Peterbilt Conventional Truck Operator's Manual v2
en
Contents
Safety
Emergency
Controls
Driving
Maintenance
Information
Index
1
2
3
4
5
6
7
Contents
2012 Paccar Inc - All Rights Reserved
This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.
PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without notice and without incurring any obligation.
The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictly prohibited without prior written authorization from PACCAR Inc.
SAFETY
Safety About This Manual . . . . . . . . . . . . . . . 1-3 Safety Alerts . . . . . . . . . . . . . . . . . . 1-4 Illustrations. . . . . . . . . . . . . . . . . . . 1-6
1-1
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Safety
Safety
About This Manual
Please take the time to get acquainted with your vehicle by reading this Operators Manual. We recommend that you read and understand this manual from beginning to end before you operate your truck. This manual explains the safe, efficient operation and maintenance of your vehicle.
NOTE After youve read this manual, it should be stored in the cab for con- venient reference and remain with this truck when sold.
Your vehicle may not have all the features or options mentioned in this manual. Therefore, you should pay careful attention to the instructions that pertain to just your vehicle. In addition, if your vehicle is equipped
with special equipment or options not discussed in this manual, consult your dealer or the manufacturer of the equipment. All information contained in this manual is based on the latest production information available at the time of publication. PACCAR reserves the right to make changes at any time without notice.
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Safety
Safety Alerts
Please read and follow all of the safety alerts contained in this manual. They are there for your protection and information. These alerts can help you avoid injury to yourself, your passengers, and help prevent costly damage to the vehicle. Safety alerts are highlighted by safety alert symbols and signal words such as "WARNING", "CAUTION", or "NOTE". Please do not ignore any of these alerts.
WARNING
WARNING!
The safety message following this symbol and signal word provides a warning against operating procedures which could cause injury or even death. They could also cause equipment or property damage. The alert will identify the hazard, how to avoid it, and the probable consequence of not avoiding the hazard.
Example:
WARNING!
Do not carry additional fuel contain- ers in your vehicle. Fuel containers, either full or empty, may leak, ex- plode, and cause or feed a fire. Do not carry extra fuel containers. Even empty ones are dangerous. Failure to comply may result in death, per- sonal injury, equipment or property damage.
1-4
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Safety
CAUTION
CAUTION
The safety alert following this symbol and signal word provides a caution against operating procedures which could cause equipment or property damage. The alert will identify the hazard, how to avoid it, and the probable consequence of not avoiding the hazard.
Example:
CAUTION
Continuing to operate your vehi- cle with insufficient oil pressure will cause serious engine damage. Fail- ure to comply may result in equip- ment or property damage.
NOTE
NOTE
The alert following this symbol and signal word provides important information that is not safety related but should be followed. The alert will highlight things that may not be obvious and is useful to your efficient operation of the vehicle.
Example:
NOTE Pumping the accelerator will not as- sist in starting the engine.
1-5
1
Safety
Illustrations General Information
Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your vehicle.
1-6
1
CONTROLS
Aftertreatment System (ATS) Introduction . . . . . . . . . . . . . . . . . . 3-3
Diesel Particulate Filter (DPF) System Introduction . . . . . . . . . . . . . . . . . . 3-4 Controlling the Regeneration Process . . . . . . . 3-4 Functionality / Notification Information . . . . . . . 3-7 DPF Regeneration . . . . . . . . . . . . . . 3-13 Stop an Automatic or Parked Regeneration. . . . 3-16 Idling in Freezing Temperatures. . . . . . . . . 3-17
Selective Catalytic Reduction (SCR) System Introduction . . . . . . . . . . . . . . . . . 3-18
3-1
3
Aftertreatment System (ATS)
Aftertreatment System (ATS)
Introduction
The Aftertreatment System (ATS) on your vehicle is made up of two systems:
1. Diesel Particulate Filter (DPF) System
2. Selective Catalytic Reduction (SCR) System
They fulfill two primary functions; particulate reduction & nitrogen oxide (NOx) reduction.
This section of the manual describes how to interact and control these two systems. See the INFORMATION section starting on page 6-3 of this
manual for more detailed information about the aftertreatment process and its components.
