Engine Aftertreatment Systems (Y53-6085-1B1) · Aftertreatment System Detail 1. Hydrocarbon Doser...

Operator’s ManualOperator’s Manual 2017 Emissions

EngineAftertreatmentSystems

EngineAftertreatmentSystems

Safety..................................... 1

Introduction..................................... 2

Maintenance..................................... 3

Information..................................... 4

Contents

© 2017 PACCAR Inc. - All Rights ReservedThis manual illustrates and describes the operation of features or equipment which may be eitherstandard or optional on this vehicle. This manual may also include a description of features andequipment which are no longer available or were not ordered on this vehicle. Please disregard anyillustrations or descriptions relating to features or equipment which are not on this vehicle. PACCARreserves the right to discontinue, change specifications, or change the design of its vehicles at anytime without notice and without incurring any obligation. The information contained in this manual isproprietary to PACCAR. Reproduction, in whole or in part, by any means is strictly prohibited withoutprior written authorization from PACCAR Inc.

Contents

Chapter 1 | SAFETYIn this Chapter:

Using this Manual..................................................................................................................................7Safety Alerts..........................................................................................................................................7Illustrations............................................................................................................................................8

SAFETY -

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Using this Manual

Please take the time to get acquainted withyour vehicle by reading this Operator’sManual. We recommend that you read andunderstand this manual from beginning toend before you operate this equipment.This manual contains useful information forthe safe and efficient operation of thisequipment. It also provides serviceinformation, with an outline for performingsafety checks and basic preventivemaintenance inspections. We have tried topresent the information you’ll need to learnabout functions, controls, and operation—and to present it as clearly as possible. Wehope you’ll find this manual easy to use.There will be times when you need to takethis manual out of the glovebox. When youdo, please be sure to return it when youare finished using it. That way it will bethere when you need it the next time orwhen you pass the vehicle on to the nextuser.

NOTE

After you’ve read this manual, it shouldbe stored in the cab for convenient ref-erence and remain with this truckwhen sold.

Your vehicle may not have all the featuresor options mentioned in this manual.Therefore, you should pay careful attentionto the instructions that pertain to just yourvehicle. In addition, if your vehicle isequipped with special equipment or optionsnot discussed in this manual, consult yourdealer or the manufacturer of theequipment.There are several tools built into thismanual to help you find what you needquickly and easily. First is the Quick Tableof Contents. Located at the front of themanual, this lists the main subjectscovered and gives section numbers whereyou can find these subjects. Use the QuickTable of Contents to find information on alarge subject like “Maintenance.” Cross-referenced citations also help you get theinformation you need. If some other part ofthe manual contains further information onthe subject you are reading about, we’ll

indicate that in a cross-reference like this:(See Safety Alerts on page 7). You won’thave to go searching for more information.Finally you’ll find a helpful Subject Index.It’s in the back of the manual andalphabetically lists the subjects covered.So if you want information on brakes, forexample, just look under Brake in theSubject Index. You’ll find all the pageslisted where brakes or braking arediscussed.All information contained in this manual isbased on the latest production informationavailable at the time of publication.Kenworth Truck Company Peterbilt MotorsCompany reserves the right to makechanges at any time without notice.

Safety Alerts

Please read and follow all of the safetyalerts contained in this manual. They arethere for your protection and information.These alerts can help you avoid injury toyourself, your passengers and help preventcostly damage to the vehicle. Safety alertsare highlighted by safety alert symbols andsignal words such as “WARNING”,“CAUTION”, or “NOTE”. Please DO NOTignore any of these alerts.

SAFETY - Using this Manual

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Warnings

The safety message following this symboland signal word provides a warning againstoperating procedures which could causedeath or injury. They could also causeequipment or property damage. The alertwill identify the hazard, how to avoid it andthe probable consequence of not avoidingthe hazard.

WARNING

Hot engine oil can be dangerous. Youcould be burned. Let the engine oilcool down before changing it. Failureto comply may result in death, person-al injury, equipment or property dam-age.

Cautions

The safety message following this symboland signal word provides a caution against

operating procedures which could causeequipment or property damage. The alertwill identify the hazard, how to avoid it, andthe probable consequence of not avoidingthe hazard.

CAUTION

Continuing to operate your vehicle withinsufficient oil pressure will cause seri-ous engine damage. Failure to complymay result in equipment or propertydamage.

Notes

The message following this symbol andsignal word provides important informationthat is not safety related but should befollowed. The alert will highlight things thatmay not be obvious and is useful to yourefficient operation of the vehicle.

NOTE

Pumping the accelerator will not assistin starting the engine.

IllustrationsSome of the illustrations throughout thismanual are generic and will NOT lookexactly like the engine or parts used inyour application. The illustrations cancontain symbols to indicate an actionrequired and\or an acceptable or NOTacceptable condition.The illustrations are intended to showrepair or replacement procedures. Theprocedure will be the same for allapplications, although the illustration maydiffer.

