2017 Emissions 2017-2018 Model Years OperatorOperator’’ss ManualManual Warranty
Contents
Engine Operation ...... 1
Engine Maintenance ...... 2
Engine Warranty ...... 3 Contents
© 2018 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. ENGINE OPERATION
1 Chapter 1 | ENGINE OPERATION
Safety - Introduction ...... 6 Emergency - What To Do If ...... 11 Operating Instructions ...... 14
Y53-1185-1E1 (04/16/18) 5 ENGINE OPERATION - Safety - Introduction Chapter 1 | Engine Operation indicate that in a cross-reference like this: (See Safety Alerts on page 6 ). You 1 NOTE Safety - Introduction won’t have to go searching for more information. Finally you’ll find a helpful After you’ve read this manual, it should Subject Index. It’s in the back of the Using this Manual be stored in the cab for convenient ref- manual and alphabetically lists the subjects erence and remain with this truck covered. So if you want information on Please take the time to get acquainted with when sold. brakes, for example, just look under Brake your vehicle by reading this Operator’s in the Subject Index. You’ll find all the Manual. We recommend that you read and Your vehicle may not have all the features pages listed where brakes or braking are understand this manual from beginning to or options mentioned in this manual. discussed. end before you operate this equipment. Therefore, you should pay careful attention This manual contains useful information for to the instructions that pertain to just your All information contained in this manual is the safe and efficient operation of this vehicle. In addition, if your vehicle is based on the latest production information equipment. It also provides service equipped with special equipment or options available at the time of publication. information, with an outline for performing not discussed in this manual, consult your Kenworth Truck Company Peterbilt Motors safety checks and basic preventive dealer or the manufacturer of the Company reserves the right to make maintenance inspections. We have tried to equipment. changes at any time without notice. present the information you’ll need to learn There are several tools built into this about functions, controls, and operation— manual to help you find what you need Safety Alerts and to present it as clearly as possible. We quickly and easily. First is the Quick Table hope you’ll find this manual easy to use. of Contents. Located at the front of the Please read and follow all of the safety There will be times when you need to take manual, this lists the main subjects alerts contained in this manual. They are this manual out of the glovebox. When you covered and gives section numbers where there for your protection and information. do, please be sure to return it when you you can find these subjects. Use the Quick These alerts can help you avoid injury to are finished using it. That way it will be Table of Contents to find information on a yourself, your passengers and help prevent there when you need it the next time or large subject like “Maintenance.” Cross- costly damage to the vehicle. Safety alerts when you pass the vehicle on to the next referenced citations also help you get the are highlighted by safety alert symbols and user. information you need. If some other part of signal words such as “WARNING”, the manual contains further information on “CAUTION”, or “NOTE”. Please DO NOT the subject you are reading about, we’ll ignore any of these alerts.
6 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Safety - Introduction
Warnings The safety message following this symbol and signal word provides a caution against 1 operating procedures which could cause NOTE equipment or property damage. The alert will identify the hazard, how to avoid it, and Pumping the accelerator will not assist the probable consequence of not avoiding in starting the engine. The safety message following this symbol the hazard. and signal word provides a warning against operating procedures which could cause Forward death or injury. They could also cause CAUTION How to use this manual. equipment or property damage. The alert will identify the hazard, how to avoid it and Continuing to operate your vehicle with This manual contains information for the the probable consequence of not avoiding insufficient oil pressure will cause seri- correct operation and maintenance of your the hazard. ous engine damage. Failure to comply PACCAR engine. Read and follow all may result in equipment or property safety instructions. Refer to the WARNING damage. in the General Safety Instructions on page WARNING 8 . Keep this manual with the equipment. Notes If the equipment is traded or sold, give the Hot engine oil can be dangerous. You manual to the new owner. could be burned. Let the engine oil cool down before changing it. Failure The information, specifications, and to comply may result in death, person- recommended maintenance guidelines in al injury, equipment or property dam- this manual are based on information in age. The message following this symbol and effect at the time of printing. PACCAR signal word provides important information reserves the right to make changes at any Cautions that is not safety related but should be time without obligation. If you find followed. The alert will highlight things that differences between your engine and the may not be obvious and is useful to your information in this manual, contact your efficient operation of the vehicle. local PACCAR Authorized Repair Location or write to:
Y53-1185-1E1 (04/16/18) 7 ENGINE OPERATION - Safety - Introduction
The illustrations are intended to show of its load ratings. See the Weight Ratings 1 PACCAR c/o PACCAR Engines repair or replacement procedures. The label on the driver's door edge. procedure will be the same for all PO Box 1518 Bellevue, WA 98009 applications, although the illustration may Every new vehicle is designed to conform differ. to all Federal Motor Vehicle Safety Standards applicable at the time of The latest technology and the highest manufacture. Even with these safety quality components were used to produce General Safety Instructions features, continued safe and reliable this engine. When replacement parts are operation depends greatly upon regular needed, we recommend using only Important safety notices about operating vehicle maintenance. Follow the genuine parts from PACCAR. and servicing your engine. maintenance recommendations found in Preventive Maintenance section. This will NOTE WARNING help preserve your investment. Make sure your vehicle is in top working Warranty information including the Improper practices, carelessness, or condition before heading out on the road, it EPA and California Emission Warranty ignoring any warnings may cause is the responsible driver's duty to do so. is located in the section entitled “En- death, personal injury, equipment or Inspect the vehicle according to the gine Warranty.” Make sure you are fa- property damage. Driver's Check List. miliar with the warranty or warranties applicable to your engine. Before performing any repair, read and • Use the proper tool for manually understand all of the safety precautions rotating the engine. DO NOT attempt and warnings. The following is a list of to rotate the crankshaft by pulling or Illustrations general safety precautions that must be prying on the fan. This practice can followed to provide personal safety. Failure Some of the illustrations throughout this cause death, personal injury, to follow these instructions may cause manual are generic and will NOT look equipment damage, or damage to death or injury. Special safety precautions exactly like the engine or parts used in the fan blades, causing premature are included in the procedures when they your application. The illustrations can fan failure. apply. contain symbols to indicate an action • Work areas should be dry, well lit, required and\or an acceptable or NOT Keep in mind that even a well maintained well ventilated, free from clutter, acceptable condition. vehicle must be operated within the range loose tools, parts, ignition sources of its mechanical capabilities and the limits and hazardous substances.
8 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Safety - Introduction
• Wear protective glasses and refrigerant systems must be properly protective shoes when working. caping. In any situation, remove the emptied and filled using equipment cap very slowly and carefully. Be ready 1 • DO NOT wear loose-fitting or torn that prevents the release of to back off if any steam or coolant be- clothing. Tie back and/or tuck in long refrigerant gas. Federal law requires gins to escape. hair. Remove all jewelry when capturing and recycling refrigerant. working. • When moving or lifting any heavy • Always use wheel chocks or proper equipment or parts, make sure to use • Before beginning any repair, jack stands to support the vehicle or proper techniques and assistance. disconnect the battery (negative [-] vehicle components before Ensure all lifting devices such as cable) and discharge any capacitors. performing any service work. DO chains, hooks, or slings are in good • Put a “DO NOT OPERATE” tag in the NOT work on anything that is condition and are of the correct load operator's compartment or on the supported only by lifting jacks or a capacity. Make sure all lifting devices controls. hoist. Before resting a vehicle on jack are positioned correctly. • Allow the engine to cool before stands, be sure the stands are rated slowly loosening the coolant filler cap for the load you will be placing on • Corrosion inhibitors and lubricating to relieve the pressure from the them. oils may contain alkali. DO NOT get the substance in eyes and avoid cooling system. • Before removing or disconnecting prolonged or repeated contact with any lines, fittings, or related items, skin. DO NOT swallow. If ingested, relieve all pressure in the air, oil, fuel, WARNING seek immediate medical attention. and cooling systems. Remain alert DO NOT induce vomiting. In case of for possible pressure when Removing the fill cap on a hot engine contact, immediately wash skin with disconnecting any device from a can cause scalding coolant to spray soap and water. In case of harmful system that contains pressure. High out and burn you badly. If the engine contact, immediately contact a pressure oil or fuel can cause death has been in operation within the previ- physician. Always keep any or personal injury. ous 30 minutes, be very careful in re- chemicals OUT OF REACH OF moving the fill cap. Protect face, • Always wear protective clothing when CHILDREN. working on any refrigerant lines and hands, and arms against escaping flu- • Naptha and Methyl Ethyl Ketone make sure that the workplace is well id and steam by covering the cap with (MEK) are flammable materials and ventilated. Inhalation of fumes can a large, thick rag. DO NOT try to re- must be used with caution. Follow cause death or personal injury. To move it until the surge tank cools down the manufacturer's instructions to protect the environment, liquid or if you see any steam or coolant es- ensure safety when using these
Y53-1185-1E1 (04/16/18) 9 ENGINE OPERATION - Safety - Introduction
materials. Always keep any • DO NOT perform any repair when California Proposition 65 Warning chemicals OUT OF REACH OF impaired, tired, fatigued or after 1 • Diesel engine exhaust and some of CHILDREN. consuming alcohol or drugs that can its constituents are known to the impair your functioning. • When working on the vehicle, be State of California to cause cancer, alert for hot parts on systems that • Some state and federal agencies in birth defects, and other reproductive have just been turned off, exhaust the United States of America have harm. gas flow, and hot fluids in lines, determined that used engine oil can • The catalyst substrate located in the tubes, and compartments. Contact be carcinogenic and can cause Diesel Particulate Filter (DPF) with any hot surface may cause reproductive toxicity. Avoid inhalation contains vanadium pentoxide, which burns. of vapors, ingestion, and prolonged has been determined by the State of contact with used engine oil. • Always use tools that are in good California to cause cancer. Always condition. Make sure you have the • DO NOT connect the jump starting or wear protective clothing and eye proper understanding of how to use battery charging cables to any protection when handling the catalyst the tools before performing any ignition or governor control wiring. assembly. Dispose of the catalyst in service work. Use only genuine This can cause electrical damage to accordance with local regulations. If replacement parts from PACCAR. the ignition or governor. catalyst material gets into the eyes, • Always use the same fastener part • Coolant is toxic. If not reused, immediately flood eyes with water for number (or equivalent) when dispose of coolant in accordance with a minimum of 15 minutes. Avoid replacing items. DO NOT use a local environmental regulations. prolonged contact with skin. In case fastener of lesser quality if of contact, immediately wash skin replacements are necessary. (e.g., CAUTION with soap and water. In case of DO NOT replace a SAE 10.9 grade harmful contact, immediately contact with 8.8 grade fastener.) a physician. Corrosive chemicals can damage the • Always torque fasteners and fuel • Other chemicals in this vehicle are connections to the required engine. DO NOT use corrosive chemi- cals on the engine. Failure to comply also known to the State of California specifications. Overtightening or to cause cancer, birth defects or under-tightening can allow leakage. may result in equipment, or property damage. other reproductive harm. • Close the manual fuel valves prior to • Battery posts, terminals, and related performing maintenance and repairs, accessories contain lead and lead and when storing the vehicle inside. compounds, chemicals known to the
10 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Emergency - What To Do If
State of California to cause cancer permits, chains, towing, hazardous and reproductive harm. Wash hands clean-up, out of fuel (roadside), 1 after handling. mechanical repairs and preventive WARNING maintenance services. If the Stop Engine warning lamp illumi- • They have multilingual agents and nates, it means you have a serious en- access to a translation service to Emergency - What To Do If gine system problem. This should be ensure quality assistance for considered an emergency. You should customers in any language. Roadside Assistance stop the vehicle as safely as possible • They can’t answer your warranty and turn OFF the ignition. The vehicle What to do in an emergency and roadside questions, but can get you in contact must be serviced and the problem cor- assistance information. with an authorized dealer who can. rected before driving again. Failure to • The PACCAR Customer Center Call toll-free to talk to someone at the comply may result in death, personal service is FREE. PACCAR Customer Center: injury, equipment or property damage. • Kenworth customers call: 1-800-KW- For engines with the engine-protection Stop Engine Lamp Assist (1-800-592-7747) | Peterbilt shutdown feature enabled, the stop engine customers call: 1-800-4Peterbilt lamp will begin to flash 30 seconds before (800-473-8372) the engine automatically shuts down. The • Open 24-7-365 days a year. warning lamp alerts the operator to the • They can help you get roadside impending shutdown. assistance. The lamp will also illuminate when the DEF • They have a custom mapping system 1 2 tank is almost empty or the soot level in the which locates authorized PACCAR DPF is at full capacity. At this level engine dealers and Independent The stop engine warning lamp will warning, regeneration cannot be performed Service Providers (ISPs) near you illuminate, and an audible tone will sound, and engine power will be derated. and lists types of services offered, when a major engine problem exists. Your hours of operation and contact vehicle will be equipped with one of the Engine may automatically shut down if the information. indicators above, 1 or 2, depending on the check engine lamp and stop engine lamp • They can assist with jump and pull engine model. are illuminated and the operator does not starts, tires, trailers, fines and correct the condition.
Y53-1185-1E1 (04/16/18) 11 ENGINE OPERATION - Emergency - What To Do If
Engine Oil Pressure Lamp Turns shifting and parking brake 1 On information.) CAUTION What to do if the engine oil pressure lamp 4. Turn OFF the engine. 5. Turn ON the emergency flasher and turns on. Continuing to operate your vehicle with use other warning devices to alert insufficient oil pressure will cause seri- other motorists. ous engine damage. Failure to comply may result in equipment or property 6. Wait a 15–20 minutes to allow oil to damage. drain into the engine oil pan, and then check the oil level. See Engine • If the oil pressure fails to rise within Oil Level. 10 seconds after the engine starts, 7. Add oil if necessary. If the problem stop the engine and determine the persists, contact an authorized cause. PACCAR engine dealer as soon as • See Engine Oil Specification for the possible. correct oil pressure ranges for your vehicle's engine. Check Engine Lamp Turns On • If the oil pressure suddenly drops, or the audible alarm and engine oil What to do if the check engine lamp turns pressure warning light come on while on. driving, do the following: It is important to maintain oil pressure within acceptable limits. If oil pressure 1. Slow down carefully. drops below the minimum psi a red 2. Move a safe distance off the road warning lamp on the oil pressure gauge and stop. and the Stop Engine Lamp will come ON. 3. Place the transmission in neutral (N) and set the parking brake. (See Or Parking Brake Valve and Operating the Transmission in your vehicle Operator's Manual, for transmission
12 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Emergency - What To Do If
sudden loss of coolant. Follow these steps if the engine is overheating. • Debris blocking air flow through the cooling module (radiator) 1
If the engine coolant temperature warning Check Engine Lamp - Turns on when a lamp comes on and the audible alarm problem exists, but the vehicle can still be sounds showing an overheat condition, or safely driven. Vehicle should be serviced to if you have any other reason to suspect the correct the problem but the situation should engine may be overheating, DO NOT not be considered an emergency. CAUTION TURN OFF THE ENGINE unless a low water warning device indicates a loss of The lamp will also illuminate when a DPF The cooling system may overheat if coolant. Follow these steps: regeneration or addition of diesel exhaust the engine coolant is at the minimum fluid (DEF) is required. For PACCAR PX level. A sudden loss of coolant, Follow these steps if the engine coolant Engines, this icon may also illuminate if the caused by a split hose or broken hose temperature is rising, or the temperature is crankcase breather element needs clamp could also lead to an overheat already above normal, and there are no attention. Another function of the check condition. Always inspect to ensure other warning alarms displayed in the engine lamp is to warn the operator of an hoses and clamps are not cracked, instrument cluster. impending idle shutdown. When the idle worn, or loose. Failure to comply may shutdown timer is 30 seconds from result in equipment or property dam- 1. Reduce engine speed, or stop. When expiring, the ECM begins flashing the age. stopped, place the transmission in check engine warning lamp once per neutral (N) and set the parking brake. second. When the timer expires, the ECM Keep the engine running. See the will turn off the warning lamp and shut NOTE vehicle operator's manual for down the engine. instructions on transmission shifting The system may also temporarily over- and parking brake information. Engine is Overheating heat during severe operating condi- tions such as: The cooling system may overheat if the coolant level is below normal or if there is • Climbing a hill on a hot day • Stopping after high-speed/high- load driving
Y53-1185-1E1 (04/16/18) 13 ENGINE OPERATION - Operating Instructions
hands, and arms against escap- normal, allow the engine to idle 3 to 5 1 WARNING ing fluid and steam by covering minutes before shutting it off. This the cap with a large, thick rag. allows the engine to cool gradually To reduce the chance of person- DO NOT try to remove it until the and uniformly. al injury, vehicle damage and/or surge tank cools down or if you 6. If overheating came from severe death from overheated engines, see any steam or coolant escap- operating conditions, the temperature which can result in a fire, never ing. In any situation, remove the should have cooled by this time. If it leave the engine idling without cap very slowly and carefully. Be has not, stop the engine and let it an alert driver present. If the en- ready to back off if any steam or cool before checking to see if the gine should overheat, as indicat- coolant begins to escape. coolant is low. ed by the engine coolant temper- 7. Be sure the vehicle is parked on level ature light, immediate action is ground or the readings may be required to correct the condition. NOTE incorrect. Check the coolant level at Continued unattended operation the cooling module surge tank. of the engine, even for a short Keep the engine running at idle time, may result in serious en- speed unless a warning icon Check the coolant level after each trip gine damage or a fire. Failure to turns on that requires the engine when the engine has cooled. The coolant comply may result in death, per- to be shut off. level should be visible within the surge sonal injury, equipment or prop- tank. Add coolant if necessary. 2. Check to ensure the Oil Pressure erty damage. Gauge reads normal. 3. Make sure the engine fan is turning WARNING by switching the Engine Fan Switch from AUTO to MAN (Manual). Operating Instructions Removing the fill cap on a hot 4. Increase the engine speed to about engine can cause scalding cool- one-half of full operating speed, or Engine Warning Lamps 1,100 to 1,200 rpm, maximum for 2 ant to spray out and burn you Explanation of engine related warning or 3 minutes. badly. If the engine has been in lamps. operation within the previous 30 5. Return the engine speed to normal minutes, be very careful in re- idle. Monitor the engine temperature. The following engine warning lamps moving the fill cap. Protect face, After the temperature returns to section covers only the lamps controlled by
14 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
the engine’s Electronic Control Module when a major engine problem exists. Your Engine may automatically shut down if the (ECM). Please refer to the vehicle vehicle will be equipped with one of the check engine lamp and stop engine lamp 1 “Operator's Manual” and “Engine indicators above, 1 or 2, depending on the are illuminated and the operator does not Aftertreatement Systems” manuals for engine model. correct the condition. additional warning lamp information.