3-3
3
Diesel Particulate Filter (DPF) System
Diesel Particulate Filter (DPF) System
Introduction
The DPF system consists of a Hydrocarbon (HC) Doser (may not apply to all engines), a Diesel Oxidation Catalyst (DOC), and a DPF. The DPF filters soot out of the exhaust. When activated, the HC Doser sprays a small amount of diesel fuel (the HC) into the exhaust. The catalyst in the DOC reacts with the HC to generate heat. The heat is used to clean (regenerate) the DPF by reducing the trapped soot to ash.
Controlling the Regeneration Process
Your vehicle is equipped with either a two-position or three-position Regeneration Switch, mounted on the dash.
If equipped with a two-position Regeneration Switch, the driver can initiate a Parked Regeneration when certain operating conditions are suitable for regeneration; however, you will NOT be able to Stop a regeneration if the ATS has initiated one automatically. Refer to Parked Regeneration on page 3-13.
If your vehicle is equipped with a three-position Regeneration Switch, the driver can control the regeneration by overriding the ATS when certain operating conditions are not suitable for regeneration. Refer to Stop an Automatic or Parked Regeneration on page 3-16.
WARNING!
If you operate in environments that contain explosive vapors or flammable materials, look to see if your vehicles Regeneration Switch is equipped with a STOP function. The STOP function must be acti- vated prior to entering the above environment(s) to prevent automatic engine regeneration from occurring, which could cause an explosion or fire. Failure to equip your vehicle with the proper switch (function) or failing to activate the STOP function before entering a combustible en- vironment may cause an explosion or fire that could lead to death, per- sonal injury, equipment or property damage.
3-4
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Diesel Particulate Filter (DPF) System
NOTE To obtain a Regeneration Switch with a STOP function, contact your nearest authorized PACCAR dealer to obtain the proper switch and re- programming of your engines ECU.
Two-Position Regeneration Switch
Two-Position Regeneration Switch
Start
Depressing the button in the START direction for at least 4 - 8 seconds will initiate a Parked Regeneration.
Three-Position Regeneration Switch
Three-Position Regeneration Switches
NOTE Refer to DPF Regeneration on page 3-13 for instructions on how to start or stop a ATS regeneration (three- position switch only).
Start
Depressing the button in the START direction for at least 4 - 8 seconds will initiate a Parked Regeneration.
3-5
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Diesel Particulate Filter (DPF) System
NOTE Parked regeneration requires that your vehicle is stopped with the parking brake set. See Parked Re- generation on page 3-13 for details.
Center (three-position switch only)
NOTE During normal vehicle driving, the Regeneration Switchmust be in the CENTER position.
CENTER is the normal position of the switch. Unless you are manually initiating a Parked Regeneration or intentionally stopping a regeneration, the switch should be in this position. Placing the switch in the CENTER position will allow an Automatic Regeneration to occur if conditions allow.
Stop (three-position switch only)
When STOP is pressed, the system will not regenerate under any conditions.
CAUTION
Do not leave the switch in the STOP position unless you need to cancel or stop a regeneration. Running the engine with the switch in the STOP position will result in increased soot levels in the DPF and could eventu- ally cause the engine to derate.
Aftertreatment System Warning Lamps
ATS specific warning lamps and indicator symbols are located on the main gauge cluster.
Diesel Particulate Filter (DPF) Warning
Lamp Symbol
High Exhaust System Temperature (HEST) Warning Lamp
Symbol
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3
Diesel Particulate Filter (DPF) System
Functionality / Notification Information
The ATS will regenerate the DPF by using hot exhaust gases normally generated by the engine. This typically occurs during highway operation (known as Passive Regeneration) and is transparent to the operation of the vehicle.
Occasionally, the exhaust gases are not hot enough for passive regeneration. When this occurs, the ATS will regenerate the DPF by increasing the exhaust temperature. This is referred to as an "Automatic" Regeneration and is also transparent to vehicle operation. An Automatic Regeneration event typically lasts 30 minutes. During and shortly after the event, the exhaust gases from the DPF may reach temperatures in excess of 650 C (1202 F). See the information in the following table on probable causes and recommended
actions related to the warning lamps and indicator symbols of the ATS.
