tubing to the crossmember and
existing harness bundles with cable ties as necessary.
30 Close air tank drains and lower the cab.
31 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
to 20 ±2 Nm (15 ±1.5 ft-lb).
32 Using Tech Tool, start VCADS Pro and Install the correct accessory kit from list below
based on the vehicle model year. There are three accessory kits that are dependent on
vehicle model year:
N o t e : A c c e s s o r y k i t mu s t b e i n s t a l l e d f o r c o n t i n u o u s a i r p u rg e t o f u n c t i o n c o r r e c t l y.
Ve h i c l e M o d e l Ye a r
L ast Five Digits o f VIN
Ac c ess ory K it P art
Number
2011
10001 to 10XXX
85135628
2012
15001 to 15XXX
85135627
2013
20001 to 20XXX
85135626
33 U s i n g Te c h To o l , s t a r t V C A D S P r o a n d p e r f o r m M I D 1 2 8 , E C U , p r o g r a mm i n g .
N o t e : If MID 128 is not programmed after the accessory kit installation, a mechanical
system error aftertreatment hydrocarbon doser occurs.
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Ins pec t and Clean the Aftertreatment Sy stem
WA R N I N G
The fuel system can be pressurised. Remove the first component carefully when working
on a high pressure fuel system.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Check the cab for loose items and secure before tilting the cab. Tilt the cab.
4 Disconnect the EGR pressure sensor connector by pushing up the lock lug.
C2058015
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5 Remove the EGR pressure sensor from the EGR venturi adapter. Remove the EGR
venturi adapter.
C2058708
6 Carefully scrape any carbon buildup from the sensor ports. Remove the separator plate
from the bottom of the venturi adapter and carefully clean carbon from the holes in the
venturi and the adapter using successively larger drill bits and finger pressure. Replace
any O-rings as necessary and reassemble.
CAUTION
Never use compressed air on the sensor. Damage to components can result.
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7 Remove inlet pipe to diesel oxidation catalyst (DOC) and inspect the DOC face with a
borescope. Using the pictures below as a reference, clean the DOC if greater than 25% of
the surface is face plugged. Remove the DOC filter to access the diesel particulate filter
(DPF) and inspect the outlet face of the DPF for soot passing through. If soot pass through
the DPF is found, replace the DPF filter. Refer to TSB EN-47 for details about DPF
condition. Reassemble the aftertreatment system.
W2076607
Good DOC
W2077116
Face-Plugged DOC
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8 Check the engine oil level. If it is overfull, drain to the proper level and notify the operator of
correct oil checking and filling procedures.
9 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
to 20 ±2 Nm (15 ±1.5 ft-lb).
10 Using Tech Tool, start VCADS Pro and perform MID 128, ECU, programming, if not done
previously.
11 Start the vehicle and engage the warm-hold button. Allow the engine to warm to 75° C
(170° F) coolant temperature. For continuous air purge variants, after 5 minutes of idling,
disconnect the line from the aftertreatment hydrocarbon doser and verify the constant air
purge operation by placing a finger over the end of the line with the engine running. After
verification, reconnect the line. If no air is flowing, the system plumbing must be fault
traced.
12 Engage warm hold button to increase DPF intake temp to 250° C (480° F), stop the
engine, turn the ignition key On and record the DPF differential pressure. Start the engine
and increase speed to maximum RPM while monitoring DPF differential pressure, just long
enough for the value to stabilize. Subtract this value from the key On value. If it is greater
than 11 kPa (1.5 PSI), remove DPF and have it professionally cleaned and inspected
locally. Only replace the DPF if it is compromised or damaged. Refer to TSB EN-47 for
details about DPF condition.
13 Perform a parked regeneration while monitoring temperatures with VCADS Pro.
N o t e : High temperature is caused by air in the aftertreatment hydrocarbon dosing
manifold that will self-bleed at increased engine speed.
a. Monitor the DPF intake temperature at the beginning of the regeneration when dosing
starts. If the temperature rises rapidly above 500° C (930° F), immediately stop the
regeneration and increase engine speed to 2000 RPM to cool the aftertreatment system.