WARNING Engine, Check Engine CAUTION If the Stop Engine warning lamp illumi- The installation of electronic devices to nates, it means you have a serious en- the On Board Diagnostics (OBD) con- gine system problem. This should be nector, the vehicle Controller Area Net- considered an emergency. You should work (CAN), or their associated wiring stop the vehicle as safely as possible is not permitted. Doing so can ad- and turn OFF the ignition. The vehicle versely affect vehicle performance must be serviced and the problem cor- and/or cause fault codes to be record- rected before driving again. Failure to Or ed. The OBD connector is provided for comply may result in death, personal temporary connection of service tools injury, equipment or property damage. and for diagnostic purposes only. For engines with the engine-protection shutdown feature enabled, the stop engine Illuminates when a non emissions related Stop Engine Lamp lamp will begin to flash 30 seconds before problem exists, but the vehicle can still be the engine automatically shuts down. The safely driven. Vehicle should be serviced to warning lamp alerts the operator to the correct the problem but the situation should impending shutdown. not be considered an emergency. The lamp will also illuminate when the DEF tank is almost empty or the soot level in the 1 2 DPF is at full capacity. At this level warning, regeneration cannot be performed The stop engine warning lamp will and engine power will be derated. illuminate, and an audible tone will sound,
Y53-1185-1E1 (04/16/18) 15 ENGINE OPERATION - Operating Instructions
Malfunction Indicator Lamp Diesel Particulate Filter (DPF) High Exhaust System Temperature 1 Warning Lamp (HEST) Warning Lamp This warning symbol will appear when the Engine aftertreatment system includes a DPF needs to be regenerated and then high exhaust system temperature (HEST) also during the regeneration cycle. This warning lamp. icon may also appear if the system is attempting to automatically regenerate Illuminates when an engine emissions while the vehicle is in Power Take Off failure has occurred. The vehicle can be operation mode. safely driven but should be serviced to correct the problem. The situation should not be considered an emergency. In some cases, the Malfunction Indicator Lamp Keep vehicle a safe distance from (MIL) will activate in conjunction with the combustible items. High Exhaust System Temperature (HEST), Diesel Particulate Filter (DPF) and Diesel Exhaust Fluid (DEF) warning lamps. Engine aftertreatment system includes a WARNING diesel particulate filter and DPF warning lamp. Temperature of the tail pipe, exhaust NOTE pipe, the diesel particular filter (DPF)/ selective catalytic reduction (SCR) de- The malfunction indicator lamp (MIL) vice and surrounding components in- will illuminate if the on-board diagnos- cluding enclosures and steps, will be tics (OBD) system detects a possible elevated during and shortly after a re- emissions system failure. The vehicle generation event or normal vehicle op- should be brought in for service at the eration when engine is under high or next opportunity to ensure the condi- heavy loading. tion is corrected. If the High Exhaust System Temperature (HEST) warning lamp is on:
16 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
• Do not park in an area of combustible the DEF gauge and additional warning seek service immediately for DEF fluid vapors or materials. You must keep lamps in the instrument cluster. quality or DEF equipment repair. 1 combustibles at least 5 ft. (1.5 m) DEF Warning Lamp in Instrument away from the exhaust (outlet) Engine Wait-To-Start Lamp stream (as it exits the tail pipe) while Cluster the HEST lamp is illuminated. Always This warning icon will appear when the park your vehicle outside. Failure to system needs some time before attempting do so could ignite an explosion or to start the engine. The lamp will illuminate harm bystanders which could result at key ON, and will stay on for a period of in serious injury. up to 30 seconds. • Do not park in an area where people Diesel Exhaust Fluid (DEF) Gauge are close by. You must keep combustibles at least 5 ft. (1.5 m) away from the exhaust outlet while the HEST lamp is illuminated. Failure to do so could result in serious injury. • Do not approach the exhaust system NOTE or surrounding areas without allowing adequate time for the system to cool The length of time the 'Wait-To-Start' down. Failure to do so could result in lamp remains illuminated depends on serious burns to the skin. the ambient temperature. The lower the ambient temperature, the longer Diesel Exhaust Fluid (DEF) Lamp the lamp will be illuminated. 1 2 Engine aftertreatment system includes a Once the Wait-to-Start lamp turns off, turn diesel exhaust fluid (DEF) warning lamp on 1. DEF Symbol the key to the starting position to start the engine. 2. DEF gauge warning lamp You may see this appear if the system has The DEF lamp(s) will illuminate when the detected a situation where the starter is too fluid in the DEF tank reaches a low level. If hot and needs to cool down. Alternatively, the lamp illuminates but the level is full,
Y53-1185-1E1 (04/16/18) 17 ENGINE OPERATION - Operating Instructions
you may see it when the engine grid heater and tear on the service brakes. However, 1 is on and needs some time to warm up. the engine compression or exhaust brake brake alone might not stop the vehicle (PACCAR PX and Cummins ISL engines) is not an emergency brake or the primary fast enough to prevent an accident. vehicle brake. The engine compression brake is NOT intended as the primary brake for the NOTE vehicle, nor is it an emergency brake. WARNING The engine compression brake only Some engines are equipped with an helps the service brakes by using en- engine starting motor protection fea- DO NOT operate the engine compres- gine back pressure to slow the drive- ture. If the starting motor is engaged sion brake when driving/operating your train. Use the service brakes for quick for 30 or more seconds, without the vehicle bobtail or with a loaded or un- stops. You could be seriously injured if engine starting, the starter will be loaded trailer on road surfaces with you relied only on the engine compres- locked out from operating, allowing for poor traction (wet, icy, or snow cov- sion brake to stop the vehicle in an proper cooling of the starting motor. ered roads) or in heavy traffic. There emergency. Failure to comply may re- During this time, the 'Wait-To-Start' may not be enough weight on the rear sult in death, personal injury, equip- lamp will flash for 2 minutes. Once the axle to provide traction. Braking ment or property damage. lamp stops flashing, the starting motor caused by the normal operation of the will be allowed to function. engine compression brake could cause you to lose control of the vehi- CAUTION cle, resulting in an injury accident. Engine Braking System Make sure the engine brake is switch- DO NOT operate the engine brake un- ed "OFF" when bobtailing or with an Information on using the engine braking til the engine oil temperature is above unloaded trailer. Failure to comply may system. 86°F (30°C). Operation below 86°F result in death, personal injury, equip- (30°C) could cause severe damage to An engine compression brake is standard ment or property damage. the engine. Idle the engine four mi- on the PX-9 engines. Optionally, this nutes at approximately 1,000 rpm to engine may be equipped with an exahust warm the engine before activating the brake. When activated, these devices WARNING engine brakes. create a braking effect on the drive wheels. Because it can help keep your vehicle’s The service brakes must be used in an brakes from overheating, it can save wear emergency. The engine compression
18 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
1. Do not use the engine compression progressively stronger braking to slow the brake to slow the vehicle down when vehicle down. 1 NOTE you are bobtailing or pulling an empty trailer. Engine compression brake controls If your vehicle is equipped with anti- include: 2. Make sure the brake is OFF before lock brakes (ABS), operation of the starting the engine. • ON/OFF switch compression brake (if turned ON) may be interrupted if the ABS system de- 3. After the engine is started, warmed • Three-position selector switch tects wheel-slip due to operation on up and you are ready to get under • Clutch switch slippery surfaces. way, turn the engine compression • Throttle sensor brake switch ON for added braking • Service brake pressure switch effect. Ideally (on normal road surfaces), you • Eaton Vorad® Anti-Lock Braking should slow your vehicle with the System compression brake (where permitted by NOTE law) and use the service brakes only for Engaging conditions for the engine stopping completely. Operating this way If your vehicle is equipped with compression brake: will greatly prolong the life of the service the Eaton Vorad® system, oper- brakes. • Engine speed must be above 1,000 ation of the compression brake rpm. may be automatically activated. • Coolant temperature must be above Compression Brake 59°F (15°C). Proper use of engine compression brakes. Compression Brake Controls Deactivation conditions for the engine compression brake: With the compression brake switch ON, the Using the compression brake controls. brake automatically creates its braking • Accelerator pedal is depressed. There are two switches on the dash panel effect when you remove your foot from the • Clutch pedal is depressed. accelerator pedal. that control the engine compression brake. A master switch turns the system ON or • Engine speed falls below 800 rpm. The brake switch is located on the OFF. A second switch, located next to the • ABS control is active. accessory dash panel. It controls whether master switch, controls the braking effect. • ECM recognizes a system problem. the brake is ON (ready to slow the vehicle This switch allows you to choose down) or OFF (no braking action).
Y53-1185-1E1 (04/16/18) 19 ENGINE OPERATION - Operating Instructions
percent engine braking. In the down (LOW) Driving 1 position there will be 33 percent engine CAUTION braking. Introduction and important information about operating your vehicle safely. Operating the engine with a compres- With the compression brake switch ON, the sion brake that will not automatically compression brake will be engaged when Correct care of your engine will result in deactivate (i.e. when the dash switch the service brake is applied. If the cruise longer life, better performance, and more is OFF, clutch pedal is depressed or control is operated in conjunction with the economical operation. throttle is applied) will cause severe in- compression brake, the compression brake Follow the daily maintenance checks listed ternal engine damage. Do not operate will engage to maintain the cruise set in Engine Maintenance on page 34 . the engine if the compression brake speed. will not deactivate. Failure to comply The new PACCAR engine associated with Compression on\off may result in equipment or property this manual does not require a “break-in” damage. procedure. This section of the manual provides all of the necessary information required for proper engine operation. Engine Compression Brake Level Switch Operation How to operate the compression brake. Compression setting There are two switches that control your vehicle’s engine compression brake. One switch turns the system ON/OFF and the second switch controls the braking level. These switches are located on the dash switch panel. For the three-position engine compression brake level switch, there will be 100 percent engine braking when the switch is Check the engine oil pressure and engine in the up (HIGH) position. In the middle coolant gauges, warning lamps, and other (MEDIUM) position, there will be 66 gauges daily to make sure they are
20 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
operational. Normally each gauge will Combustible Vapors make a full sweep when ignition key is 1 cycled ON to indicate that the gauge is operating correctly.
1 Do Not Use Combustible Gas in Turbo
NOTE
Numerous safety devices (i.e. engine shutoff devices) are available to mini- mize the risk of engine overspeeding caused by combustible vapors being ingested into the air intake system.
Y53-1185-1E1 (04/16/18) 21 ENGINE OPERATION - Operating Instructions
DO NOT operate your vehicle in an • If starter is engaged continuously 1 area where combustible chemicals or for 30 seconds, you must wait five vapors may be present. Failure to minutes before trying to start the comply may result in death, personal engine to allow the starter motor to injury, equipment or property damage. cool down.
With the key in the ON position, the engine NOTE warning lamps will come on momentarily and then go out. The engine warning IT IS THE RESPONSIBILITY OF THE lamps include: OWNER AND OPERATOR TO OPER- ATE THE VEHICLE IN A SAFE ENVI- PACCAR recommends the installation of RONMENT. an air intake shutoff device or a similar safety device to minimize the risk of overspeeding, as can occur when the NOTE vehicle is being operated in a combustible Check engine lamp; amber in color. environment, such as from a fuel spill or If the engine is running, do not in- gas leak. crease engine speed (rpm) or operate the vehicle until the low oil pressure WARNING warning lamp turns off.
Combustible vapors near the air intake system could be ingested into the en- CAUTION Stop engine lamp; red in color. gine, causing the engine to suddenly accelerate and overspeed. This condi- Engaging the starter motor for more tion could result in operator losing con- than 30 seconds in any five minute pe- trol of the vehicle if an unexpected in- riod may cause it to overheat and can crease in engine rpm occurs. Combus- damage the starter. tible vapors could also cause a fire.
22 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
Normal Starting Procedure After the engine is started, the voltmeter, if equipped, may show a gauge fluctuation Steps for starting the engine in normal 1 under certain engine temperature temperatures. conditions (both warm and cold). This Allow the Wait-To-Start warning lamp to cycling operation is caused by the post- Diesel particulate filter (DPF) status turned off. Engine Wait-To-Start Lamp on heat cycle of the intake manifold heater indicator; yellow in color. page 17 system. The number of cycles and the length of the cycling operation is controlled Follow this engine starting procedure when by the engine control module. The cycling the outside temperature is above 50°F action will cause temporary dimming of the (10°C). headlamps, interior lamps, and other vehicle electrical accessories. 1. Ensure the parking brake is set ON Diesel Exhaust Fluid (DEF) indicator; and the transmission shift lever is in yellow in color. neutral. For automatic transmissions, Cold Weather Starting be sure the shift lever is in the neutral position (N). For automatic Steps for starting the engine in cold transmissions that have park (P) temperatures. position, place the shift lever in park. Allow the Wait-to-Start warning lamp to 2. With the accelerator pedal in the idle turn off. Engine Wait-To-Start Lamp on position, turn the ignition key to the page 17 START position to start the engine. High exhaust system temperature (HEST); 3. If the engine does not start after 10 Follow this engine starting procedure when amber in color. seconds, release the key. Wait an the outside temperature is below 50°F additional 10 seconds to allow the (10°C). starter motor to cool, then try staring the engine again. 4. Once the engine has started, wait for Malfunction Indicator Lamp; amber in color. the oil pressure to rise, and the low oil pressure warning lamp to turn off, before increasing rpm.
Y53-1185-1E1 (04/16/18) 23 ENGINE OPERATION - Operating Instructions
3. For coolant temperatures below Starting Procedure After Extended 1 150°F (70°C), use a low gear and Shutdown or Oil Change CAUTION drive at moderate engine speed until Guideline on starting the engine after the engine coolant has reached prolonged shutdown or oil change. To reduce the possibility of damage to operating temperature. Do not let the the lubricating oil pan, due to the ma- engine idle longer than necessary. If After extended shutdown or an oil change terials used in the manufacture of the the vehicle cannot be driven, an follow the Normal Starting Procedure on lubricating oil pan, under no circum- elivated idle speed may be used page 23 . stances should an external heat instead to warm the engine. source be applied directly or indirectly The engine will run at idle only until the to the lubricating oil pan. minimum oil pressure is detected by the CAUTION ECM. It can take more cranking time to 1. Follow the Normal Starting start the engine after an extended shut Procedure on page 23 . Do not operate the engine at low down or oil change. Refer to the vehicle operator's manual idle for long periods of time when the coolant temperature is below instructions for any additional cold weather Operating the Engine starting procedures. the normal operating range. This could result in the following: 2. If starting a cold engine, slowly After the engine starts: increase the engine speed. This • Fuel dilution of the lubri- Monitor the oil pressure and coolant provides adequate lubrication to the cating oil temperature gauges frequently. Refer to bearings and gives ample time to • Carbon buildup in the Engine Oil Capacities and Pressures on allow the oil pressure to stabilize. combustion chamber page 45 and Engine Coolant • Sticking of the valves in Specifications on page 50 for CAUTION the cylinder head recommended operating pressures and • Reduced performance temperatures. Shut off the engine if any pressure or temperature does NOT meet The use of starting aids, such as • Damage to aftertreatment the specifications. ether, may result in damage to components the engine and aftertreatment system.
24 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
Engine Operating Range que rpm for more than 30 seconds. Information on operating the engine at Failure to comply may result in equip- 1 proper rpm. ment or property damage. Proper Engine Operating Range PACCAR engines are designed to operate at full throttle under momentary conditions down to peak torque engine speed. This is consistent with recommended operating practices.