The ATS may not be able to regenerate the DPF when the vehicle is driven at extended low speeds or with frequent start and stops. In such cases, warning lamps and indicator symbols will alert the operator to take action. The operator should be aware of whether the lamps are on unaccompanied or in combination with others. The following table will describe each warning lamp(s) and what actions are needed from the operator.
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Diesel Particulate Filter (DPF) System
Notification of High Exhaust System Temperature
NOTIFICATION OF HIGH EXHAUST SYSTEM TEMPERATURE Warning
Indicator Condition Operator Actions
HEST lamp on
Any one or combination of these conditions: Exhaust outlet temperature is elevated above normal (at least 450 C /
842 F) and vehicle slows below 8 kph / 5 mph. Normal driving but engine is under heavy loading. Automatic Regeneration in process Parked Regeneration in process
Follow all warnings listed below. Use the DISABLE function of the Regeneration Switch if the situation requires. Follow the instructions described under Stop an Automatic or Parked Regeneration on page 3-16.
WARNING!
Temperature of the tail pipe, exhaust pipe, diesel particular filter (DPF), selective catalytic reduction (SCR) device and surrounding components including enclosures and steps, will be elevated during and shortly after a regeneration event or normal vehicle operation when engine is under high or heavy loading. If the High Exhaust System Temperature (HEST)
warning lamp is on: Do not park in an area of combustible vapors or materials. You must keep combustibles at least 1.5 m (5 ft) away from the exhaust
(outlet) stream (as it exits the tail pipe) while the HEST lamp is illuminated. Always park your vehicle outside. Failure to do so could ignite an explosion or harm bystanders which could result in serious injury.
Do not park in an area where people are close by. You must keep combustibles at least 1.5 m (5 ft) away from the exhaust outlet while the HEST lamp is illuminated. Failure to do so could result in serious injury.
Temperature of the tail pipe, exhaust pipes, diesel particular filter (DPF), selective catalytic reduction (SCR) device and surrounding components including enclosures and steps becomes elevated during engine operation or any regeneration event and can cause serious burns to the skin. Allow adequate cooling time before approaching, working on or near any part of the exhaust system or surrounding
components.
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Diesel Particulate Filter (DPF) System
Notification Regeneration is Required
NOTIFICATION REGENERATION IS REQUIRED Warning Level
Warning Indicators Condition Operator Actions
1
DPF lamp on
The soot level in the DPF is above the desired level and requires regeneration.
The DPF requires regeneration soon. Follow the instructions described under DPF Regeneration on page 3-13.
NOTE If you ignore the warning lamp and do not initi- ate regeneration at the soonest, safest possible time, the DPF will become increasingly clogged with soot and can lead to severe engine derate.
2
DPF lamp flashes
The soot level in the DPF continues to stay above the desired level and requires regeneration.
Regenerate the DPF as soon as safely possible. Follow the instructions described under DPF Regeneration on page 3-13.
CAUTION
If you do not initiate regeneration after the DPF warning lamp begins to flash, you only have a short time before the Check Engine lamp will illuminate and the engine will go into a protection mode and derate power.
3-9
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Diesel Particulate Filter (DPF) System
NOTIFICATION REGENERATION IS REQUIRED Warning Level
Warning Indicators Condition Operator Actions
3
DPF lamp flashes
Check Engine lamp on
The soot level in the DPF continues to stay above the desired level and requires regeneration. The engine power will derate.
Regenerate the DPF immediately. Follow the instructions described under DPF Regeneration on page 3-13 for PACCAR MX engines, Parked Regeneration on page 3-13 for PACCAR PX and Cummins engines.
CAUTION
If you do not initiate regeneration after the DPF warning lamp begins to flash and the Check En- gine lamp is on, you only have a short time before the Stop Engine lamp will illuminate and the en- gine power will derate severely. No regeneration will be allowed at the next stage.
NOTE Under some conditions after prolonged stationary idling, a Parked Regeneration may be required without a Level 1 or Level 2 warning.