Once the temperatures drop below 300° C (575° F), restart the regeneration.
b. If the engine exhaust temperature does not achieve 250° C (480° F) during the first 15
minutes of the regeneration, replace the EGR valve and restart the regeneration.
N o t e : A leaking EGR valve will reduce exhaust temperature and decrease regeneration
effectiveness.
c. Continue monitoring the temperatures during the regeneration. During the second 15
minutes of the regeneration, the DPF intake temperature and the DPF outlet temperature
must achieve 450° C (850° F). If it does not reach this level, fuel quality or DOC condition
(if it had not been replaced) is suspect.
14 After the first regeneration has been completed successfully, complete a second
regeneration to insure the system is thoroughly cleaned.
15 Allow the aftertreatment system to cool below 250° C (480° F) after the second
regeneration. Recheck the DPF differential pressure after the regenerations, at maximum
RPM and subtracting the key-on value. The adjusted value must stabilize at or below 4
kPa (0.5 PSI). If not, the DPF must be replaced.
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Update Software
N o t e : Engine must be running to perform this procedure.
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.
2 Using Tech Tool, start VCADS Pro and perform MID 128, ECU, programming, if not done
previously.
3 Check MID 233 and MID 144 for any open software updates and perform all required
updates.
4 Using VCADS, select 17070–3 Learned Data Reset.
W2077033
5 Check the current “Fuel Pump Tuning Mode” by selecting the start button in the “Fuel
Pump Tuning Mode” section of the screen. The current “Fuel Pump Tuning Mode” should
display “Off”.
W2077034
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6 Click on the start button in the “$Fuel pump Learning value” section of the screen.
W2077036
7 Click on the start button in the “Reset of fuel pump tuning” section of the screen
W2077037
8 You will need to satisfy all of the conditions for performing the “Reset of fuel pump tuning”.
W2077038
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9 Once the “Fuel Pump Tuning Mode” is initiated, the display will show “Fast”, then “Slow”,
then “Off”.
W2077470
10 Once the “Fuel Pump Tuning Mode” displays “Off” switch your display to “Job Card View”
by clicking on the job card icon.
W2077039
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11 Select the “Results” tab. Next, select “Learned Data Reset” in the “Completed Operations”
menu. Then, click on the time and date stamp in the sub operations menu.
W2077040
12 The final “$Current learned value” of the pump should be between 50,000 and -450,000.
13 Clear diagnostic trouble codes (DTC). Repairs are complete.
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Job Card
1 Send Job Card directly to UDT.
2 Sending addresses are: attn; [email protected], cc; akihiro.kawano@udtrucks.
co.jp / [email protected].
3 Make sure to show VIN.
4 XML file is too big, use ZIP or LZH compressed files.
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R ei mbu rs ement
Wa r r a n t y C o d e
K744
Tr o u b l e C o d e
12500379
Failed P art Number
5221323765
Failed P art Name
EECU
Lab or Ra te
Continuous Air Purge Kit Installation and Update Software
3 hours/unit
Inspect and Clean the Aftertreatment System and Update Software
4 hours/unit
Continuous Air Purge Kit Installation, Inspect and Clean the
Aftertreatment System and Update Software
5 hours/unit
Operation Cod e
999X
Parts Dispo sition
Dispose of removed parts following local regulations
UD Trucks North America engages in a comprehensive program of testing and evaluating to
provide the best possible product. UD Trucks North America however, is not committed to, or
liable for updating existing vehicles.
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SUBJECT: PDI Reimbursement discontinued October 1, 2012
Department: Service
Section: PART V Warranty Policy
and Procedure Manual
Model(s): All
Model Year(s): All
Effective Date: 10/19/2012
Form #: Warranty Letter 12-104
Rev #:
Supersedes:
Reimbursement for Pre-Delivery Inspection (PDI) claims has been discontinued for all UD Truck
models and model years effective October 1, 2012.
For vehicles sold on or after October 1, 2012 it is still recommended that a PDI be performed and
the completed PDI Inspection Form is retained with the vehicle service records.
.
The Information contained in this bulletin should not be interpreted as the basis for a warranty claim.
Form #: Warranty Letter 12-104
Rev #:
Page 1