CAUTION Continuous operation with engine coolant temperature above or below the engine Operating the engine beyond the max- coolant temperature specifications listed in imum engine speed can cause severe “ Engine Coolant Specifications on page engine damage. Use proper operating 50 ” can damage the engine. techniques for the vehicle to prevent engine overspeed. See Engine Speci- 1. Full Throttle rpm fications for maximum engine speed. 2. Peak Torque Failure to comply may result in equip- ment or property damage. CAUTION
Operating the engine at full throttle be- low peak torque will shorten engine life to overhaul, can cause serious engine damage, and is considered engine abuse. DO NOT operate the engine at full throttle operation below peak tor-
Y53-1185-1E1 (04/16/18) 25 ENGINE OPERATION - Operating Instructions
Extended Idling Long periods of idle-time (3 hours or more) on or off, to remove these hydrocarbon 1 may accelerate the build up of soot in the deposits and moisture. The engine speed diesel particulate filter (DPF), especially in will remain elevated for 20-60 minutes. If CAUTION cold weather. The system will illuminate the necessary, the rpms may be lowered by DPF warning light on the instrument cluster briefly depressing the throttle, clutch, or Prolonged periods of idling can result and a message on the Driver Information brake pedal. If the driver cancels the in lower than optimal engine/transmis- Display to indicate that the DPF requires automatic cycle using the pedals, the sion operating temperatures which regeneration. This is not a problem with the system will restart the cycle 10 minutes could cause increased rates of wear. vehicle; however, it indicates that the driver later with increased rpm until all of the An idle shutdown feature (available on needs to start a parked DPF regeneration deposits are removed from the DPF. If the PACCAR engines) can be program- to prevent equipment damage caused by vehicle cannot perform an automatic cycle, med to shut the engine down after a soot build up. If the DPF lamp turns ON the driver may be prompted with message period of low idle operation with no and the driver is prompted to through driver to regenerate the DPF with a "Do Not driver activity. A flashing warning lamp notifications, perform a parked DPF Drive" message. The driver must complete will inform the driver of an impending Regeneration. a regeneration before driving. If the "Do shutdown. Failure to comply may re- Not Drive" message is ignored and a DPF sult in equipment or property damage. regeneration is not fully completed before CAUTION driving, there is a high possibility of equipment damage. If you ignore the warning lamp and do CAUTION not initiate regeneration at the soon- If an engine must idle for an extended est, safest possible time, the DPF will period of time, idle the engine at the lowest If the truck is equipped with power become increasingly clogged with soot rpm that maintains the engine coolant at take off (PTO) equipment, the engine and can lead to severe engine derate. 150°F (70°C), or above. shutdown system can be deactivated Failure to comply may result in equip- when the PTO is operational; however, ment or property damage. engine idle periods should not exceed five minutes whenever possible. Fail- Extended engine idling may also increase ure to comply may result in equipment hydrocarbon deposits and moisture in the or property damage. DPF. The engine will increase rpm automatically, regardless if the DPF lamp is
26 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
before shutdown. This will allow circulating Electromagnetic Interference coolant and lubricating oil to carry heat Information on electromagnetic 1 CAUTION away from the cylinder head, valves, interference (EMI). pistons, cylinder liners, turbocharger, and DO NOT idle the engine for excessive- bearings. This way you can prevent engine If not installed correctly, some vehicle ly long periods. Long periods of idling, damage that may result from uneven accessories (CB radios, mobile more than 10 minutes, can cause poor cooling. transmitters, etc.) can generate and use engine performance. radio frequency energy that may cause electromagnetic interference (EMI) Following these guidelines will help reduce NOTE between the accessory and the engine wear during idling and the electronically controlled fuel system. Under frequency of DPF regenerations. For engines equipped with an elec- these conditions, PACCAR is not liable for tronic control module (ECM), ensure any performance problems with either the the ignition switch is turned OFF for a fuel system or the accessory. EMI is not minimum of 100 seconds prior to dis- Engine Shutdown considered by PACCAR to be an engine connecting the continuous (unswitch- failure and therefore is not warrantable. Prevent engine damage by following these ed) battery power supply. If the un- shutdown precautions. switched battery power supply is dis- System EMI Susceptibility connected in less than 100 seconds after the ignition switch is turned OFF, PACCAR products are designed and NOTE active fault codes and incorrect ECM tested for minimum sensitivity to incoming information may occur. electromagnetic energy. The fuel system DO NOT shut off the engine immedi- EMI susceptibility has been designed with ately. A hot engine stores a great a high tolerance against EMI and in most amount of heat and it does not cool CAUTION normal circumstances, if not all, down immediately after it is shut off. electromagnetic energy-emitting devices Always cool the engine down before that meet the Federal Communications Failure to follow the correct shutdown shutting it off. You will greatly increase Commission legal requirements should procedure may result in damage to the its service life. cause no interference. turbocharger and shorten the turbo- charger life. Idle the engine at 1,000 rpm for four minutes. Then low idle for 30 seconds
Y53-1185-1E1 (04/16/18) 27 ENGINE OPERATION - Operating Instructions
System EMI Radiation Levels maximum filtering to reject incoming electromagnetic noise. poor traction (wet, icy, or snow cov- 1 Electronic components are required to ered roads) or in heavy traffic. There pass various PACCAR and industry EMI may not be enough weight on the rear specifications. Our testing has shown that Operating on Level and Dry axle to provide traction. Braking when the engine is properly installed and Pavement caused by the normal operation of the maintained, it will not interfere with properly engine compression brake could Tips for driving on level and dry roads. installed onboard communication cause you to lose control of the vehi- equipment. cle, resulting in an injury accident. Make sure the engine brake is switch- If any interference condition is noticed, WARNING ed "OFF" when bobtailing or with an follow these suggestions to reduce the unloaded trailer. Failure to comply may amount of EMI: DO NOT use the engine brake when operating on road surfaces with poor result in death, personal injury, equip- 1. Locate the accessory receiving traction (such as wet, icy, or snow cov- ment or property damage. antenna further away. ered roads or gravel). Retarders can 2. Check with the accessory supplier cause the wheels to skid on a slippery Remove Foot from Accelerator representative in your area to: surface. You could lose control of the vehicle and/or jackknife if the wheels • Accurately calibrate the begin to skid, resulting in an accident. accessory for proper frequency, Failure to comply may result in death, power output, and sensitivity. personal injury, equipment or property 30 40 50 • Determine the optimum antenna damage. 20 60 10 70 location by obtaining antenna 0 80 MPH reflective energy data measurements. WARNING • Ensure that the optimum antenna type and mounting arrangement DO NOT operate the engine compres- is being used. sion brake when driving/operating your • Ensure the accessory equipment vehicle bobtail or with a loaded or un- To reduce vehicle speed, put the engine is properly constructed for loaded trailer on road surfaces with brake ON/OFF switch in the "ON" position. Remove your foot from the accelerator
28 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
pedal and clutch pedal. The engine brakes will immediately begin to operate, slowing must use the service brakes for quick vehicle and/or jackknife if the wheels 1 the vehicle. or emergency stops. Failure to comply begin to skid, resulting in an accident. may result in death, personal injury, Failure to comply may result in death, For operation on dry and relatively flat equipment or property damage. personal injury, equipment or property surfaces, when greater retarding power is damage. not required, put the two-position selector "Control speed" is the speed at which the switch in the "LOW" position. forces pushing a vehicle down a grade are equal to the forces holding it back. CAUTION For operation on dry pavement when maximum retarding power is required, put Do Not Exceed Governed Engine Speed The engine ECM maintains a record of the three-position selector switch in the maximum rpm. Exceeding the maxi- "HI" position. 30 40 50 1 3 5 30 40 50 1 3 5 mum rpm will be considered driver 20 60 20 60 10 70 10 70 abuse and will affect the engine war- 0 80 2 4 R 0 80 2 4 R MPH MPH Operating on Grades and Dry 2100 2300 ranty. See Engine Spcifications. Pavement Tips for driving on grades and dry roads. OK OK RPM RPM WARNING
WARNING DO NOT use an exhaust brake when driving bobtail or with an unloaded The engine brake is not intended as trailer. There may not be enough the primary brake for the vehicle, nor weight on the rear axle to provide trac- is it an emergency brake. The service WARNING tion. This could cause a loss of control brakes must be used in an emergency. and jackknife resulting in an injury ac- Relying solely on the engine brake to DO NOT use the engine brake when cident. Make sure the exhaust brake is stop the vehicle in an emergency operating on road surfaces with poor switched “OFF” when bobtailing or could cause an accident and lead to traction (such as wet, icy, or snow cov- with an unloaded trailer. Failure to personal injury. The engine brake only ered roads or gravel). Retarders can comply may result in death, personal helps the service brakes by using cause the wheels to skid on a slippery injury, equipment or property damage. pressure to slow the drive train. You surface. You could lose control of the
Y53-1185-1E1 (04/16/18) 29 ENGINE OPERATION - Operating Instructions
1 Slow Down Around Curves Braking Truck on Grade CAUTION
Never exceed governed engine speed because engine damage can occur. Operating engine beyond the gov-
25 erned speed causes additional strain MPH on valve train and internal engine com- ponents. Operate the engine within governed engine speed.
NOTE The engine brake is NOT intended as the primary brake for the vehicle, nor is it an WARNING Once you have determined what the emergency brake. The engine brake only safe speed is for your vehicle, operate helps the service brakes by using pressure DO NOT drive with frequent or contin- the engine brakes with the transmis- to slow the drivetrain. Use the service uous use of the service brakes. This sion in the lowest gear that will not brakes for quick stops. can overheat the brakes and result in cause the engine speed to exceed the excessive lining wear, increased stop- rated engine speed. The optimum ping distances, possibly an accident braking power of the engine brakes is and may lead to personal injury. Be- reached at rated engine speed. Cor- fore descending a steep grade, shift to rect gear selection, therefore, is criti- a lower gear, keep the vehicle speed cal. low, and avoid continuous application to the brakes. Failure to comply may The selector switch can be used to vary result in death, personal injury, equip- braking power as road conditions change. ment or property damage. Vehicle service brakes must be used when additional braking power is required.
30 Y53-1185-1E1 (04/16/18) ENGINE OPERATION - Operating Instructions
Tips for Operation on Slick Roads When driving on slick roads, start with the “ON/OFF” switch in the “OFF” position and 1 NOTE the two-position selector switch in the WARNING “LOW” position. If your tractor is equipped The longer or steeper the hill, the more with a twin-screw rear axle, position the important it is to use your engine To reduce the possibility of personal power divider switch in the “unlocked” brakes. Make maximum use of your injury or property damage, always al- position. Remove your foot from the engine brakes by gearing down and low for extra distance between your accelerator pedal to make sure the vehicle letting the engine brakes do the work. vehicle and other objects when using will maintain traction with the retarding the service brakes or engine brakes on power of the engine alone. If the vehicle Shift to a Lower Gear on Grade slick roads. drive wheels begin to skid or if there is a fishtailing motion, DO NOT activate the engine brakes. If traction is maintained 40 The operation of any vehicle is difficult to 30 40 50 1 3 5 30 50 1 3 5 20 60 20 60 predict on slick roads. The first 10 to 15 using the retarding power of the engine 10 70 10 70 0 80 2 4 R 0 80 MPH MPH 2 4 R minutes of rainfall are the most dangerous, alone and more braking power is required, 2100 2100 as road dirt and oil mixed with rain create a switch the two-position selector switch to very slippery surface. the “LOW” position and activate the engine OK OK brakes by switching the “ON/OFF” switch RPM RPM to the “ON” position. If the vehicle’s drive WARNING wheels begin to skid or there is a fishtailing motion, switch the “ON/OFF” switch to the DO NOT use any of the vehicle’s re- “OFF” position. If traction is maintained tarders in any situation that requires when the engine brakes are activated and an immediate stop and/or in situations more braking power is required, move the If frequent use of the vehicle service of poor traction (such as wet, icy or two-position selector switch to the “HI” brakes is required, it is recommended that snow covered roads). Trying to use position. Again, if the vehicle has lost a slower control speed be used by the retarder instead of the service traction or if there is a fishtailing motion, selecting a lower transmission gear. brakes may cause a loss of vehicle switch the “ON/OFF” switch to the “OFF” control, which may result in an acci- position. DO NOT attempt to use the dent involving death or personal injury. engine brakes in the “HI” position.
Y53-1185-1E1 (04/16/18) 31 ENGINE OPERATION - Operating Instructions
1
32 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE
Chapter 2 | ENGINE MAINTENANCE 2 Maintenance Requirements ...... 34 Maintenance Schedule Intervals ...... 37 Preventative Maintenance Schedule ...... 38 Engine Specifications ...... 41 Engine Lubricating Oil Recommendations and Specifications ...... 42 Engine Oil Capacities and Pressures ...... 45 Engine Lubrication and Filter Intervals ...... 46 Cooling System Maintenance ...... 48 Engine Coolant Specifications ...... 50 Extended Life Coolant ...... 51 Fuel Recommendations ...... 52 Warranty and the Use of Biodiesel Fuel ...... 53 Recommendations to Avoid Fuel Gelling ...... 54 Diesel Exhaust Fluid Recommendations and Specifications ...... 54 Maintenance Procedures ...... 56 Engine Identification ...... 69
Y53-1185-1E1 (04/16/18) 33 ENGINE MAINTENANCE - Maintenance Requirements Chapter 2 | Engine Maintenance manufacturer's maintenance recommendations. monoxide to enter the cab, resulting in Maintenance death or personal injury. Requirements WARNING 2 Cleaning the Engine Never idle your vehicle for prolonged Engine cleaning precautions. Engine Maintenance periods of time if you sense that ex- Introduction and important maintenance haust fumes are entering the cab. In- When cleaning the engine, follow the requirements. vestigate the cause of the fumes and instructions from the vehicle manufacturer correct it as soon as possible. If the operator's manual and observe all PACCAR recommends that the engine be vehicle must be driven under these environmental protection regulations. maintained according to the maintenance conditions, drive only with the windows schedule in this section. open. Failure to repair the source of the exhaust fumes may result in death, CAUTION If the engine is operating in ambient personal injury, equipment or property temperatures below 0°F (-18°C) or above damage. DO NOT direct water onto electrical 100°F (38°C), perform maintenance at components, plug connectors, seals or shorter intervals. Shorter maintenance flexible hoses on the engine. Water intervals are also required if the engine is WARNING may enter the part causing electrical operated in a dusty environment or if damage or contaminating the engine frequent stops are made. Exhaust fumes from the engine con- oil. To prevent damage to engine com- Some of these maintenance procedures tain carbon monoxide, a colorless and ponents, keep the water moving at all require special tools or must be completed odorless gas. DO NOT breathe the en- times while cleaning the engine. Fail- by qualified personnel. Contact your local gine exhaust gas. A poorly maintained, ure to comply may result in equipment PACCAR authorized repair location for damaged or corroded exhaust system damage. detailed information. can allow carbon monoxide to enter the cab. Entry of carbon monoxide into If your engine is equipped with a the cab is also possible from other ve- component or accessory not manufactured hicles nearby. Failure to properly main- by PACCAR Inc, refer to the component tain your vehicle could cause carbon
34 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Requirements
Daily or Refueling Maintenance Engine Fuel Filter / Water Separator on Chassis Fuel Filter / Water Checks page 35 Separator Visual Inspection of Engine Daily and refueling maintenance check for Coolant Level on page 35 the chassis fuel filter/water separator. Daily and refueling visual check of engine. 2 Chassis Fuel Filter / Water Separator on This procedure should be followed as part This procedure should be followed as part page 35 of daily and refueling maintenance checks. of daily and refueling maintenance checks. Engine Oil Level on page 56 1. Drain trapped water (if equipped). 1. Check for any signs of fluid leaks. Cooling Fan on page 35 and Coolant Cooling Fan 2. Ensure all access caps/covers are Level on page 35 installed and tight. Daily and refueling maintenance check for 3. Excessive oil, coolant or fuel Aftertreatment Exhaust Piping on page engine cooling fan. consumption 36 This procedure should be followed as part 4. Loose or damaged parts Air Intake Piping on page 36 of daily and refueling maintenance checks. 5. Worn or damaged belts 6. Worn or damaged wiring harnesses How to Drain Moisture from Air Tank on 1. Inspect for cracks. 7. Any change in system appearance page 36 2. Inspect for clearance to other components. 8. Odor of fuel Diesel Exhaust Fluid on page 37 9. Odor of electronic devices. Coolant Level 10. When operating the engine, listen for Crankcase Breather Tube - Check Daily and refueling maintenance check for any unusual system noises which engine coolant level. can indicate service is required. Engine Fuel Filter / Water Separator Replacement or top up coolant should Daily Maintenance Items Daily and refueling maintenance check for have the same antifreeze concentration the engine fuel filter/water separator. and corrosion inhibitor content as the Daily maintenance tasks below must be original coolant in the cooling system. If performed to properly maintain the engine: Automatic water drain, no maintenance required. operating in sub-freezing conditions, a 60/40 mix of antifreeze and distilled water may be substituted.
Y53-1185-1E1 (04/16/18) 35 ENGINE MAINTENANCE - Maintenance Requirements
Always dilute antifreeze to the correct 3. Check coolant level. It should be Air Intake Piping concentration based on freeze protection visible through the clear plastic surge Daily and refueling maintenance check for before adding it to the cooling system. tank. engine air intake piping. Adding or using 100% antifreeze in a 4. Add coolant as necessary until 2 cooling system may result in cooling proper level is reached. This procedure should be followed as part system plugging and overheating of daily and refueling maintenance checks. problems. NOTE 1. Inspect hose/pipe condition – This procedure should be followed as part deterioration/signs of leaking. of daily and refueling maintenance checks. The pressure cap (on the side of 2. Inspect hose clamps for tightness the surge tank) should NEVER Perform the following steps to check the and pinching/cutting of hoses. be removed. The fill cap (On the coolant level: 3. Inspect clearance to other top, not the side of the surge components. tank) is the correct fill point. 1. Check that vehicle is a on a level 4. Check air restriction gauge. surface. 2. Ensure engine has not been run for Aftertreatment Exhaust Piping How to Drain Moisture from Air Tank several hours. Daily and refueling maintenance check for aftertreatment exhaust piping. CAUTION This procedure should be followed as part 1. Locate the various air tanks on the of daily and refueling maintenance checks. vehicle Due to thermal expansion the 2. On the air tank, look for a valve, coolant level CANNOT be 1. Inspect for cracks. typically on the bottom of the tank. checked if the coolant is above 2. Inspect for clearance to other ambient temperature or the en- components (i.e. electrical gine has not completely cooled. harnesses, etc.). The coolant level indicated on a 3. Inspect hose/pipe condition – warmed system will be inaccu- deterioration/signs of leaking. rate and can lead to low coolant conditions during cold-starts.