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Diesel Particulate Filter (DPF) System
NOTIFICATION REGENERATION IS REQUIRED Warning Level
Warning Indicators Condition Operator Actions
4
DPF lamp flashes (MX engine only)
Check Engine lamp on (MX engine only)
Stop Engine lamp on
Dash chime will sound
The soot level in the DPF is now at full capacity. Engine power derates (decrease rate depends on engine make)
NOTE The engine derate sequence is engine specific; therefore, to learn how this system works on your vehicle, refer to the Engine Manufacturer's Opera- tion and Maintenance Manual supplied with your vehicle.
At this point, you CANNOT regenerate the DPF. Tow your vehicle to an Authorized PACCAR Dealer to have the DPF removed. They will either have to clean it or replace it.
WARNING!
If the Stop Engine warning lamp illuminates, it means you have a serious engine system prob- lem. This should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to comply may result in death, personal injury, equipment or property damage.
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Diesel Particulate Filter (DPF) System
Quick Reference Guide
3-12
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Diesel Particulate Filter (DPF) System
DPF Regeneration
Carefully read the following instructions to regenerate the DPF. If you have any problems or difficulties contact your nearest authorized PACCAR dealer for assistance.
The ATS requires conditions typically found in highway driving to regenerate the DPF. If the DPF warning lamp is illuminated, the easiest option is to assist the ATS by proceeding to the nearest highway.
Select a highway that has a posted legal speed of more than 56 kph (35 mph).
Drive your vehicle until the DPF lamp goes off. This may take 30 - 45 minutes of speeds greater than 32 kph (20 mph).
If your operation or planned route in the immediate future limits your ability to reach highway speeds, proceed
to the next section titled Parked Regeneration.
Parked Regeneration
In very limited applications or operations, the DPF must be regenerated by initiating a Parked Regeneration. Follow these seven steps to initiate a Parked Regeneration:
1. Pull the vehicle over to a safe location.
2. Ensure no one is in the immediate vicinity of the tail pipe.
3. Maintain a minimum of 1.5 m (5 ft) of clearance to any combustible materials from the edge and top of the vehicle.
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Diesel Particulate Filter (DPF) System
WARNING!
Parking the vehicle too close to any combustible materials or vapors may start a fire, ignite an explosion or burn someone standing close by. Before pushing the Regeneration Switch on the dash, walk around your vehicle and ensure you have at least 1.5 m (5 ft) clearance from the sides and top of your vehicle to any combustibles. Ensure no one is in the immediate vicinity of the tail pipe. Failure to comply could ignite a fire or cause an explosion, resulting in death, personal injury, equipment or property damage.
WARNING!
Never initiate a regeneration in a closed building or enclosure. Al- ways park your vehicle outside and ensure no one is in the immediate vicinity. Failure to comply could ig- nite a fire or cause an explosion, resulting in death, personal injury, equipment or property damage.
NOTE Typical operation areas or materi- als that can contain explosive va- pors, flammable materials or people in close proximity of the vehicle are:
Fuel depots
Grain elevators
Dry grass, leaves or trees
Transfer refuse stations/dumps
Parking lots
Load/unload terminals
NOTE While the list above may appear comprehensive, it is your respon- sibility to take the necessary pre- cautions and be aware of your surroundings and ensure that no combustibles (materials or vapors) or bystanders are close by before initiating a regeneration.
4. Verify that the following conditions are met before proceeding. A Parked Regeneration will not initiate if any of these conditions are not met:
Parking brake is applied / set
Engine is at low idle
DPF warning lamp is illuminated or flashing
Coolant is at operating temperature
No throttle
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Diesel Particulate Filter (DPF) System
PTO is disengaged
Transmission is in neutral
Cruise control switch is off
5. Get out and walk all around vehicle to ensure that the vehicle is at least 1.5 m (5 ft) away from all combustible materials and no one is in the immediate vicinity.
6. Climb back into the vehicle.
7. Push the Regeneration (START) Switch located on the dash for at least 4 - 8 seconds to initiate a Parked Regeneration.
After regeneration starts if any of the conditions (in step 4) change or become activated regeneration will automatically shut off.
Regeneration Switch
NOTE Acknowledgment that a Parked Re- generation has initiated will vary by engine. The most predominant ac- knowledgement to you will be an in- crease in engine RPM and overall engine noise.
NOTE A Parked Regeneration may take 30 or more seconds to initiate as the ATS system conducts various self- checks to verify all the system re- quirements have been met.