SAFETY - Illustrations

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SAFETY - Illustrations

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Chapter 2 | INTRODUCTIONIn this Chapter:

Vehicle Emissions Controls.................................................................................................................12Lamps................................................................................................................................................. 12What is a Diesel Particulate Filter?..................................................................................................... 14Functionality / Notification Information................................................................................................ 14Extended Idling................................................................................................................................... 15Warning Symbols Quick Reference.................................................................................................... 15Notification of High Exhaust System Temperature..............................................................................17Notification Regeneration is Required.................................................................................................18Controlling Regeneration Process...................................................................................................... 19How to Enable an Automatic Regeneration of the DPF......................................................................21How to Start a Parked Regeneration.................................................................................................. 22Stop an Automatic or Parked Regeneration........................................................................................23What is a Selective Catalyst Reduction System?............................................................................... 24DEF Gauge......................................................................................................................................... 24

INTRODUCTION -

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Why is the DEF Warning Light on?..................................................................................................... 25Functionality / Notification Information................................................................................................ 26

INTRODUCTION -

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Vehicle EmissionsControls

This vehicle has an exhaust AftertreatmentSystem (ATS), to control vehicle exhaustemissions.The exhaust Aftertreatmentsystem consist of a Diesel Particulate Filter(DPF), Selective Catalyst Reduction(SCR), Regeneration Switch and warninglights. The DPF will trap soot from theengine exhaust gases. The SCR usesDiesel Exhaust Fluid to reduce the levels ofNOx in the engine exhaust. The ATS willperiodically clean (regenerate) the DPF.Aftertreatment System Detail

1. Hydrocarbon Doser from Turbo

2. Aftertreatment Unit (DPF, DEFDoser and SCR)

3. Filtered/Treated Exhaust4. Diesel Exhaust Fluid (DEF) Tank

Lamps

Aftertreatment System WarningLamps

ATS specific warning lamps and indicatorsymbols are located on the main gaugecluster.

Diesel Particulate Filter (DPF)Warning LampThis warning symbol will appear when theDPF needs to be regenerated and thenalso during the regeneration cycle. Thisicon may also appear if the system isattempting to automatically regeneratewhile the vehicle is in Power Take Offoperation mode.

Engine aftertreatment system includes adiesel particulate filter and DPF warninglamp.

Diesel Exhaust Fluid (DEF) LampEngine aftertreatment system includes adiesel exhaust fluid (DEF) warning lamp onthe DEF gauge and additional warninglamps in the instrument cluster.

DEF Warning Lamp in Instrument Cluster

Diesel Exhaust Fluid (DEF) Gauge

21

INTRODUCTION - Vehicle Emissions Controls

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1. DEF Symbol2. DEF Gauge Warning Lamp

The DEF lamp(s) will illuminate when thefluid in the DEF tank reaches a low level. Ifthe lamp illuminates but the level is full,seek service immediately for DEF fluidquality or DEF equipment repair.

High Exhaust System Temperature(HEST) Warning LampEngine aftertreatment system includes ahigh exhaust system temperature (HEST)warning lamp.

Keep vehicle a safe distance fromcombustible items.

WARNING

Temperature of the tail pipe, exhaustpipe, the diesel particular filter (DPF) /selective catalytic reduction (SCR) de-vice and surrounding components in-cluding enclosures and steps, will be

elevated during and shortly after a re-generation event or normal vehicle op-eration when engine is under high orheavy loading.

If the High Exhaust System Temperature(HEST) warning lamp is on:

• Do not park in an area ofcombustible vapors or materials.You must keep combustibles atleast 1.5 m (5 ft) away from theexhaust (outlet) stream (as it exitsthe tail pipe) while the HEST lampis illuminated. Always park yourvehicle outside. Failure to do socould ignite an explosion or harmbystanders which could result inserious injury.

• Do not park in an area wherepeople are close by. You must keepcombustibles at least 1.5 m (5 ft)away from the exhaust outlet whilethe HEST lamp is illuminated.Failure to do so could result inserious injury.

• Do not approach the exhaustsystem or surrounding areaswithout allowing adequate time forthe system to cool down. Failure to

do so could result in serious burnsto the skin.

Malfunction Indicator Lamp

Illuminates when an engine emissionsfailure has occurred. The vehicle can besafely driven but should be serviced tocorrect the problem. The situation shouldnot be considered an emergency. In somecases, the Malfunction Indicator Lamp(MIL) will activate in conjunction with theHigh Exhaust System Temperature(HEST), Diesel Particulate Filter (DPF) andDiesel Exhaust Fluid (DEF) warning lamps.

NOTE

The malfunction indicator lamp (MIL)will illuminate if the on-board diagnos-tics (OBD) system detects a possibleemissions system failure. The vehicleshould be brought in for service at thenext opportunity to ensure the condi-tion is corrected.

INTRODUCTION - Lamps

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Emissions System Lamp

Perform the following steps if an emissionsrelated derate occurs and the emissionslamp comes on.