36 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Schedule Intervals
4. Continue pulling until the air comes tertreatment Systems Operator’s out free of water. Manual for DEF information. Diesel Exhaust Fluid Daily and refueling maintenance check of Maintenance Schedule 2 diesel exhaust fluid (DEF). Intervals This procedure should be followed as part of daily and refueling maintenance checks. Maintenance schedule intervals. 1. Check level of diesel exhaust fluid.
3. To eject moisture from the air system NOTE tanks, pull the line that is connected to the moisture ejection valve. It is recommended to top up DEF when refueling. See Engine Af-
PX-9 Maintenance Intervals
Maintenance Interval Miles Kilometers Hours Months
A 7,500 12,000 250 3
B 15,000 24,000 500 6
C 30,000 48,000 1,000 12 (1 year)
D 60,000 96,000 2,000 N/A
E 60,000 96,000 2,000 24 (2 years)
F 150,000 241,500 5,000 48 (4 years)
Y53-1185-1E1 (04/16/18) 37 ENGINE MAINTENANCE - Preventative Maintenance Schedule
PX-9 Maintenance Intervals (continued)
Maintenance Interval Miles Kilometers Hours Months 2 G 200,000 321,500 6,500 N/A H 750,000 1,200,000 12,000 72 (6 years)
Intervals, perform all previous maintenance checks that are due for scheduled hour, or time interval based on the En- Preventative Maintenance maintenance. gine Lubrication and Filter Intervals. Schedule NOTE NOTE List of recommended maintenance tasks and intervals that should be performed for This maintenance schedule is for a Due to the design of the crankcase PACCAR PX series engines. normal duty cycle engine operation. ventilation module, routine service of Severe duty/vocational applications this component is not required. Perform maintenance at whichever interval will need to adjust mileage, kilometer, occurs first. At Maintenance Schedule
38 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Preventative Maintenance Schedule
PX-9 Preventative Maintenance Schedule
Recommended Preventative Maintenance Interval 2 Component 1 Maintenance Task A B C D E F G H
Emissions Components Diesel Particulate Filter (DPF) - Clean •
Diesel Exhaust Fluid (DEF) Filter on page 66 - • Replace
Crankcase Breather Element - Replace •
Exhaust System - Check for Leaks •
Exhaust System - Replace Flex Pipe(s) •
Air System & Compressor Air Compressor on page 67 - Check •
Air Cleaner on page 68 •
Charge Air System Charge Air Piping on page 68 •
Charge Air Cooler on page 68 •
Charging / Cranking System Electrical Harness / Cables on page 68 •
Batteries, Cables, and Connections on page • 68
Y53-1185-1E1 (04/16/18) 39 ENGINE MAINTENANCE - Preventative Maintenance Schedule
PX-9 Preventative Maintenance Schedule (continued)
Recommended Preventative Maintenance Interval 2 Component 1 Maintenance Task A B C D E F G H
Cooling System Coolant/Antifreeze Condition on page 63 - • Check
Radiator Hoses on page 64 •
Radiator Pressure Cap - Check •
Change Extended Life Coolant on page 51 •
Crankshaft Crankshaft - Vibration Damper on page 69 - • Rubber Type Replace
Crankshaft - Vibration Damper on page 69 - • Viscous Type Check
Drive Belts Engine Belt Checks on page 65 •
Fan Belt Tensioner on page 65 •
Engine Lubrication Replace oil and filter Engine Lubrication and Filter Intervals
Fuel System Fuel Filter on page 59 - Spin On Type Replace •
Mounting Bolts Engine Mounting Bolts on page 69 •
Overhead Set (Valves) Adjust •
40 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Specifications
PX-9 Preventative Maintenance Schedule (continued)
Recommended Preventative Maintenance Interval Component 1 Maintenance Task 2 A B C D E F G H
Engine Brake Assembly Adjust •
Engine Steam Clean Check •
1 Follow the manufacturers' recommended maintenance procedures for the starter, alternator, batteries, electrical components, exhaust brake, charge-air cooler, radiator, air compressor, air cleaner, refrigerant compressor, and fan clutch.
Engine Specifications
Engine specifications including horsepower, firing order, displacement, weight, and other engine characteristics.
PACCAR PX-9
Horsepower See the EPA label on top of the front timing gear cover.
Firing Order 1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine) Clockwise
Displacement 540 in³ (8.9 liters)
Y53-1185-1E1 (04/16/18) 41 ENGINE MAINTENANCE - Engine Lubricating Oil Recommendations and Specifications
PACCAR PX-9 (continued)
Bore and Stroke 4.49 in. × 5.69 in. (114 mm × 144.5 mm) 2 Approximate dry weight (without standard accessories) 1,695 lb (769 kg) Wet wait 1,770 lb (803 kg)
Engine brake adjustment 0.090 in. (2.286 mm)
Overhead adjustment Intake valve adjustment 0.012 in. (0.305 mm)
Exhaust valve adjustment 0.022 in. (0.559 mm)
necessary to achieve the engine's design Filter Specifications life. If other brands are substituted, the purchaser should ensure the filter Engine Lubricating Oil Use of non-genuine filters. specification meet or exceed the Recommendations and Fleetguard specifications. PACCAR is not responsible for problems Specifications caused by non-genuine filters that do not meet PACCAR performance or durability CAUTION PACCAR engine oil type, viscosity, and requirements. additives. Use of non-genuine oil filters can Contact your local PACCAR authorized cause severe engine damage. A major factor in maintaining engine repair location for specific part numbers. performance and durability is the proper Fleetguard filters are standard on new use of quality engine lubricating oils used PACCAR engines. PACCAR recommends in conjunction with the appropriate oil drain their use. and filter change intervals. Attempting to extend the oil and filter change interval Fleetguard products meet all PACCAR test beyond the manufacturers standards to provide the quality filtration recommendations may decrease engine
42 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Lubricating Oil Recommendations and Specifications
life due to factors such as corrosion, oil specifications and biodiesel or biodiesel deposits, and wear. blended fuel is not used as fuel for the engine. Use of 0W-40 and 0W-30 synthetic NOTE See Engine Lubrication and Filter Intervals oils that meet API CK-4 or CJ-4 to determine which oil drain interval to use certification can be used in operations If the type/oil capacity of each lubricat- 2 for an application. where the ambient temperature never ing oil pan is not known: exceeds 32°F (0°C). 0W-40 and 0W-30 oils • Contact a PACCAR® Authorized NOTE do not offer the same level of protection Repair Location against fuel dilution as do higher • Determine the capacity of the oil multigrade oils. Higher cylinder wear can It is the operator’s responsibility to fol- pan option for the engine being be experienced when using 0W-40 or low these recommendations to ensure serviced by using QuickServe™ 0W-30 oils in highload situations. Using a that the engine warranty is not affect- Online and the engine serial num- multigrade oil helps improve engine ed. ber. cranking in low-temperature conditions, • Fill the lubricating oil pan to the The primary PACCAR recommendation is reduces deposit formation and increases engine durability. The use of a fuel smallest oil pan capacity listed for for the use of SAE 10W-30 API CK-4 or the engine being serviced. Then CJ-4 multigrade lubricating oil for normal economy oil such as an API FA-4 oil is not approved for this engine. add 1 US qt (0.95 liters) of oil at a operation at ambient temperatures above time until it reaches the high mark 5°F (-15°C). For ambient temperatures on the dipstick. Record the num- below 5°F (-15°C) SAE 5W-30 may be ber of quarts/liters added, so the used, provided it meets API CK-4 or CJ-4 capacity is known the next time the oil is drained.
Y53-1185-1E1 (04/16/18) 43 ENGINE MAINTENANCE - Engine Lubricating Oil Recommendations and Specifications
Engine Oil Viscosity Chart
2 Temperature °F -40 -20 0 20 40 60 80 100 120 140
1 5W40 or 15W40 1. All seasons 2 10W30 2. All seasons 3 10W30 3. Winter conditions 4. Winter conditions 4 5W30 5. Arctic conditions 5 0W30
-40 -30 -20 -10 0 10 20 30 40 50 60 Temperature °C
New Engine Break-In Oils NOTE PACCAR does not approve the use of special “break-in” engine lubricating oils for Any of the oil weights listed in the new or rebuilt PACCAR engines. It is chart above are acceptable to use as recommended to use the same lubricating long as the oil meets API CK-4/CJ-4 oil for engine break-in that will be used oil specifications. during normal operation.
44 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Oil Capacities and Pressures
precise amounts of additives blended into such as corrosion, deposits, and wear. the lubricating oil to meet stringent CAUTION Failure to comply may result in equip- performance requirements. ment damage. A sulfated ash limit of 1.85 percent has These oils meet performance 2 been placed on all engine lubricating Additional information regarding lubricating characteristics that conform to the lubricant oils recommended for use in PACCAR oil availability throughout the world is industry standards and are sufficient engines. Higher ash oils can cause available in the EMA Lubricating Oils Data protection when used according to the valve and/or piston damage and lead Book for Heavy-Duty Automotive and recommendations. Aftermarket lubricating to excessive oil consumption. Failure Industrial Engines. The data book can be oil additives are not necessary to enhance to comply may result in equipment ordered from: Engine Manufacturers engine oil performance and may in some damage. Association, Two North LaSalle Street, cases reduce the oil's capability to protect Chicago, IL 60602; (312) 827-8733, the engine. ( www.enginemanufacturers.org). CAUTION Aftermarket Oil Additive Usage Engine Oil Capacities and The use of a synthetic-base oil does PACCAR does not recommend the use of Pressures not justify extended oil change inter- aftermarket oil additives. Today's high- vals. Extended oil change intervals quality engine lubricating oils are very can decrease engine life due to factors sophisticated. Most oils already contain Engine oil system specifications.
Engine Oil Capacity and Acceptable Pressures
PACCAR PX-9
At Low Idle (minimum allowable) 10 psi (69 kPa) Oil Pressure At Road Speed (minimum allowable) 30 psi (207 kPa)
Regulated oil pressure 55 psi (379 kPa)
Y53-1185-1E1 (04/16/18) 45 ENGINE MAINTENANCE - Engine Lubrication and Filter Intervals
Engine Oil Capacity and Acceptable Pressures (continued)
Lubricating oil filter capacity 4 qts. (3.8 liters) 2 Pan only 16-20 qts. (15.1-18.9 liters) Lubricating oil capacity, low to Standard oil pan Cylinder block stiffener plate 19-23 qts. (18-21.8 liters) high (U.S. qts.) High capacity oil pan 20-24 qts. (18.9- 22.7 liters)
Standard oil pan Pan only 24 qts. (22.7 liters) Total system capacity (U.S. qts., Cylinder block stiffener plate 27 qt. (25.6 liters) oil pan and new oil filter) High capacity oil pan 28 qt. (26.5 liters)
for the oil change and oil filter change interval. Engine Lubrication and NOTE Filter Intervals If the average vehicle speed/mph is Idle time must be factored into calcu- unknown and the vehicle is not equipped lating average vehicle speed. with an hour meter: Oil change intervals for normal and severe duty applications. The intervals are based on the vehicles 1. See the "Typical Application(s)" average speed/miles per hour (mph) column. Use the lowest interval listed See the following table to determine the (Includes idle time). Locate your vehicles for your application. maximum recommended oil change and oil average vehicle speed/mph in the first 2. Connect an electronic service tool. filter change intervals in miles (kilometers)/ column to determine the oil change/filter The electronic service tool can hours or months, whichever comes first. change interval to use. If the vehicle is provide the average vehicle speed Replace the fuel filters (pressure and equipped with an hour meter, it is recorded by the engine control suction side) at the same interval as the oil acceptable to use the engine hours listed module (ECM). This can be done at a and oil filter are changed. PACCAR Authorized Repair Location.
46 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Lubrication and Filter Intervals
prolong the life of internal moving com- NOTE CAUTION ponents. Follow the oil and filter change intervals as recommended in A Maintenance Monitor feature is Extending the oil and filter change in- this section of the manual. Failure to 2 available through the engine's ECM. terval beyond the recommendations comply may result in equipment or This feature can be enabled by a PAC- will decrease the engine life due to property damage. CAR Authorized Repair Location. factors such as corrosion, deposits, and wear. Engine oil filters capture dirt and remove deposits from the oil to
Vehicles Average Typical Miles Kilometers Hours Months Speed Application(s)
Below 5 mph 1,500 2,400 500 6 Shuttle or Transit bus
5 to 10 mph 4,000 6,450 500 6 Shuttle or Transit bus, Refuse truck, 10 to 15 mph 6,000 9,650 500 6 Cement mixer, Dump truck, Feedlot truck, Yard spotter
15 to 20 mph 8,500 13,700 500 6 Cement mixer, Dump truck, Truck 20 to 25 mph 10,500 16,900 500 6 crane, Fire truck/ Emergency vehicle, School bus, Delivery truck
Y53-1185-1E1 (04/16/18) 47 ENGINE MAINTENANCE - Cooling System Maintenance
Vehicles Average Typical Miles Kilometers Hours Months Speed Application(s)
25 to 30 mph 12,000 19,300 500 6 Linehaul truck, Fire 2 truck/Emergency 30 to 40 mph 15,000 24,100 500 6 vehicle, School bus, Motor coach bus
Higher than 40 mph 20,000 32,200 500 12 Recreational vehicle
Cummins Inc. bases the oil drain Caterpillar EC-1 requirements. PACCAR critical to engine and cooling system specifications on duty cycle and oil recommends only using a 50/50 mixture of component health and longevity. contamination. This contamination occurs distilled water and ELC when cooling in all engines, at varying rates, regardless system service is required. A 50/50 mixture of the drain interval. of ELC and distilled water will provide WARNING freeze protection down to –34°F (–37°C), Maintaining the correct oil and filter change which is adequate for most locations in Coolant is toxic. DO NOT get the fluid interval is a vital factor in preserving the North America. For extremely cold in eyes. If contact occurs, flood eyes integrity of an engine. Lubricating oil filters operating conditions, a 60/40 mixture with large amounts of water for 15 mi- must be changed when the oil is changed. (coolant/water ratio) can be used to nutes. Avoid prolonged or repeated provide freeze protection down to -62°F contact with skin. In case of contact, (-52°C). immediately wash skin with soap and Cooling System water. DO NOT take internally. If swal- Unless otherwise optioned, factory fill lowed, seek immediate medical atten- Maintenance coolant is an ethylene glycol, nitrited tion. DO NOT induce vomiting. Failure organic acid technology (NOAT) extended to comply may result in death, person- Information about concentration and life coolant (ELC) formulation at a 50/50 al injury, equipment or property dam- condition of coolant, including filter. coolant-to-distilled water mixture. The age. factory fill exceeds ASTM D6210 and The cooling system in your vehicle was Caterpillar EC-1 requirements. Maintaining factory filled with extended life coolant that coolant chemistry and freeze protection is meets or exceeds all ASTM D6210 and
48 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Cooling System Maintenance
CAUTION CAUTION Glycol Concentration Level
Desired The engine cooling system has very Use of non-genuine coolant filters can Freeze 2 Coolant specific maintenance and inspection cause severe engine damage. Level Point °F / Water requirements. Failure to follow require- (°C) ments can damage the engine. Engine Concentration Ratio damage can include but is not limited Check the level of freeze/boilover to freezing, boiling, corrosion, pitted 40% -12 (-24) protection, which is determined by the cylinder liners. This information is glycol concentration. Use a glycol 45% -23 (-31) found in the engine manufacturers refractometer to determine glycol level. Recommended owner’s manual. It is the owner’s re- 50% -34 (-37) Add coolant to obtain the coolant/water sponsibility to follow all requirements Levels ratio required to provide the protection you listed in the engine manufacturers 55% -50 (-46) need. A 50/50 mix of coolant and water is owner’s manual. adequate for most applications. For 60% -62 (-52) extremely cold operating conditions, the NOTE ratio can be adjusted to a higher concentration of coolant. Condition Coolant is harmful to the environment. Perform a visual inspection of the coolant. Unused coolant must be stored as a NOTE It should have no cloudiness or floating toxic hazardous material in leakproof debris. Determine the chemical inhibitor containers. Used coolant must be Maximum recommended ELC concen- concentration level by using an extended processed as industrial chemical tration is 60% ELC and 40% water by life coolant specific test kit or test strips. waste. Please follow HAZMAT guide- volume (a 60/40 coolant mixture). The Inhibitor concentration level determines lines with both used and unused cool- minimum recommended concentration corrosion protection. If you are concerned ants. is 40%. about possible coolant quality, contamination, or mechanical problems, submit a coolant sample for analysis. Improper maintenance may cause coolant
Y53-1185-1E1 (04/16/18) 49 ENGINE MAINTENANCE - Engine Coolant Specifications
degradation and could result in damage to the cooling system and engine and refill the system completely with • Build up in coolant low-flow areas components. Consult your dealer or one type of coolant. • Plug the radiator and oil cooler the coolant manufacturer’s representative • Damage the water pump seal for recommended extended life coolant test Cooling System Sealing Additives 2 and Soluble Oils • Damage heat transfer surfaces kits, test strips, and laboratory sample • Damage seals and hoses procedures. • Corrode brass and copper OK Coolant Extender Failure to comply may result in equip- ment or property damage. Add extended life coolant extender, if 1 necessary, according to the corrosion inhibitor concentration required. DO NOT add coolant extender to nitrite-free coolant. Engine Coolant Checking Coolant Level Specifications 1. Do not use soluble oils or sealing Check the coolant level daily. See Coolant additives. Level on page 35 . Engine capacity, pressure, and temperature specifications. CAUTION CAUTION The use of sealing additives or soluble When adding coolant, avoid mixing dif- oils in the cooling system can cause Engine Coolant Specifications for ferent brands and formulations. If the damage to the engine. These additives PACCAR PX-9 coolant is mixed with more than 25% can plug various areas of the radiator, of a different formulation (for example, EGR system and oil cooler. The plug- Coolant Capacity 16.5 qt (15.6 liters) mixing OAT and NOAT coolants), en- ging of the cooling system can hamper (engine only) gine corrosion damage could occur. If heat transfer, causing internal engine mixing exceeds 25% of total system damage. DO NOT use sealing addi- Standard 180-200°F volume, it is recommended to flush tives or soluble oils in the cooling sys- modulating (82-93°C) tem. The use of sealing additives can: thermostat range
50 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Extended Life Coolant
Minimum 13 psi (90 kPa) • Conduct coolant maintenance checks diluting percentages when servicing a recommended including freeze point, pH, nitrite and vehicle filled with nitrite-free coolant. pressure cap carboxylate tests at least twice annually to maintain engine Additional Recommendations: Maximum top tank 225°F (107°C) protection. • Antifreeze is essential for freeze, 2 coolant Nitrited Extended Life Coolant overheat, and corrosion protection. temperature The use of supplemental coolant For nitrited formulations (NOAT), a heavy- Winterfronts — 120 in.² (774 cm²) additives (SCAs) is not duty extended life coolant that meets Minimum allowed recommended for extended-life ASTM D6210 and Caterpillar EC-1 air passage area coolants. specifications must be used. Recommended Extended Life The change interval for extended-life Coolant Suppliers coolant containing nitrite and molybdate is NOTE 750,000 miles (1,200,000 km) or 12,000 Authorized PACCAR Engine dealer hours of on-road use (8 years or 15,000 Coolant volumes are dependent on hours of off-highway use) on initial fill with ® chassis model and cab/ sleeper heater no extender added. The change interval is options. 1,000,000 miles (1,600,000 km)/20,000 hours/8 years with an extender addition at 500,000 miles (800,000 km)/10,000 Extended Life Coolant hours/4 years. Nitrite-Free Extended Life Coolant Information on using Extended Life Coolant Nitrite-free organic acid technology coolant (ELC). (OAT) may be used if it meets DAF 74002. Perform these maintenance procedures The change interval for nitrite free coolant according to the Preventative Maintenance is 600,000 miles (1,000,000 km) or 6 Schedule. years, with no extender needed. DO NOT add coolant extender to nitrite-free coolant. Follow the coolant supplier's drain/flush/fill/
Y53-1185-1E1 (04/16/18) 51 ENGINE MAINTENANCE - Fuel Recommendations
make sure all steps are taken for dis- system. Failure to comply may result Fuel Recommendations pensing or using clean fuel in your ve- in equipment or property damage. hicle. Failure to comply may result in 2 Precautions and recomendations for equipment or property damage. selecting and using the right diesel fuel. CAUTION
CAUTION DO NOT use high-sulfur diesel fuel as WARNING it will damage the exhaust aftertreat- Unapproved fuel can reduce economy ment system. Also, the engine will not The use of diesel fuel that has been or possibly damage fuel system com- meet emission regulations. Use only mixed with other fuels may cause an ponents. Unapproved fuels typically do ultra-low-sulfur diesel (ULSD) fuel. explosion. DO NOT mix gasoline, alco- not have enough lubricity elements in Failure to comply may result in equip- hol, or gasohol with diesel fuel. Make the fuel to properly lubricate the fuel ment or property damage. sure you know your fuel source and injection system. Be sure you follow use the recommended diesel fuel as the fuel recommendations as indicated indicated in this section of the manual. in this section of the manual. Failure to Failure to comply may result in death, comply may result in equipment or personal injury, equipment or property property damage. damage.