If you are unable to initiate a Parked Regeneration and the DPF warning lamp is illuminated, contact your nearest PACCAR dealer for assistance.
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Diesel Particulate Filter (DPF) System
Stop an Automatic or Parked Regeneration
NOTE The information in this section only applies to vehicles equipped with a three-position Engine Regeneration Switch with a STOP position.
If an Automatic or Parked Regeneration is in process and you want the regeneration to stop, OR you want to prevent a regeneration from occurring, your vehicle is equipped with a switch that can STOP an Automatic or Parked Regeneration. Since Automatic Regenerations can occur at any time, you must depress the STOP portion of the Regeneration Switch ANYTIME you plan to drive your vehicle into a building, enclosure or area where the activation of a regeneration is not allowed. If the regeneration does not stop, turn the vehicle ignition OFF.
WARNING!
Never allow an Automatic Regen- eration to automatically start while inside a building such as a service bay, shop or building of any kind. Anytime you are parking your vehi- cle inside a building or enclosure, ALWAYS press the Regeneration (STOP) Switch prior to entering the building. Failure to comply could ignite a fire or cause an explosion, resulting in death, personal injury, equipment or property damage.
WARNING!
Never initiate a Parked Regenera- tion in a closed building or enclo- sure. Always park your vehicle out- side. Failure to comply could ignite a fire or cause an explosion, resulting in death, personal injury, equipment or property damage.
WARNING!
If you operate in environments that contain explosive vapors or flammable materials, look to see if your vehicles Regeneration Switch is equipped with a STOP function. The STOP function must be acti- vated prior to entering the above environment(s) to prevent automatic engine regeneration from occurring, which could cause an explosion or fire. Failure to equip your vehicle with the proper switch (function) or failing to activate the STOP function before entering a combustible en- vironment may cause an explosion or fire that could lead to death, per- sonal injury, equipment or property damage.
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Diesel Particulate Filter (DPF) System
NOTE To obtain a Regeneration Switch with a STOP function, contact an au- thorized PACCAR dealer to obtain the proper switch and reprogram- ming of your engines ECU.
Idling in Freezing Temperatures
Idling the engine for 3 or more hours in freezing temperatures causes the build up of soot and moisture in the DPF. Extra heat is required to oxidize the soot and moisture by using the following methods:
DPF Regeneration: If the DPF Lamp turns on, follow the instructions described under DPF Regeneration on page 3-13.
NOTE If you ignore the warning lamp and do not initiate regeneration at the soonest, safest possible time, the DPF will become increasingly clogged with soot and can lead to engine shutdown.
PACCAR PX-7 and PX-9 Engines and Cummins ISL Engine: Regardless if the DPF lamp is on or off, the engine speed will automatically increase to 1000 to 1100 RPM and remain at this speed for 10 minutes to perform an automated DPF cleaning. If necessary, the RPMs can be lowered by depressing the throttle, clutch, or brake pedal. If the engine continues to idle, the aftertreatment system will try again to raise the idle speed until the aftertreatment temperatures are suitable.
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Selective Catalytic Reduction (SCR) System
Selective Catalytic Reduction (SCR) System
Introduction
The SCR system consists of a Diesel Exhaust Fluid (DEF) Doser and a SCR Catalyst. The DEF Doser sprays a small amount of DEF into the exhaust. The SCR Catalyst reacts with the DEF to break down the Nitrogen Oxides (NOx) in the exhaust into nitrogen and water vapor.
Diesel Exhaust Fluid (DEF) Gauge
1 DEF Symbol
2 DEFWarning Lamp
DEF is consumable and needs to be replenished, so monitor the DEF level gauge as you would the fuel level gauge.
The DEF warning lamp will illuminate for the following 3 reasons:
1. DEF Level Warning: To warn you to refill the DEF tank. The warning lamp will turn on when the gauge needle is near or in the red zone. There are 4 stages to this warning.
CAUTION
If the DEF warning lamp turns on due to the DEF level, refill the DEF tank. Failure to refill may cause the engine to derate and limit vehicle speed.
2. DEF Quality: The engine detects that DEF quality is below acceptable levels. The gauge needle is in the upper region, indicating there is fluid, but the quality is poor. There are 3 stages to these warnings.