CAUTION CAUTION Using diesel fuels blended with lubri- Dirt or water in the fuel system can cants may cause damage to your ex- cause severe damage to both the fuel haust aftertreatment system. Service pump and the fuel injectors. Due to the intervals for aftertreatment systems precise tolerances of diesel injection will be reduced. DO NOT use diesel systems, it is extremely important that fuel blended with lubricating oil in en- the fuel be kept clean and free of dirt gines equipped with an aftertreatment or water. Know your fuel source and
52 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Warranty and the Use of Biodiesel Fuel
that are operated at temperatures CAUTION above 32ºF (0ºC). Warranty and the Use of Biodiesel Fuel If ultra-low-sulfur diesel (ULSD) fuel is Using diesel fuel with a lower-than- 2 not used, the engine may not meet recommended cetane number can cause emission regulations, and damage hard starting instability, and excessive Biodiesel information and warranty may occur to the exhaust aftertreat- white smoke. To maintain satisfactory precautions. operation at low ambient temperatures, it is ment system. The use of high-sulfur PACCAR Inc. approves the use of important to specify diesel fuel of the diesel fuel will damage the exhaust af- biodiesel fuel blends up to 20 percent by correct cetane number. tertreatment system and impact the volume in diesel fuel providing that the engine emission. ULSD fuel is re- PACCAR requires all permissible fuels to following conditions are met: quired for correct operation of the af- have adequate fuel lubricity. Lubricity can tertreatment. The engine has been op- • The biodiesel used in the blend be determined by ASTM, specification timized for use with an aftertreatment meets ASTM Standard D6751 or EN D6079, ISO 12156, High Frequency system together with ULSD fuel to 14214 specifications. Reciprocating Rig (HFRR) in which the fuel meet the 2013 U.S. Environmental must have a wear scar diameter of 0.02 in. • The biodiesel used in the blend is Protection Agency regulations. Failure (0.5 mm) or less. sourced from a BQ-9000 Accredited to comply may result in equipment or Producer. property damage. The use of Ultra-low-sulfer diesel (ULSD) • The finished blend meets the fuel fuel is required for this engine in order to properties of the ASTM Standard meet emission regulations and to prevent D975 (up to B5 blend) or D7467 (B6 NOTE damage to the engine and exhaust system. to B20 blend). The use of other grades of diesel fuels • If using B6-B20 the engine oil and oil PACCAR recommends that the cetane other than ULSD fuel will be considered a filter are changed per the modified number of diesel fuel be a minimum of use of incorrect fuel for the engine. schedule. See the Engine 45 for engines that are expected to op- PACCAR is not responsible for failures Preventative Maintenance Schedule. erate at temperatures below 32ºF caused by the use of incorrect fuel, oil or • If using B6-B20 the fuel filter is (0ºC) and a minimum of 42 for engines DEF or by water, dirt or other containments changed every 25,000 miles (40,000 in the fuel or DEF. km).
Y53-1185-1E1 (04/16/18) 53 ENGINE MAINTENANCE - Recommendations to Avoid Fuel Gelling
The use of approved biodiesel fuel does Operators should also be aware that diesel fuel and aftertreatment not affect the PACCAR engine warranty. biodiesel energy content (by volume) is systems Failures caused by the use of non- lower than diesel which can reduce fuel • Only use the additive for the approved biodiesel fuels or other fuel economy by up to two percent. minimum time needed 2 additives that are of unacceptable quality • Follow the additive manufacturer's or do not meet specified industry standards instructions exactly are not considered as defects of parts or Recommendations to workmanship by PACCAR and therefore will not be covered by the PACCAR engine Avoid Fuel Gelling warranty. Diesel Exhaust Fluid Information to prevent fuel gelling in cold Recommendations and PACCAR recommends that customers weather. intending to use biodiesel blends become Specifications familiar with the additional handling • Use appropriate fuel grade/blend for considerations of these fuels such as conditions ageing, metal compatibility and tendency to • Spec your vehicle with proper cold absorb water. Please reference the fuel weather equipment (12V electric pre- CAUTION supplier’s technical information or industry heater, fuel blending valve, fuel/ guidelines such as the American Trucking coolant heater, 12V fuel line heaters It is unlawful use Diesel Exhaust Fluid Association Truck Maintenance Council and fuel tank heaters) (DEF) that does not meet the specifi- document RP 357. cations provided or to operate the ve- PACCAR does not recommend the use of hicle/equipment without DEF. Failure In particular, operators should be aware fuel additives, however, should a customer to comply may result in equipment or that biodiesel blends are more prone to decide there is a need for temporary use of property damage. cold flow (gelling) and filter plugging issues a winter fuel additive, PACCAR offers the compared to conventional diesel fuel. If following guidance: vehicles are expected to be operated in temperatures below freezing, care should • Use an industry known, high quality be taken to ensure that both the biodiesel product (EPA-approved) fuel used and the appropriate vehicle fuel • Check the product label to ensure it system accessory heaters are utilized. is compatible with ultra-low sulfur
54 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Diesel Exhaust Fluid Recommendations and Specifications
For engines using SCR operating in the United States and Canada, it is WARNING CAUTION recommended that the DEF used be certified by the American Petroleum Diesel Exhaust Fluid (DEF) contains PACCAR Inc requires the use of DEF Institute (API). 2 urea. DO NOT get the substance in meeting ISO 22241-1 (DIN 70070) spec- your eyes. In case of contact, immedi- ifications. There is NO acceptable sub- ately flush eyes with large amounts of stitute. Failure to use the correct DEF NOTE water for a minimum of 15 minutes. may cause engine damage and/or void DO NOT swallow internally. In the the warranty. To ensure the correct DEF is used, event the diesel exhaust fluid is ingest- PACCAR Inc recommends the use of ed, contact a physician immediately. • Some locations may reference the TRP® CleanBlue Diesel Exhaust Fluid Reference the Materials Safety Data DIN 70070 standard. DEF specifi- which is available in different quantity Sheet (MSDS) for additional informa- cation limits of this standard are options from small to bulk containers. tion. Failure to comply may result in identical to ISO 22241-1. personal injury. PACCAR Inc is not responsible for failures or damage resulting from what PACCAR CAUTION Inc determines to be abuse or neglect, including but not limited to: operation Never attempt to create Diesel Ex- without correctly specified DEF; lack of haust Fluid (DEF) by mixing agricultur- maintenance of the aftertreatment system; al grade urea with water. Agricultural improper storage, or shutdown practices; grade urea does not meet the neces- unauthorized modifications of the engine sary specifications required and the af- and aftertreatment system. PACCAR is tertreatment system may be damaged. also not responsible for failures caused by Failure to comply may result in equip- incorrect DEF or by water, dirt or other ment damage. contaminants in the DEF. Refer to your engine and vehicle operator's manuals for DEF Availability maintenance, storage, and shutdown information. • DEF is readily available at truck stops and at all PACCAR Engine
Y53-1185-1E1 (04/16/18) 55 ENGINE MAINTENANCE - Maintenance Procedures
dealers. For assistance locating DEF, This procedure should be followed as part contact your local PACCAR of routine maintenance checks. authorized repair location. Maintenance Procedures 1. Twist the dipstick handle to unlock it, • If your vehicle is out of DEF and you then pull the dipstick out of the 2 are unable to locate a source to Engine Oil Level holder. purchase DEF, please contact the vehicle OEM customer care center at How to check engine oil level 2. Wipe the dipstick clean with a lint- free cloth. the telephone number provided in the To check engine oil level, park vehicle on 3. Reinsert the dipstick into the holder. vehicle operator’s manual. The level ground and wait 15 minutes after vehicle OEM customer care center shutting off engine. After the engine is shut 4. Remove the dipstick from the holder will be able to contact the nearest off it will take at least 15 minutes for all the and check the oil level. The oil level dealer location to you and arrange for engine oil to return to the sump. should always be between the two an emergency shipment of DEF to marks on the dipstick. your location 24 hours a day. 5. Reinstall the dipstick and twist to lock NOTE it in place. The following are other common names used for Diesel Exhaust Fluid (DEF): It takes approximately 15 minutes for • AUS 32 (Aqueous Urea Solution 32) all the oil to run into the sump when the engine is ‘warm.’ If the level is • AdBlue checked immediately after switching • NOx Reduction Agent off the engine, the dipstick will show a • Catalyst Solution low oil level. Regardless of what the DEF is called, the Make sure that the vehicle suspension is DEF must meet the ISO 22241-1 (DIN sitting flat, both lengthwise and crosswise. 70070) specifications. Check this carefully on a vehicle with air suspension. Engine coolant should be at or above the operating temperature of 180°F (82°C).
56 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
Oil Level Indication on Dipstick Engine Oil Dip Stick Markings This procedure should be followed when oil level is low and more oil needs to be High and low marks on the dipstick indicate added. level of oil in the oil pan. 1. Top up with oil, if necessary, via the 2 filler opening. Use the correct grade NOTE in the correct quantity. 2. After topping up, wait one minute and On the engine oil dipstick, the differ- 1 check the oil level again. ence between the low oil level mark (2) and high oil level mark (1) is two 3. Reinstall the oil fill cap and twist to US quarts (1.9 liters). lock it in place.
2 Engine Oil Filter Procedure for replacing engine oil filters. Always use quality engine lubricating oils in conjunction with the appropriate oil drain and filter change intervals. Refer to the “Preventative Maintenance Schedule” for 1. High oil level (1) the recommended oil and filter change 2. Low oil level (2) service interval.
Topping Up the Engine Oil CAUTION
Steps for topping up the engine oil. Use of non-genuine oil filters can If checking the engine oil just after stopping cause severe engine damage. the engine, wait 15 minutes for the oil to drain back into the oil pan before checking the fluid level.
Y53-1185-1E1 (04/16/18) 57 ENGINE MAINTENANCE - Maintenance Procedures
Oil Filter Removal Preparation After Replacing Engine Oil Filter(s) battery clamp and the negative termi- This procedure should be followed before nal before working on the vehicle. Procedure for what to do after installing replacing engine oil filters. Working on a vehicle while the battery new oil filters. is connected may result in electrical in- 2 Follow the steps below after installing new jury or damage. Always disconnect the oil filters: CAUTION battery at the negative terminal when performing service procedures. Failure 1. Reconnect the chassis battery cable Before beginning to remove and/or to comply may result in death, person- at the negative battery terminal. See disconnect any components, wait at al injury or equipment damage. "Oil Filter Removal Preparation." least 5 minutes after the key switch is turned OFF for the aftertreatment DEF 2. Add SAE-approved CK-4/CJ-4 engine oil to the maximum level dosing system to purge the DEF from WARNING the system. The DEF system purges marked on the dipstick. If the engine is running a different weight of oil, be to prevent damage from freezing. Fail- Electrical shock hazard: Never discon- ure to comply may result in equipment sure to top-off the engine oil with the nect the battery clamp when the en- same brand and viscosity of oil. or property damage. gine is running. Disconnecting the bat- 3. Start and run the engine for 5 to 10 tery clamps while the engine is running minutes and check for any oil leaks. may result in death, personal injury or WARNING equipment damage from electrical arc- 4. Remove oil collection pan and ing or damage to electrical compo- dispose of any spillage properly. Turn off the engine and place the igni- nents. 5. Shut down the engine, check the oil tion switch in the OFF position before level and top up as necessary. See disconnecting the battery clamps. DO 1. Disconnect the chassis battery cable "Engine Oil Level." NOT place any tools or other materials at the negative battery terminal. on top of or close to the batteries. This 2. Place an oil collection pan directly can cause a dangerous high current under the oil filter. short circuit and, in the worst case, a battery explosion. Keep all objects away from the battery terminals. Al- ways break the contact between the
58 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
Fuel Filter Important information on replacing engine NOTE NOTE mounted cartridge type fuel filters. Use of poor quality fuel may require The engine and fuel module should be 2 Perform these maintenance procedures more frequent fuel filter element serv- operated in cold climates with accepta- according to the Preventative Maintenance ice. ble cold climate fuel blends which no- Schedule. ticeably reduces wax gelling in the fuel Description filter cartridge. The fuel module in- cludes a 12V preheater to support pre- WARNING The fuel filter/water separator module heat of the fuel for initial start-up in provides fine-particle filtration, water mild climates. Failure to operate with When removing the fuel filter, a quanti- separation, water-in fuel-sensing, acceptable cold climate fuel may result ty of fuel will escape. DO NOT smoke automatic water draining, lifetime in insufficient fuel flow to the fuel injec- or allow an open flame in close prox- purification of drained water with a tion system. imity. Failure to do so could ignite a charcoal filter, 12V preheating and system fire or cause an explosion which could manual priming in a singular easy to Biodiesel result in serious injury to you and/or service module. bystanders. Failure to comply may re- For information on alternative fuels, such sult in death, personal injury, equip- Replace the suction side and the pressure as biodiesel, and additional information for ment or property damage. side fuel filters at the same time. It is fuel recommendations and specifications recommended to replace the fuel filters at refer to "Fuels for Cummins® Engines," the same interval as the oil and oil filter are Bulletin 3379001. NOTE changed. If the oil drain interval being used is greater than 15,000 mi (24,000 km), as The fuel filter and the hand pump are determined by the Engine Lubrication and located on the left-hand side of the en- Filter Intervals, the fuel filter change can be gine, as viewed from the driver's seat. extended until the oil drain interval.
Y53-1185-1E1 (04/16/18) 59 ENGINE MAINTENANCE - Maintenance Procedures
Fuel Filter Removal 4. Fuel Filter Housing cleaned and reused. Dispose of the filter as chemical waste. Procedure for removing the engine fuel 1. Clean the fuel filter cap and filter. surrounding area to ensure dirt does 4. Remove the fuel filter cartridge. not fall into the fuel module. 2 Follow the steps below to remove the fuel filter: Fuel Filter Installation Fuel Module CAUTION Procedure for installing the PACCAR PX-7 or PX-9 fuel filter. Dirt in the fuel system can lead to significant damage to the fuel Follow the steps below to install a new fuel 1 system. Failure to comply may filter: result in equipment or property damage. 1. Verify the sealing O-ring that is supplied with the filter kit is installed 2 2. Loosen the fuel tank cap to relieve on the fuel filter cap and lightly coat any pressure in the fuel tank. the O-ring with fuel. 3. Remove the fuel filter cap by rotating 2. Install the new fuel filter cartridge to it counter-clockwise with a wrench, 3 the cap, then insert into the fuel automatic draining of fuel will be module. initiated, wait 5 minutes for complete fuel draining to prevent fuel from leaking or dripping on the starter NOTE motor. Depending on the vehicle’s fuel 4 system configuration the fuel fil- NOTE ter housing may not completely drain of fuel. If this is the case, The fuel filter cartridge is a dis- take care when installing the new 1. Fuel Filter Cap posable filter and must not be filter as this may cause fuel to 2. Fuel Filter spill from the filter housing. 3. Manual Priming Pump
60 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
3. Tighten the fuel filter cap by rotating it During this time the pumping the engine to start. If the starter is clockwise until the filter cap O-ring resistance will increase but the full engaged for longer than 20 seconds makes contact with the fuel module. time is required to fully prime the fuel without starting, additional priming Then tighten the filter cap to 30 lb-ft system. Then tighten the knob by pump actuation may be necessary. (40 N·m) as specified on the filter rotating it clockwise. 2 cap. 4. If installing a new fuel filter on a CAUTION PX-7, loosen the fuel priming pump CAUTION knob by rotating it counter-clockwise. If the engine is cranked exces- Operate priming pump at a maxi- sively Starter Protection will be mum rate of 30 strokes per mi- triggered and starter engage- NOTE nute to prevent damage to pump. ment will be restricted for 10 mi- nutes. 6. Check for leakage at the fuel filter The PX-9 uses an electric pri- cap. Tighten if necessary. 8. Check the system for leakage while ming pump. If installing a new idling. Then turn the engine off and fuel filter on a PX-9 engine first check the system again for leakage. vent the fuel system at the quick- WARNING disconnect fitting at the pressure side filter head inlet. The vent Check the fuel filter for signs of Starting After the Fuel Tank Has overflow may be routed back to leakage. DO NOT smoke or al- Run Dry or After Fuel System the fuel tank, or, into a vented low an open flame in close prox- Service has been Performed container. Cycle the ignition imity. Failure to do so could ignite switch to the ON position every 2 a fire or cause an explosion Procedure for starting the engine after minutes (to power the electric lift which could result in serious in- running out of fuel. pump) until fuel appears in the jury to you and/or bystanders. chassis-mounted fuel filter hous- Failure to comply may result in Follow the steps below to restart the ing and a solid stream of fuel death, personal injury, equipment engine: flows out of the vent., then skip or property damage. to Step 6. 7. Start the engine and allow it to idle 5. Operate the priming pump by moving for several minutes. Note that it could the knob in and out for 150 seconds. take up to 15 seconds of cranking for
Y53-1185-1E1 (04/16/18) 61 ENGINE MAINTENANCE - Maintenance Procedures
WARNING NOTE CAUTION Check the fuel filter for signs of Allowing the engine to idle for 2 The following instructions should only leakage. DO NOT smoke or al- several minutes with the fuel be used in emergency situations when low an open flame in close prox- blending valve in the prime posti- the fuel tank has run dry. Failure to fol- imity. Failure to do so could ignite tion assists in purging air from low the starting instructions below may a fire or cause an explosion the fuel system. damage the starter motor. which could result in serious in- 6. Check the system for leakage while jury to you and/or bystanders. idling. Then turn the engine off and 1. Loosen the fuel primer pump knob by Failure to comply may result in check the system again for leakage. rotating it counter-clockwise. death, personal injury, equipment 2. If equipped with a return fuel or property damage. 7. If the engine does not start within this blending valve, turn the valve to the time, repeat steps two and three until PRIME (closed) position. 5. Start the engine and allow it to idle the engine starts. If the engine still for several minutes. Note that it could 3. Operate the priming pump by moving does not start, allow the starter to take up to 15 seconds of cranking for the knob in and out for 150 seconds. cool down for at least 5 minutes the engine to start. If the starter is During this time the pumping before repeating the procedure. engaged for longer than 20 seconds resistance will increase, but the full without starting, additional priming Fuel Blending Valve time is required to fully prime the fuel pump actuation may be necessary. system. 2 1 CAUTION CAUTION If the engine is cranked exces- Operate priming pump at a maxi- sively Starter Protection will be mum rate of 30 strokes per mi- triggered and starter engage- nute to prevent damage to pump. ment will be restricted for 10 mi- 4. Check for leakage at the fuel nutes. filtercap. Tighten if necessary.
62 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
Valve Position 1. Run (open) Cooling System 2. Prime (closed) Important information on replacing coolant WARNING 8. If equipped with a return fuel filters. blending valve, turn the bypass to the Handle coolant and antifreeze careful- 2 RUN (open) position. Your engine may be equipped with a ly. Ethylene glycol antifreeze is poison- coolant filter designed to capture and ous. Store in original fluid container remove harmful deposits from the cooling only, and always keep out of the reach NOTE system to help prolong system life. Refer to of children. Never remove the filler cap the Preventative Maintenance Schedule for (vertically mounted) on the surge tank Failure to return the bypass to the recommended coolant filter change while the engine is still hot. Wait until the RUN (open) position will pre- service interval. the coolant temperature is below vent fuel recirculation and heat- 120°F (50°C). Scalding steam and flu- ing. WARNING id under pressure may escape and cause serious personal injuries. The pressure cap (horizontally mounted) WARNING Do not remove the surge tank fill cap on a hot engine. It can cause scalding on the surge tank should never be opened. Failure to comply may result DO NOT loosen any fuel line fit- coolant to spray out and you could be burned. If the engine has been operat- in death, personal injury, equipment or tings in order to bleed the fuel property damage. system of air. The system is un- ed within the last 30 minutes, be very der high pressure which, when careful in removing the radiator cap. Protect face, hands, and arms against relieved, could cause death, per- Coolant/Antifreeze Condition sonal injury, equipment or prop- escaping fluid and steam by covering erty damage. the cap with a large, thick rag. Failure Maintenance checks for ensuring proper to comply may result in death, person- coolant\anti-freeze condition. al injury, equipment or property dam- age Perform these maintenance procedures according to the Preventative Maintenance Schedule.
Y53-1185-1E1 (04/16/18) 63 ENGINE MAINTENANCE - Maintenance Procedures
• Nitrite level NOTE NOTE • Carboxylate level Inhibitor concentration level de- 2 Test the engine coolant at least twice Checking Coolant Condition termines corrosion protection. If per year to determine if the coolant Recommended coolant checks. you are concerned about possi- must be replaced. If it is determined ble coolant quality, contamina- that the coolant should be replaced, To ensure the Extended Life Coolant (ELC) tion, or mechanical problems, make sure to flush the coolant system. in your vehicle always provides maximum submit a coolant sample to your Contact a PACCAR® Authorized Re- protection, perform the following tests: dealer for analysis. Improper pair Location for flushing the coolant maintenance may cause coolant system. 1. Check the coolant color at every degradation and could result in maintenance interval. It should have damage to the cooling system Service interval is every oil change or no cloudiness, floating debris, or oils. and engine components. Consult 15,000 mi (24,000 km), 500 hours, or 6 2. Test the freeze point at least twice a your dealer or the coolant manu- months, whichever occurs first. A heavy- year. A refractometer or test strips facturer's representative for rec- duty, year-round antifreeze that meets the can be used to measure the ommended extended life coolant chemical composition of GM6038M must protection level. test kits, test strips, and laborato- be used. The change interval is 2 years or 3. Determine the pH and chemical ry sample procedures. 240,000 mi (385,000 km), whichever inhibitor concentration level by using occurs first. Antifreeze is essential for an ELC-specific test kit or test strips. freeze and corrosion protection. 4. Keep the cooling system full by Radiator Hoses Supplemental coolant additives are topping-up using ELC pre-diluted to a essential for liner pitting and scaling Maintenance checks for radiator hoses. 50/50 blend, unless a different ratio protection. of water/antifreeze has been Perform these maintenance procedures 1. Check the following anti-freeze substituted (depending on operating according to the Preventative Maintenance conditions: conditions). Schedule. • Coolant level 1. Check the following radiator hose • Freeze point conditions: • pH level
64 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
• Hose condition, deterioration/ Fan Belt Tensioner automatic belt tensioner's roller, as signs of leaking shown in the image. Maintenance checks for fan belt tensioner. • Hose clamp torque 4. Rotate the flex-bar as shown in the Perform these maintenance procedures diagram to relieve belt tension. according to the Preventative Maintenance 2 5. With the belt tensioner pressure Drive Belts Schedule. relieved, remove the poly V-belt from Maintenance checks and procedures for 1. Check and correct fan belt tensioner. the pulleys. engine drive belts. • Mounting bolt torque • The tensioner can be temporarily • Tensioner maintains proper belt blocked with a 0.16-0.2 in. (4-5 NOTE tension mm) thick pin (bore). This facilitates removal and installation Always fit the same type of belts as of the poly V-belt. the ones replaced. Poly V-belt and Fan Drive Belt 6. After removing the belt, carefully Removal allow the belt tensioner to spring Engine belt replacement procedures for back to the stop (if it had not been Engine Belt Checks poly V-belt and fan drive belts. temporarily blocked). 7. Inspect the pulleys for damage, rust, Maintenance check for engine drive belts. Perform these maintenance procedures and grease deposits. Clean or Perform these maintenance procedures according to the Preventative Maintenance replace as necessary. according to the Preventative Maintenance Schedule. Schedule. 1. Disconnect the electrical ground wire Poly V-belt and Fan Drive Belt 1. Inspect the engine drive belts for the from the battery. Installation following conditions: 2. Reach between the fan blades and Procedure to install poly v-belt and fan remove the fan blade mounting bolts drive engine belts. • Condition, signs of wear/ using a 9/16 in. socket to remove the deterioration mounting nuts. Follow the steps below to install the poly V- • Alignment 3. Place a flex-bar with a 15 mm socket belt and fan drive belts: on the fastener securing the
Y53-1185-1E1 (04/16/18) 65 ENGINE MAINTENANCE - Maintenance Procedures
1. Place the new poly V-belt over the back to its normal position. If the 3. Reinstall fan blade using fan blade pulleys, making certain the belt falls tensioner had been temporarily bolts and new 9/16 in. nylon patch into all the belt pulley grooves. blocked, relieve tensioner pressure lock nuts. enough to remove the locking pin, 4. Reconnect the electrical ground wire 2 then allow the tensioner to spring to the battery. NOTE back to its normal position.
When installing the belts do not Diesel Exhaust Fluid (DEF) Filter wrap belt around the tensioner NOTE until after the belt has been Maintenance tasks for diesel exhaust fluid wrapped around all other pulleys Do not reuse nylon patch lock filter and idlers. nuts. Replace with new lock nuts when reinstalling parts. Perform these maintenance procedures 2. After installing the belt, carefully according to the Preventative Maintenance allow the belt tensioner to spring Schedule.
66 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Maintenance Procedures
Medium and Large DEF Tank Small DEF Tank Filter Access 2
1. Replace the aftertreatment DEF 2. From the bottom of the tank, remove Air Compressor dosing unit (DEF module) filter the cover plate by removing the according to the maintenance various fasteners holding it on then Maintenance procedures for the air schedule. allow the cover plate to drop down. compressor.
Y53-1185-1E1 (04/16/18) 67 ENGINE MAINTENANCE - Maintenance Procedures
Perform these maintenance procedures 1. Check and correct the following Charging - Cranking System according to the Preventative Maintenance charge air piping components: Schedule. Electrical Harness / Cables • Hose/pipe condition – 1. Check and correct for carbon buildup deterioration/signs of leaking Maintenance checks for the electrical 2 harnesses and cables. • Hose clamps for tightness Air Intake System • Clearance to other components Perform these maintenance procedures according to the Preventative Maintenance Air Cleaner Charge Air Cooler Schedule. Maintenance checks for the charge air Proper maintenance procedures for the air 1. Check the following electrical cooler. cleaner. components: Perform these maintenance procedures Perform these maintenance procedures • Inspect for loose connections, according to the Preventative Maintenance according to the Preventative Maintenance corrosion, chafing, and broken Schedule. Schedule. retention clips 1. Check and correct for restriction: 1. Check and correct the following Batteries, Cables, and Connections components of the charge air cooler: • Service filter element when air Maintenance checks for electrical cleaner restriction gauge (option) • Cracked tubes or header components. locks in the extreme high position. • Clogged fins/tubes • Check hose/pipe condition – • Hose/pipe condition – Perform these maintenance procedures deterioration/ signs of leaking. deterioration/signs of leaking according to the Preventative Maintenance Schedule. • Check hose clamp torque. • Hose clamp torque Charge Air Piping 1. Check the following electrical components: Maintenance checks for charge\air piping. • Condition – electrolyte level, Perform these maintenance procedures cracks, signs of leaking, according to the Preventative Maintenance overcharging Schedule. • Hold-downs – tightness
68 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Identification
• Battery box mounting bolt – 2. Check mount and leg for fractures, the front timing gear cover (PX-9). The torque breaks or deformation. Replace as engine EPA label must not be changed necessary. unless approved by PACCAR. 3. Check for complete insertion of motor Crankshaft - Vibration Damper PX-9 EPA Label Location mount. Replace as necessary. 2 Maintenance checks for the engine crankshaft. CAUTION Perform these maintenance procedures according to the Preventative Maintenance DO NOT re-torque or reuse ex- No. Catalyst Schedule. isting flange head bolts. These 1. If equipped with a rubber-type bolts are factory set to the speci- crankshaft damper, perform the fied torque. If bolts are loose or following checks of vibration damper: damaged, they must be replaced with the new bolts. Failure to • Inspect for cracks, nicks, leakage comply may result in equipment or property damage. • Check fastener torque Engine Identification
Engine Mounting Bolts The engine dataplate contains information Maintenance guidelines for engine Engine Identification specific to that engine. The engine serial mounting bolts. number (ESN) and control parts list (CPL) PX Engine EPA Label provide information for service and Perform these maintenance procedures ordering parts. according to the Preventative Maintenance EPA label location and label information. Schedule. Check for the following: The EPA label provides important details 1. Inspect both mount and leg about the engine. This label is located on fasteners. Check for loose or broken top of the engine valve cover (PX-7) or on bolts. Replace as necessary.
Y53-1185-1E1 (04/16/18) 69 ENGINE MAINTENANCE - Engine Identification
1 2 3 4 5 2
6 7 8 9
Have the following engine data available when communicating with a PACCAR Authorized Repair Location: 1. Date of manufacture 2. Engine Serial Number (ESN) 3. Engine model information 4. Fuel rate 5. Control Parts List (CPL) 6. Idle speed 7. Valve Lash 8. Advertised horsepower and rpm rating 9. Engine Displacement
70 Y53-1185-1E1 (04/16/18) ENGINE MAINTENANCE - Engine Identification
NOTE Not all engines have ECM dataplates. 2 The engine control module (ECM) dataplate is located on the front of the ECM. The following information is found on Bosch dataplate includes: the engine control module dataplate: • Pump serial number • ECM part number (PN) • PACCAR part number • ECM serial number (SN) 1. Dataplate • Factory code • ECM date code (DC) 2. Engine Serial Number • Bosch part number • Engine serial number (ESN) If the engine dataplate (1) is NOT legible, • Date code • ECM Code: identifies the software in the ESN (2) can be found on the engine the ECM. block, on top of the lubricating oil cooler Engine Control Module Dataplate housing. Additional engine information is NOTE on the electronic control module (ECM) dataplate. The presence of an ECM dataplate de- pends on the manufacturing plant and Fuel Injection Pump Dataplate the date the engine was manufac- tured. If an ECM dataplate was not in- The Bosch fuel injection pump dataplate is stalled by the manufacturing plant, cal- located on the fuel pump. ibration data can be found on the en- gine dataplate.