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Selective Catalytic Reduction (SCR) System
CAUTION
If the DEF warning lamp turns on due to DEF Quality, see Contamina- tion/Incorrect Fluid for corrective ac- tion. Failure to correct may cause the engine to derate and limit vehi- cle speed.
3. SCR System Tampering: To warn you when the engine system detects failures that may be the result of tampering with the SCR system. The gauge needle is in the upper region, indicating there is fluid, but system failure is detected. There are 3 stages to this warning.
CAUTION
If the DEF warning lamp turns on due to System Tampering, see your authorized PACCAR dealer to have this repaired. Failure to repair the system may cause the engine to de- rate and limit vehicle speed.
System Status Non-Emergency Vehicles Emergency Vehicles DEF Level Warning See table on page 3-20. See table on page 3-23. DEF Quality (except PX) See table on page 3-21. See table on page 3-24. SCR System Tampering See table on page 3-22. See table on page 3-25.
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Selective Catalytic Reduction (SCR) System
DEF Level Warning Non-Emergency Vehicles
DEF LEVEL WARNING NON-EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on Engine
0 None DEF Level sufficient None
1 DEF Warning Lamp on
DEF Level fallen below initial warning None
2 DEF Warning Lamp
flashing
DEF Level fallen below critical
warning None
3 DEF Warning Lamp
flashing Check Engine Lamp
on
DEF Level empty Engine power derated
4 DEF Warning Lamp
flashing Check Engine Lamp
on Malfunction Indicator Lamp (MIL) on (Not on
MX engine)
Stop Engine Lamp may be on
DEF level empty and either engine has been shut down or a fuel re-fill has
occurred
Engine power derated and / or vehicle speed significantly limited
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Selective Catalytic Reduction (SCR) System
DEF Quality Non-Emergency Vehicles
DEF QUALITY NON-EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on
Engine
0 None No Quality Issue None
1 DEF Warning Lamp on
(MX engine only) Check Engine Lamp on
(Not on ISX Engine) Malfunction Indicator Lamp (MIL) on (May not apply to
all engines)
Quality Issue Detected
None
2 DEF Warning Lamp flashing (MX engine only)
Check Engine Lamp on MIL on (May not apply to all engines)
Detected + 1 hour
Engine power derated 25%
3 DEF Warning Lamp flashing (MX engine only)
Check Engine Lamp on MIL on (May not apply to all engines)
Detected + 2 hours
Engine power derated 40%, additional 1% per minute
4 DEF Warning Lamp flashing (MX engine only)
Check Engine Lamp on MIL on (May not apply to all engines)
Stop Engine Lamp may be on
Detected + 3 hours
Engine power derated and / or vehicle speed reduced to 8 kph (5 mph)
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Selective Catalytic Reduction (SCR) System
SCR Component Failure Non-Emergency Vehicles
SCR COMPONENT FAILURE NON-EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on
Engine 0 None No Issue None
1 DEF Warning Lamp on (MX
engine only) Check Engine Lamp on Malfunction Indicator
Lamp (MIL) on (May not apply to all engines)
Failure Detected None
2 DEF Warning Lamp flashing
(MX engine only) Check Engine Lamp on MIL on (May not apply
to all engines)
Detected + 1 hour
Engine power derated
3 DEF Warning Lamp flashing
(MX engine only) Check Engine Lamp on MIL on (May not apply
to all engines) Stop Engine Lamp
may be on
Detected + 5 hours
Engine power derated and / or vehicle speed significantly
limited
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Selective Catalytic Reduction (SCR) System
DEF Level Warning Emergency Vehicles
DEF LEVEL WARNING EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on Engine
0 None DEF Level Sufficient None
1 DEF Warning Lamp on
DEF Level fallen below initial warning None
2 DEF Warning Lamp
flashing
DEF Level fallen below critical
warning None
3 DEF Warning Lamp
flashing Check Engine Lamp
on
DEF Level less than 5%
Vehicle speed limited to 88 kph
(55 mph)
4 DEF Warning Lamp
flashing Check Engine Lamp
on Malfunction Indicator
Lamp (MIL) on Stop Engine Lamp
may be on