Y53-1185-1E1 (04/16/18) 71 ENGINE MAINTENANCE - Engine Identification
PACCAR Engine Nomenclature • Date code NOTE The PACCAR engine nomenclature Variable Geometry Turbocharger 2 provides the following information: Dataplate The electronic actuator on the VGT is a serviceable component and has a PX-9 240 separate dataplate that contains infor- mation to assist in servicing or re- 1 placement. 2
1. Horsepower Rating 2. Engine Model
Air Compressor Dataplate The Holset® variable geometry turbocharger (VGT) dataplate is located on NOTE the turbocharger inlet compressor housing. The dataplate contains the following Not all engines are equipped with an information to assist in servicing or air compressor. replacement: • Assembly part number The air compressor dataplate is typically located on the side of the air compressor. • Serial number The dataplate contains the following • Customer number information to assist in servicing or • Model number replacement: • Part number • Serial number
72 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY
Chapter 3 | ENGINE WARRANTY
United States and Canada Engine Warranty ...... 74 3
Y53-1185-1E1 (04/16/18) 73 ENGINE WARRANTY - United States and Canada Engine Warranty Chapter 3 | Engine Warranty service, from a defect in material or factory PACCAR and Owner workmanship (warrantable failure). This Responsibilites coverage begins on the date of delivery United States and Canada Description of responsibilites for PACCAR and ends two years or 250,000 miles and the owner of a PACCAR Brand Engine Warranty (400,000 kilometers) or 6,250 hours, Engine. whichever occurs first, after the date of Engine Warranty for Standard delivery of the engine to the first purchaser PACCAR Responsibilities 3 or first lessee. Applications PACCAR will pay for all parts and labor PACCAR PX-9 engine coverage for Engine aftertreatment components needed to repair the damage to the engine standard applications . included in the PACCAR critical parts list resulting from a warrantable failure. (CPL) and marked with a PACCAR part Products Warranted number are covered under base engine PACCAR will pay for the lubricating oil, warranty. antifreeze, filter elements, belts, hoses, This warranty applies to new PACCAR and other maintenance items that are not PX-9 engines sold and used in the United Additional coverage is outlined in reusable due to the warrantable failure. States 1 or Canada and operated in on- Emissions Warranty on page 79 . highway applications with one exception – PACCAR will pay for reasonable labor there is different warranty coverage for costs for engine removal and reinstallation engines used in the fire apparatus truck when necessary to repair a warrantable applications. failure. The PACCAR PX-9 engine is warranted PACCAR will pay during the base engine directly to the first purchaser or first lessee warranty period of two years or 250,000 by PACCAR. miles (400,000 kilometers) or 6,250 hours, whichever occurs first: reasonable costs for Base Engine Warranty towing a vehicle disabled by a warrantable failure to the nearest authorized repair This warranty covers any failures of the location. In lieu of the towing expense and engine which result, under normal use and
1 United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.
74 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
in its sole discretion, PACCAR may pay are not reusable due to the warrantable engine facility where applicable, subject to reasonable costs for a mechanic to travel failure. The owner is responsible for PACCAR’s time, mileage, and hour to and from the location of the vehicle communication expenses, meals, lodging limitations of the engine warranty. The when an engine repair is performed at the and similar costs incurred as a result of a maximum time, mileage and hour site of the failure. warrantable failure. limitations of the engine warranty begin running on the date of delivery to the first Owner Responsibilities The owner is responsible for non-engine purchaser or first lessee. The accrued repairs and for “downtime” expenses, The owner is responsible for the operation time, mileage, or hours is calculated when 3 cargo damage, fines, all applicable taxes, and maintenance of the engine as the engine is brought into an authorized all business costs and other losses specified in the applicable PACCAR dealer for correction of warrantable resulting from a warrantable failure. Operator’s Manual. The owner is also failures. responsible for providing proof that all The owner is responsible for non-engine Failures, other than those resulting from recommended maintenance has been repairs and for “downtime” expenses, defects in material or factory workmanship, performed. cargo damage, fines, all applicable taxes, are not covered by this warranty. PACCAR all business costs and other losses Before the expiration of the applicable is not responsible for failures or damage resulting from a warrantable failure. warranty, the owner must notify a PACCAR resulting from what PACCAR determines to authorized engine dealer or an authorized be abuse or neglect, including, but not Cummins Distributor of any warrantable Warranty Limitations - Standard limited to: damage due to accident; failure and make the engine available for Applications operation without adequate coolants or repair by such facility. The warrantable lubricants; overfueling; overspeeding; lack failure must be brought to the attention of a Limitations of engine warranty for standard of maintenance of lubricating, cooling or PACCAR authorized engine dealer within applications. intake systems; improper storage, starting, 30 days of discovery. Except for engines Your sole and exclusive remedy against warm-up, run-in or shutdown practices; disabled by a warrantable failure, owner PACCAR and the selling dealer arising failure to perform regeneration in a timely must also deliver the engine to the repair from your purchase and use of this engine manner; unauthorized modifications of the facility. is limited to the repair or replacement of engine. PACCAR is also not responsible “warrantable failures” at authorized United for failures caused by incorrect oil or fuel or The owner is responsible for the cost of diesel exhaust fluid or by water, dirt or lubricating oil, antifreeze, filter elements States and Canadian PACCAR engine dealers or an authorized Cummins other contaminants in the fuel, oil, or diesel and other maintenance items provided exhaust fluid. Failure of replacement parts during warranty repairs unless such items Distributor, or an authorized PACCAR
Y53-1185-1E1 (04/16/18) 75 ENGINE WARRANTY - United States and Canada Engine Warranty
used in repairs due to the above non- of the part it replaced and is entitled to the THIS LIMITED WARRANTY IS THE SOLE warrantable conditions is not warrantable. remaining coverage hereunder. WARRANTY MADE BY PACCAR AND THE SELLING DEALER. EXCEPT FOR This warranty does not apply to PACCAR is not responsible for damage or THE ABOVE LIMITED WARRANTY, accessories supplied by the vehicle original loss resulting from engine horsepower/ PACCAR AND THE SELLING DEALER equipment manufacturer (OEM) which are torque upgrades. MAKE NO OTHER WARRANTIES, covered by the OEM vehicle warranty. PACCAR reserves the right to interrogate EXPRESS OR IMPLIED. PACCAR AND 3 Failures resulting in excessive oil electronic control module (ECM) data for THE SELLING DEALER EXPRESSLY consumption are covered for the duration purposes of failure analysis. DISCLAIM ANY WARRANTY OF of the coverage or 250,000 miles (400,000 MERCHANTABILITY OR WARRANTY OF kilometers) or 6,250 hours from the date of PACCAR does not warrant antifreeze, FITNESS FOR A PARTICULAR delivery of the engine to the first purchaser lubricants, filters, filter elements, or any PURPOSE. other part which is considered a or first lessee, whichever occurs first. PACCAR AND THE SELLING DEALER Before a claim for excessive oil maintenance item. PACCAR does not warrant services to remove ash from the SHALL NOT BE LIABLE FOR consumption will be considered, the owner INCIDENTAL OR CONSEQUENTIAL must submit adequate documentation to DPF either at or before a regular service interval as indicated in the maintenance DAMAGES INCLUDING, BUT NOT show that consumption exceeds PACCAR LIMITED TO: LOSS OF INCOME OR published standards. schedule or when the system indicates that the DPF requires cleaning unless the LOST PROFITS; ENGINE OR VEHICLE Failures of belts and hoses supplied by service is required as part of a warrantable DOWNTIME; THIRD PARTY DAMAGE, PACCAR are covered for the first year from repair. INCLUDING DAMAGE OR LOSS TO the date of delivery of the engine to the first OTHER ENGINES, VEHICLES OR purchaser or first lessee. PACCAR DOES NOT COVER WEAR OR PROPERTY, ATTACHMENTS, TRAILERS WEAROUT OF COVERED PARTS. AND CARGO; LOSS OR DAMAGE TO Parts used to repair a warrantable failure PERSONAL CONTENTS; THIS WARRANTY AND THE EMISSION may be new parts, approved rebuilt parts, COMMUNICATION EXPENSES; WARRANTY SET FORTH HEREINAFTER or repaired parts. PACCAR is not LODGING AND/OR MEAL EXPENSES; ARE THE SOLE WARRANTIES MADE responsible for failures resulting from the FINES; APPLICABLE TAXES OR BY PACCAR IN REGARD TO THESE use of parts not approved by PACCAR. A BUSINESS COSTS OR LOSSES; ENGINES. new approved or rebuilt part used to repair ATTORNEYS’ FEES; AND ANY a warrantable failure assumes the identity LIABILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY.
76 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
This warranty gives you specific legal years or 100,000 miles (160,000 PACCAR will pay during the base engine rights, and you may also have other rights kilometers), whichever occurs first. warranty period of two years or 100,000 which vary from state to state. miles (160,000 kilometers), whichever Engine aftertreatment components occurs first: reasonable costs for towing a included in the PACCAR critical parts list vehicle disabled by a warrantable failure to Engine Warranty for Fire Apparatus (CPL) and marked with a PACCAR part the nearest authorized repair location. In Truck Applications number are covered under base engine lieu of the towing expense and in its sole warranty. discretion, PACCAR may pay reasonable 3 PACCAR PX-9 engine coverage for fire costs for a mechanic to travel to and from apparatus truck applications. PACCAR and Owner the location of the vehicle when an engine This warranty applies to new PACCAR Responsibilites repair is performed at the site of the failure. PX-9 engines sold and used in the United Description of responsibilites for PACCAR Owner Responsibilities 2 States or Canada and operated in fire and the Fire Truck owner. apparatus truck applications. The owner is responsible for the operation PACCAR Responsibilities and maintenance of the engine as The PACCAR PX-9 engine is warranted specified in the applicable PACCAR directly to the first purchaser or first lessee PACCAR will pay for all parts and labor Operator’s Manual. The owner is also by PACCAR. needed to repair the damage to the engine responsible for providing proof that all resulting from a warrantable failure. recommended maintenance has been Base Engine Warranty PACCAR will pay for the lubricating oil, performed. The base engine warranty covers any antifreeze, filter elements, belts, hoses, Before the expiration of the applicable failures of the engine which result, under and other maintenance items that are not warranty, the owner must notify a PACCAR normal use and service, from a defect in reusable due to the warrantable failure. authorized engine dealer or an authorized material or factory workmanship Cummins Distributor of any warrantable (warrantable failure). This coverage begins PACCAR will pay for reasonable labor failure and make the engine available for on the date of delivery to the first costs for engine removal and reinstallation repair by such facility. The warrantable purchaser or first lessee and ends after five when necessary to repair a warrantable failure. failure must be brought to the attention of a
2 United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.
Y53-1185-1E1 (04/16/18) 77 ENGINE WARRANTY - United States and Canada Engine Warranty
PACCAR authorized engine dealer within Warranty Limitations - Fire Truck operation without adequate coolants or 30 days of discovery. Except for engines lubricants; overfueling; overspeeding; lack Limitations of engine warranty for fire truck disabled by a warrantable failure, owner of maintenance of lubricating, cooling or applications. must also deliver the engine to the repair intake systems; improper storage, starting, facility. Your sole and exclusive remedy against warm-up, run-in or shutdown practices; PACCAR and the selling dealer arising failure to perform regeneration in a timely The owner is responsible for the cost of from your purchase and use of this engine manner; unauthorized modifications of the lubricating oil, antifreeze, filter elements 3 is limited to the repair or replacement of engine. PACCAR is also not responsible and other maintenance items provided “warrantable failures” at authorized United for failures caused by incorrect oil or fuel or during warranty repairs unless such items States and Canadian PACCAR engine diesel exhaust fluid or by water, dirt or are not reusable due to the warrantable dealers or an authorized Cummins other contaminants in the fuel, oil, or diesel failure. The owner is responsible for Distributor, or an authorized PACCAR exhaust fluid. Failure of replacement parts communication expenses, meals, lodging engine facility where applicable, subject to used in repairs due to the above non- and similar costs incurred as a result of a PACCAR’s time, mileage, and hour warrantable conditions is not warrantable. warrantable failure. limitations of the engine warranty. The This warranty does not apply to maximum time, mileage and hour The owner is responsible for non-engine accessories supplied by the vehicle original limitations of the engine warranty begin repairs and for “downtime” expenses, equipment manufacturer (OEM) which are running on the date of delivery to the first cargo damage, fines, all applicable taxes, covered by the OEM vehicle warranty. all business costs and other losses purchaser or first lessee. The accrued resulting from a warrantable failure. time, mileage, or hours is calculated when Failures resulting in excessive oil the engine is brought into an authorized consumption are covered for the duration The owner is responsible for a $100 (U.S. dealer for correction of warrantable of the coverage or 100,000 miles (160,000 Dollars) deductible per each service visit failures. kilometers) from the date of delivery of the under this plan in the 3rd, 4th, and 5th engine to the first purchaser or first lessee, Failures, other than those resulting from years of base engine warranty. The whichever occurs first. Before a claim for defects in material or factory workmanship, deductible will not be charged during the excessive oil consumption will be are not covered by this warranty. PACCAR first two years of the base engine warranty. considered, the owner must submit is not responsible for failures or damage adequate documentation to show that resulting from what PACCAR determines to consumption exceeds PACCAR published be abuse or neglect, including, but not standards. limited to: damage due to accident;
78 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
Failures of belts and hoses supplied by service is required as part of a warrantable OTHER ENGINES, VEHICLES OR PACCAR are covered for the first year from repair. PROPERTY, ATTACHMENTS, TRAILERS the date of delivery of the engine to the first AND CARGO; LOSS OR DAMAGE TO purchaser or first lessee. PACCAR DOES NOT COVER WEAR OR PERSONAL CONTENTS; WEAROUT OF COVERED PARTS. COMMUNICATION EXPENSES; Parts used to repair a warrantable failure THIS WARRANTY AND THE EMISSION LODGING AND/OR MEAL EXPENSES; may be new parts, approved rebuilt parts, FINES; APPLICABLE TAXES OR or repaired parts. PACCAR is not WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BUSINESS COSTS OR LOSSES; 3 responsible for failures resulting from the ATTORNEYS’ FEES; AND ANY use of parts not approved by PACCAR. A BY PACCAR IN REGARD TO THESE ENGINES. LIABILITY YOU MAY HAVE IN RESPECT new approved or rebuilt part used to repair TO ANY OTHER PERSON OR ENTITY. a warrantable failure assumes the identity THIS LIMITED WARRANTY IS THE SOLE of the part it replaced and is entitled to the WARRANTY MADE BY PACCAR AND This warranty gives you specific legal remaining coverage hereunder. THE SELLING DEALER. EXCEPT FOR rights, and you may also have other rights which vary from state to state. PACCAR is not responsible for damage or THE ABOVE LIMITED WARRANTY, loss resulting from engine horsepower/ PACCAR AND THE SELLING DEALER torque upgrades. MAKE NO OTHER WARRANTIES, EXPRESS OR IMPLIED. PACCAR AND Emissions Warranty PACCAR reserves the right to interrogate THE SELLING DEALER EXPRESSLY Emissions coverage for all applications in electronic control module (ECM) data for DISCLAIM ANY WARRANTY OF the United States. purposes of failure analysis. MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR This emission warranty applies to new PACCAR does not warrant antifreeze, PURPOSE. PACCAR engines marketed by PACCAR lubricants, filters, filter elements, or any that are used in the United States 3 in other part which is considered a PACCAR AND THE SELLING DEALER vehicles designed for transporting persons maintenance item. PACCAR does not SHALL NOT BE LIABLE FOR or property on a street or highway. warrant services to remove ash from the INCIDENTAL OR CONSEQUENTIAL DPF either at or before a regular service DAMAGES INCLUDING, BUT NOT Coverage interval as indicated in the maintenance LIMITED TO: LOSS OF INCOME OR schedule or when the system indicates that LOST PROFITS; ENGINE OR VEHICLE PACCAR warrants to the first purchaser or the DPF requires cleaning unless the DOWNTIME; THIRD PARTY DAMAGE, first lessee and each subsequent INCLUDING DAMAGE OR LOSS TO purchaser that the engine is designed, built
Y53-1185-1E1 (04/16/18) 79 ENGINE WARRANTY - United States and Canada Engine Warranty
and equipped so as to conform at the time dealer. Your vehicle contains air, fuel, and limitations of the engine warranty begin of sale by PACCAR with all U.S. Federal electrical components that may affect running on the date of delivery to the first emission regulations applicable at the time engine emission controls. The use of non- purchaser or first lessee. The accrued of manufacture and that it is free from genuine engine or vehicle replacement time, mileage, or hours is calculated when defects in material or factory workmanship parts that are not equivalent to the the engine is brought into an authorized which would cause it not to meet these PACCAR engine or OEM vehicle dealer for correction of warrantable regulations within the longer of the manufacturer’s original part may impair the failures. 3 following periods: (A) Five years or engine and vehicle emissions control 100,000 miles (160,000 kilometers) of system from working or functioning Failures, other than those resulting from operation, whichever occurs first, as effectively, and may jeopardize your defects in material or factory workmanship, measured from the date of delivery of the emissions warranty coverage. are not covered by this warranty. PACCAR engine to the first purchaser or first lessee is not responsible for failures or damage or (B) The base engine warranty. resulting from what PACCAR determines to Warranty Limitations - Emissions be abuse or neglect, including, but not If the vehicle in which the engine is limited to: damage due to accident; installed is registered in the state of Limitations of engine emissions warranty. operation without adequate coolants or California, a separate California Emissions Your sole and exclusive remedy against lubricants; overfueling; overspeeding; lack Control Warranty Statement on page 81 PACCAR and the selling dealer arising of maintenance of lubricating, cooling or also applies. See California Emissions from your purchase and use of this engine intake systems; improper storage, starting, Warranty. is limited to the repair or replacement of warm-up, run-in or shutdown practices; failure to perform regeneration in a timely Replacement Parts “warrantable failures” at authorized United States and Canadian PACCAR engine manner; unauthorized modifications of the PACCAR recommends that any service dealers or an authorized Cummins engine. PACCAR is also not responsible parts used for maintenance, repair or Distributor, or an authorized PACCAR for failures caused by incorrect oil or fuel or replacement of emission control systems engine facility where applicable, subject to diesel exhaust fluid or by water, dirt or be new or genuine approved rebuilt parts PACCAR’s time, mileage, and hour other contaminants in the fuel, oil, or diesel and assemblies, and that the engine be limitations of the engine warranty. The exhaust fluid. Failure of replacement parts serviced by an authorized PACCAR engine maximum time, mileage and hour
3 United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.
80 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
used in repairs due to the above non- PACCAR AND THE SELLING DEALER be designed, built, and equipped to meet warrantable conditions is not warrantable. SHALL NOT BE LIABLE FOR the State’s stringent anti-smog standards. INCIDENTAL OR CONSEQUENTIAL PACCAR must warrant the emission PACCAR is not responsible for non-engine DAMAGES INCLUDING, BUT NOT control system on your diesel engine for repairs, downtime expenses, cargo LIMITED TO: LOSS OF INCOME OR the periods of time listed below provided damage, fines, all applicable taxes, all LOST PROFITS; ENGINE OR VEHICLE there has been no abuse, neglect or business costs or other losses resulting DOWNTIME; THIRD PARTY DAMAGE, improper maintenance of your diesel from a warrantable failure. INCLUDING DAMAGE OR LOSS TO engine. 3 OTHER ENGINES, VEHICLES OR PACCAR does not warrant antifreeze, Your emission control system may include lubricants, filters, filter elements, or any PROPERTY, ATTACHMENTS, TRAILERS AND CARGO; LOSS OR DAMAGE TO parts such as the fuel injection system and other part which is considered a engine electronic control module. Also maintenance item. PACCAR does not PERSONAL CONTENTS; COMMUNICATION EXPENSES; included may be hoses, connectors and warrant services to remove ash from the other emission related assemblies. DPF either at or before a regular service LODGING AND/OR MEAL EXPENSES; interval as indicated in the maintenance FINES; APPLICABLE TAXES OR If an emission-related part on your engine schedule or when the system indicates that BUSINESS COSTS OR LOSSES; is found to have a defect in material or the DPF requires cleaning unless the ATTORNEYS’ FEES; AND ANY factory the part will be repaired or replaced service is required as part of a warrantable LIABILITY YOU MAY HAVE IN RESPECT by PACCAR. This is your emission control repair. TO ANY OTHER PERSON OR ENTITY. system defects warranty. THIS LIMITED EMISSION WARRANTY IS Emissions coverage for on-highway THE SOLE WARRANTY MADE BY California Emissions Control applications in the State of California PACCAR RELATING TO THE EMISSION Warranty Statement EQUIPMENT. EXCEPT FOR THE ABOVE This emission control system warranty LIMITED WARRANTY, PACCAR MAKES Your Warranty Rights and applies to diesel engines (hereafter, NO OTHER WARRANTIES, EXPRESS Obligations engines) certified with the California Air OR IMPLIED. PACCAR EXPRESSLY Resources Board beginning with the year The California Air Resources Board and DISCLAIMS ANY WARRANTY OF 2013, marketed by PACCAR, and PACCAR are pleased to explain the MERCHANTABILITY OR WARRANTY OF registered in California for use in on- emission control system warranty on your FITNESS FOR A PARTICULAR highway applications. 2017 - 2018 model year diesel engine. In PURPOSE. California, new motor-vehicle engines must
Y53-1185-1E1 (04/16/18) 81 ENGINE WARRANTY - United States and Canada Engine Warranty
Manufacturer's Warranty Coverage warranty coverage if your engine or a part The owner is responsible for downtime has failed due to abuse, neglect, improper expenses, cargo damage, fines, all This warranty coverage is provided for five maintenance or unapproved modifications. applicable taxes, all business costs, and years or 100,000 mi (160,000) km or 3,000 other losses resulting from a warrantable hours of engine operation, whichever first If you have any questions regarding your condition. occurs from the date of delivery of the warranty rights and responsibilities, you engine to the first purchaser or first lessee. should contact Kenworth Truck Company 3 Where a warrantable condition exists, 1-425-828-5000, Peterbilt Motor Company Emissions Components Statement PACCAR will repair your engine at no cost at 1-940-591-4220, or the California Air to you including diagnosis, parts and labor. Resource Board at: State of California emissions components Owner's Warranty Responsibilities statement for the PACCAR PX-9 engine California Air Resource Board, 9528 coverage. This list of emission control parts As the engine owner, you are responsible Telstar Avenue, El Monte, CA 91731 may be covered by the Emission Control for the performance of the required System Warranty under certain failure maintenance listed in your PACCAR A warranted part which is scheduled for modes. operator’s manual. You are responsible for replacement as required maintenance is presenting your engine to an authorized Aftertreatment System warranted up to the first scheduled PACCAR engine dealer or an authorized replacement point. • Aftertreatment electroconnections Cummins Distributor as soon as a problem • Aftertreatment inlet and outlet exists. The warranty repairs should be Prior to the expiration of the applicable modules completed in a reasonable amount of time, warranty, the owner must give notice of • Aftertreatment temperature interface not to exceed 30 days. any warranted emission control failure to module an authorized PACCAR engine dealer and PACCAR recommends that you retain all deliver the engine to such facility for repair. • Aftertreatment temperature sensors receipts covering maintenance on your • Decomposition chamber engine, but PACCAR cannot deny warranty The owner is responsible for incidental • DEF dosing valve solely for the lack of receipts or for the costs such as: communication expenses, • DEF level sensor failure to ensure the performance of all meals, lodging incurred by owner or scheduled maintenance. employees of owner as a result of a • DEF line heater control relay warrantable condition. • DEF quality sensor As the engine owner, you should also be • DEF tank/lines heating elements of aware that PACCAR may deny you heat exchanger and pipe
82 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
• DEF tank and lines • Turbocharger actuator Exhaust Gas Recirculation (EGR) • DEF tank heater coolant control • Turbocharger assembly System Component valve • Turbocharger compressor intake • EGR cooler • DEF temperature sensors pressure/temperature sensor • EGR differential pressure sensor • Diesel Exhaust Fluid (DEF) dosing • Turbocharger speed sensor • EGR mixer/venturi unit (Pump) Base Engine System Component • EGR temperature sensor • Diesel oxidation catalyst • EGR valve 3 • Diesel particulate filter (except for • Camshaft ash maintenance) • Camshaft valve lobe Fueling System • Diesel particulate filter differential • Clean idle sticker • Fuel injectors pressure sensor EGR • Coolant temperature sensor • Fuel lines • Exhaust gas piping from • Crankcase breather • Fuel pressure sensor turbocharger out to the last • Engine oil pressure sensor aftertreatment device • Fuel pump • Engine speed, position sensor, cam • Fuel pump actuator • NOx sensors position sensor • SCR catalyst • Secondary fuel pressure/temperature • Exhaust valve sensor Air Handling Component Electronic Control System • Ambient air temperature sensor Component Replacement Parts • Charge air cooler and associated • DEF lamp State of California emissions statement on plumbing • Engine control module replacement parts. • Exhaust gas pressure sensor • Engine control module calibration • Exhaust manifold • OBD connector PACCAR recommends that any service parts used for maintenance, repair or • Grid heater • On Board Diagnostic (OBD) replacement of emission control systems • Intake manifold Malfunction Indicator Lamp (MIL) be new or genuine PACCAR approved • Intake manifold temperature/pressure • Wiring harness circuits connected at rebuilt parts and assemblies, and that the sensor both ends to emissions warrantable engine be serviced by an authorized • Throttle actuator/valve components PACCAR engine dealer or an authorized
Y53-1185-1E1 (04/16/18) 83 ENGINE WARRANTY - United States and Canada Engine Warranty
Cummins Distributor. Your vehicle contains PACCAR Responsibilities constitutes an emergency. PACCAR will air, fuel, and electrical components that reimburse the owner for expenses State of California emissions statement on may affect engine emission controls. The (including diagnosis), not to exceed the PACCAR's responsibility. use of non-genuine engine or vehicle manufacturers suggested retail price for all replacement parts that are not equivalent The warranty coverage begins when the warranted parts replaced and labor to the PACCAR engine or OEM vehicle engine is delivered to the first purchaser or charges based on the manufacturers manufacturer’s original part may impair the first lessee. Repairs and service will be recommended time allowance for the 3 engine and vehicle emissions control performed by any authorized PACCAR warranty repair and the geographically system from working or functioning engine dealer or an authorized Cummins appropriate hourly labor rate. effectively, and may jeopardize your Distributor using new or genuine PACCAR Replaced parts and paid invoices must be emissions warranty coverage. approved rebuilt parts and assemblies. presented at an authorized PACCAR PACCAR will repair any of the emission The owner may elect to have maintenance, engine dealer or an authorized Cummins control parts found by PACCAR to be replacement or repair of the emission Distributor as a condition of reimbursement defective without charge for parts or labor control parts performed by a facility other for emergency repairs not performed by an (including diagnosis which results in than an authorized PACCAR engine dealer authorized PACCAR engine dealer or an determination that there has been a failure or an authorized Cummins Distributor and authorized Cummins Distributor. of a warranted emission control part). may elect to use parts other than new or genuine approved rebuilt parts and Warranty Limitations assemblies for such maintenance, Emergency Repairs replacement or repair; however, the cost of State of California emissions statement on State of California emissions statement on such service or parts and subsequent warranty limitations. failures resulting from such service or parts emergency repairs. Your sole and exclusive remedy against will not be covered under this emission In the case of an emergency where an PACCAR and the selling dealer arising control system warranty, except for authorized PACCAR engine dealer or an from your purchase and use of this engine “ Emergency Repairs on page 84 .” authorized Cummins Distributor is not is limited to the repair or replacement of available, repairs may be performed by any “warrantable failures” at authorized United available repair location or by any States and Canadian PACCAR engine individual using any replacement parts. A dealers or an authorized Cummins part not being available within 30 days or a Distributor, or an authorized PACCAR repair not being complete within 30 days engine facility where applicable, subject to
84 Y53-1185-1E1 (04/16/18) ENGINE WARRANTY - United States and Canada Engine Warranty
PACCAR’s time, mileage, and hour PACCAR is not responsible for failures WARRANTY, PACCAR AND THE limitations of the engine warranty. The resulting from improper repair or the use of SELLING DEALER MAKE NO OTHER maximum time, mileage and hour parts which are not genuine PACCAR WARRANTIES, EXPRESS OR IMPLIED. limitations of the engine warranty begin approved parts. PACCAR AND THE SELLING DEALER running on the date of delivery to the first EXPRESSLY DISCLAIM ANY purchaser or first lessee. The accrued PACCAR is not responsible for the material WARRANTY OF MERCHANTABILITY OR time, mileage, or hours is calculated when and labor costs of emission control parts WARRANTY OF FITNESS FOR A the engine is brought into an authorized and assemblies replaced during Scheduled PARTICULAR PURPOSE. 3 dealer for correction of warrantable Maintenance of the engine as specified in failures. PACCAR Operator’s Manuals. PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR Failures, other than those resulting from PACCAR does not warrant antifreeze, INCIDENTAL OR CONSEQUENTIAL defects in material or factory workmanship, lubricants, filters, filter elements, or any DAMAGES INCLUDING, BUT NOT are not covered by this warranty. PACCAR other part which is considered a LIMITED TO: LOSS OF INCOME OR is not responsible for failures or damage maintenance item. PACCAR does not LOST PROFITS; ENGINE OR VEHICLE resulting from what PACCAR determines to warrant services to remove ash from the DOWNTIME; THIRD PARTY DAMAGE, be abuse or neglect, including, but not DPF either at or before a regular service INCLUDING DAMAGE OR LOSS TO limited to: damage due to accident; interval as indicated in the maintenance OTHER ENGINES, VEHICLES OR operation without adequate coolants or schedule or when the system indicates that PROPERTY, ATTACHMENTS, TRAILERS lubricants; overfueling; overspeeding; lack the DPF requires cleaning unless the AND CARGO; LOSS OR DAMAGE TO of maintenance of lubricating, cooling or service is required as part of a warrantable PERSONAL CONTENTS; intake systems; improper storage, starting, repair. COMMUNICATION EXPENSES; warm-up, run-in or shutdown practices; THIS WARRANTY, TOGETHER WITH LODGING AND/OR MEAL EXPENSES; failure to perform regeneration in a timely THE EXPRESS COMMERCIAL FINES; APPLICABLE TAXES OR manner; unauthorized modifications of the WARRANTIES ARE THE SOLE BUSINESS COSTS OR LOSSES; engine. PACCAR is also not responsible WARRANTIES MADE BY PACCAR IN ATTORNEYS’ FEES; AND ANY for failures caused by incorrect oil or fuel or REGARD TO THESE ENGINES. LIABILITY YOU MAY HAVE IN RESPECT diesel exhaust fluid or by water, dirt or TO ANY OTHER PERSON OR ENTITY. other contaminants in the fuel, oil, or diesel THIS LIMITED EMISSIONS WARRANTY exhaust fluid. Failure of replacement parts IS THE SOLE WARRANTY MADE BY used in repairs due to the above non- PACCAR AND THE SELLING DEALER. warrantable conditions is not warrantable. EXCEPT FOR THE ABOVE LIMITED
Y53-1185-1E1 (04/16/18) 85 ENGINE WARRANTY - United States and Canada Engine Warranty
3
86 Y53-1185-1E1 (04/16/18) Index
Index
A D
Additives to Cooling System 48 Diesel Exhaust Fluid 37 After Replacing Engine Oil Filter(s) 58 Diesel Exhaust Fluid (DEF) Lamp 17 Aftertreatment Exhaust Piping 36 Diesel Exhaust Fluid filter 66 Air Cleaner 68 Diesel Particulate Filter (DPF) Warning Lamp 16 Air Compressor 67 Drive Belts 65 Air Intake Piping 36 Driving 20 Antifreeze 63 E B ELC 64 Batteries, Cables, and Connections 68 Electrical Harness / Cables 68 Biodiesel 59 Electromagnetic Interference 27 Engine Belt Checks 65 Engine Braking System 18 C Engine Compression Brake Level Switch Operation 20 Engine Coolant Specifications 50 Charge Air Cooler 68 Engine Cooling Recommendations and Specifications 48 Charge Air Piping 68 Engine Fuel Filter / Water Separator 35 Chassis Fuel Filter / Water Separator 35 Engine is overheating 13 Check Engine Lamp Turns On 12 Engine Lubricating Oil Recommendations and Specifications 42 Checking Coolant Condition 64 Engine Lubrication and Filter Intervals 46 Cleaning the Engine 34 Engine Maintenance 34 Cold Weather Starting 23 Engine Mounting Bolts 69 Compression Brake 19 Engine Oil Capacities and Pressures 45 Compression Brake Controls 19 Engine Oil Filter 57 Coolant Level 35 Engine Oil Filter Specificaitons 42 Cooling Fan 35 Engine Oil Level 56 Cooling System 63 Engine Oil Pressure Lamp Turns On 12 Cooling System Overheating 13 Engine Operating Range 25 Crankshaft - Vibration Damper 69 Engine Shutdown 27 Engine Specifications for operator manual 41
Y53-1185-1E1 (04/16/18) 87 Index
Engine Wait-To-Start Lamp 17 Engine Warning Lamps 14 N T Engine, Check Engine 15 Exhaust Brake 18 Normal Starting Procedure 23 Topping Up the Engine Oil 57 Extended Life Coolant 51, 64 O U F Oil Filter Removal Preparation 58 ULSD 52 Fan Belt Tensioner 65 Oil Level Indication on Dipstick 57 Ultra Low Sulfer Diesel 52 Forward 7 Operating on Grades and Dry Pavement 29 Fuel Filter 59 Operating on Level and Dry Pavement 28 Fuel Filter Installation 60 Operating the Engine 24 V Fuel Filter Removal 60 Fuel Recommendations 52 P Visual Inspection of Engine 35
G Poly V-belt and Fan Drive Belts 65 W Poly V-belt and Fan Drive Install 65 General Safety Instructions 8 Preventative Maintenance Schedule 38 Warranty and the Use of Biodiesel Fuel 53 PX Cooling System Maintenance 48 H R High Exhaust System Temperature (HEST) Warning Lamp 16 Radiator Hoses 64 Recommendations and Specifications 54 Recommendations to avoid fuel gelling in cold I temperatures 54 Roadside Assistance 11 Idling in Freezing Temperatures, Extended 26 Illustrations 8 S
M Safety 6 Safety Alerts 6 Maintenance Schedule Intervals 37 Starting After the Fuel Tank Has Run Dry 61 Malfunction Indicator Lamp 16 Starting Procedure After Extended Shutdown or Oil Change 24 Stop Engine Lamp 11, 15
88 Y53-1185-1E1 (04/16/18)
WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside. • Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary. For more information go to www.P65warnings.ca.gov/diesel.
PACRI Engines P.O. Box 1518 Bellevuevue, WA 98009 Y53-1185-1E1