DEF Level empty and vehicle has been shut down
Vehicle speed limited to 40 kph
(25 mph)
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3
Selective Catalytic Reduction (SCR) System
DEF Quality Emergency Vehicles
DEF QUALITY EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on Engine
0 None No DEF Quality Issue None
1 DEF Warning Lamp on
(MX engine only) Check Engine Lamp on (Not on ISX Engine)
MIL on (May not apply to all engines)
Quality Issue Detected None
2 DEF Warning Lamp flashing (MX engine
only)
Check Engine Lamp on
MIL on (May not apply to all engines)
Detected + 10 hours Vehicle speed limited to 88 kph
(55 mph)
3 DEF Warning Lamp flashing (MX engine
only)
Check Engine Lamp on
MIL on (May not apply to all engines)
Stop Engine Lamp may be on
Detected + 20 hours and the engine has been shut down
Vehicle speed limited to 40 kph
(25 mph)
3-24
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Selective Catalytic Reduction (SCR) System
SCR Component Failure Emergency Vehicles
SCR COMPONENT FAILURE EMERGENCY VEHICLES Warning Level Warnings Indicators Condition Effect on Engine
0 None No Issue None
1 DEF Warning Lamp on (MX engine only)
Check Engine Lamp on
Malfunction Indicator Lamp (MIL) on (May not apply to all
engines)
Failure Detected None
2 DEF Warning Lamp flashing (MX engine
only)
Check Engine Lamp on
MIL on (May not apply to all engines)
Detected + 10 hours Vehicle speed limited to 88 kph
(55 mph)
3 DEF Warning Lamp flashing (MX engine
only)
Check Engine Lamp on
MIL on (May not apply to all engines)
Stop Engine Lamp may be on
Detected + 40 hours and the engine has been shut down
Vehicle speed limited to 40 kph
(25 mph)
3-25
3
INFORMATION
Information Introduction . . . . . . . . . . . . . . . . . . 6-3 Tampering with Aftertreatment System . . . . . . . 6-4
Diesel Particulate Filter (DPF) System Overview . . . . . . . . . . . . . . . . . . . 6-5
Selective Catalytic Reduction (SCR) System Overview . . . . . . . . . . . . . . . . . . . 6-7 Diesel Exhaust Fluid (DEF) Recommendations and Specifications . . . . . . . . . . . . . . . . 6-8
Storage . . . . . . . . . . . . . . . . . . . 6-10 Handling . . . . . . . . . . . . . . . . . . . 6-11 Disposal . . . . . . . . . . . . . . . . . . . 6-11 Contamination/Incorrect Fluid . . . . . . . . . 6-12 Freezing . . . . . . . . . . . . . . . . . . . 6-12
6-1
6
Information
Information
Introduction
The Aftertreatment System (ATS) on your vehicle is made up of two systems:
1. Diesel Particulate Filter (DPF) System
2. Selective Catalytic Reduction (SCR) System
They fulfill two primary functions: particulate reduction & nitrogen oxide (NOx) reduction.
This section of the manual provides more detailed information about the aftertreatment process and its components.
6-3
6
Information
Tampering with Aftertreatment System
The aftertreatment system for your vehicle as installed from the factory was specifically designed to meet the emissions requirements of the US Environmental Protection Agency and California Air Resources Board. Any changes of component locations or modifications of any aftertreatment system components may reduce the emission effectiveness and you may be subject to fines under the United States Clean Air Act.
6-4
6
Diesel Particulate Filter (DPF) System
Diesel Particulate Filter (DPF) System
Overview
The DPF system consists of a Hydrocarbon (HC) Doser (may not apply to all engines), a Diesel Oxidation Catalyst (DOC), and a DPF.
The components of the DPF system perform the following functions:
The ATS inlet and outlet adapt the vehicle exhaust piping to the ATS, and also provide a mounting location for the aftertreatment gas temperature sensors.
The DPF differential pressure sensor measures the restriction across the DPF.
The DPF filters soot out of the exhaust.
When activated, the HC Doser sprays a small amount of diesel fuel (the HC) into the exhaust. The catalyst in the DOC reacts with the HC to generate heat. The heat is used to clean (regenerate) the DPF by reducing the trapped soot to ash.
Soot is composed of the partially burned particles of fuel that occur during normal engine operation (black smoke).
Over time, both soot and ash accumulate in the DPF and must be removed. Soot is removed by a process called regeneration. Ash is removed by removing the DPF and cleaning it at specified intervals.
A vehicle with a DPF has up to two additional indicator lamps on the dashboard. The two additional lamps, along with the check
engine lamp, alert the operator of the status of the DPF.
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Diesel Particulate Filter (DPF) System
CAUTION Do not submerge or allow water to enter the DPF assembly. Compo- nents of the assembly can be dam- aged and effect the performance of the aftertreatment system. Failure to comply may result in equipment or property damage.
NOTE Refer to your engine manufacturers Operators Manual for diesel partic- ulate filter (DPF) maintenance infor- mation.
NOTE Refer to your vehicle or engine man- ufacturers Operators Manual for additional information on the engine indicator lamps.
NOTE Ultra low sulfur diesel (ULSD) fuel is required for engines equipped with an aftertreatment diesel particulate filter. If ULSD is not used, the engine may not meet emissions regula- tions, and the DPF or aftertreatment Diesel Oxidation Catalyst (DOC) can be damaged.
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Selective Catalytic Reduction (SCR) System
Selective Catalytic Reduction (SCR) System
Overview
The SCR system is composed of several main components:
1. Diesel Exhaust Fluid (DEF) Controller (Except PX)
2. DEF Dosing Unit (DEF Module)
3. DEF Dosing Valve
4. SCR Catalyst
NOTE It is unlawful to tamper with, modify, or remove any component of the SCR system. It is also unlawful to use DEF that does not meet the specifications provided or to operate the vehicle/equipment with no DEF.
DEF is required for an engine equipped with a SCR system. DEF is a fluid that
is sprayed into the exhaust gas prior to the SCR catalyst. The DEF vaporizes and decomposes to form carbon dioxide and ammonia. The ammonia reacts with the NOx emissions over the aftertreatment SCR catalyst to form nitrogen and water.
DEF:
may have a slight ammonia smell
is colorless
is non-toxic and non-polluting
is non-flammable
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Selective Catalytic Reduction (SCR) System
Diesel Exhaust Fluid (DEF) Recommendations and Specifications
WARNING!
It is unlawful to tamper with or re- move any component of the af- tertreatment system. It is also un- lawful to use a Diesel Exhaust Fluid (DEF) that does not meet the spec- ifications provided or to operate the vehicle/equipment without Diesel Exhaust Fluid (DEF).
WARNING!
Diesel Exhaust Fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow inter- nally. In the event the diesel exhaust fluid is ingested, contact a physician immediately. Reference the Mate- rials Safety Data Sheet (MSDS) for additional information.
CAUTION Never attempt to create Diesel Ex- haust Fluid (DEF) by mixing agricul- tural grade urea with water. Agricul- tural grade urea does not meet the necessary specifications required and the aftertreatment system may be damaged.
CAUTION
PACCAR Inc requires the use of DEF meeting ISO 22241-1 (DIN 70070) specifications. There is NO acceptable substitute. Failure to use the correct DEF may cause engine damage and/or void the warranty.
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Selective Catalytic Reduction (SCR) System
NOTE Some locations may reference the DIN 70070 standard. DEF specifica- tion limits of this standard are identi- cal to ISO 22241-1.
PACCAR Inc is not responsible for failures or damage resulting from what PACCAR Inc determines to be abuse or neglect, including but not limited to: operation without correctly specified DEF; lack of maintenance of aftertreatment; improper storage, or shutdown practices; unauthorized modifications of the engine and aftertreatment. PACCAR is also not responsible for failures caused by incorrect DEF or by water, dirt or other contaminants in the DEF. Refer to your engine and vehicle operator's manuals for maintenance, storage, and shutdown information.
For engines using SCR operating in the United States and Canada, it is recommended that the DEF used be certified by the American Petroleum Institute (API).
NOTE To ensure the correct DEF is used, PACCAR Inc recommends the use of TRP CleanBlue Diesel Exhaust Fluid which is available in different quantity options from small to bulk containers.
DEF is readily available at truck stops and at all PACCAR Engine dealers. For assistance locating DEF, contact your local PACCAR authorized repair lo