1. Add DEF fluid (more than 1/4 tank).2. Perform parked regeneration.3. Seek service at the next stop if the

warning light is still on.

Stop Engine Lamp

1 2The stop engine warning lamp willilluminate, and an audible tone will sound,when a major engine problem exists. Yourvehicle will be equipped with one of theindicators above, 1 or 2, depending on theengine model.

WARNING

If the Stop Engine warning lamp illumi-nates, it means you have a serious en-gine system problem. This should beconsidered an emergency. You shouldstop the vehicle as safely as possibleand turn OFF the ignition. The vehiclemust be serviced and the problem cor-rected before driving again. Failure tocomply may result in death, personalinjury, equipment or property damage.

For engines with the engine-protectionshutdown feature enabled, the stop enginelamp will begin to flash 30 seconds beforethe engine automatically shuts down. Thewarning lamp alerts the operator to theimpending shutdown.The lamp will also illuminate when the DEFtank is almost empty or the soot level in theDPF is at full capacity. At this levelwarning, regeneration cannot be performedand engine power will be derated.Engine may automatically shut down if thecheck engine lamp and stop engine lampare illuminated and the operator does notcorrect the condition.

What is a DieselParticulate Filter?

The diesel particulate filter is a componentof the overall vehicle emission system thattraps particulate matter, soot, from theexhaust. Soot is composed of the partiallyburned particles of fuel that occur duringnormal engine operation (black smoke).

Functionality / NotificationInformation

The ATS will regenerate the DPF by usinghot exhaust gases normally generated bythe engine. This typically occurs duringhighway operation (known as "Passive"Regeneration) and is transparent to theoperation of the vehicle.Occasionally, the exhaust gases are nothot enough for Passive Regeneration.When this occurs, the ATS will regeneratethe DPF by increasing the exhausttemperature. This is referred to as an"Automatic" Regeneration and is alsotransparent to vehicle operation. AnAutomatic Regeneration event typically

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lasts 30 minutes. During and shortly afterthe event, the exhaust gases from the DPFmay reach temperatures in excess of 650°C (1202° F). See the information in thefollowing table on probable causes andrecommended actions related to thewarning lamps and indicator symbols of theATS.The ATS may not be able to regenerate theDPF when the vehicle is driven atextended low speeds or with frequentstarts and stops. In such cases, warninglamps and indicator symbols will alert theoperator to take action. The operatorshould be aware of whether the lamps areon unaccompanied or in combination withothers. The following table will describeeach warning lamp(s) and what actions areneeded from the operator.Related concepts

Extended Idling

Idling the engine for 3 or more hours infreezing temperatures accelerates the buildup of soot in the DPF. The system willilluminate the DPF warning light on theinstrument cluster to indicate that the DPFrequires regeneration. If the DPF Lampturns on, follow the instructions describedunder How to Enable an AutomaticRegeneration of the DPF on page 21.

CAUTION

If you ignore the warning lamp and donot initiate regeneration at the soon-est, safest possible time, the DPF willbecome increasingly clogged with sootand can lead to severe engine derate.Failure to comply may result in equip-ment or property damage.

Extended idling may also increasehydrocarbon deposits and moisture in theDPF. The engine will increase RPM

automatically, regardless if the DPF lamp ison or off, to remove these hydrocarbondeposits and moisture. The engine speedwill remain elevated for 20 to 60 minutes. If necessary, the RPMs can be lowered bydepressing the throttle, clutch, or brakepedal. The system will restart this cyclewith high idle until all of the deposits areremoved from the DPF. If the vehiclecannot perform an automatic cycle, thedriver will be prompted with a message toRegenerate the DPF. If the levels ofhydrocarbon deposits and moisturecontinue to build up, the system willilluminate the DPF Lamp along with theStop Engine Lamp.

Warning Symbols QuickReference

INTRODUCTION - Extended Idling

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FOR INFORMATION SEEK SERVICE TAKE IMMEDIATE ACTION

Hot Exhaust - StayClear Check Engine

CoolantTemperature

Stop vehicle andidle engine.

Regenerate DPF Engine - EmissionsEngine Oil Pressure Stop the engine or

the engine mayautomaticallyshutdown.1See Diesel Exhaust

Fluid (DEF) Lampon page 12.

See EmissionsSystem Lamp onpage 14.

1 2

Stop EngineSymbols2

Any of the above icons may appear alone or together to alert of necessary action to be taken as soon as possible. Warnings may beeither tell-tales or lights within the gauge associated with that fluid. These lights will start flashing to notify of the upcoming enginederate.

1 May not apply for fire or emergency vehicle applications.2 Either symbol 1 or 2 will appear depending on engine make for the vehicle.

INTRODUCTION - Warning Symbols Quick Reference

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Notification of HighExhaust SystemTemperatureThese conditions will result in the HighExhaust System Temparture (HEST)indicator turning on.

Warning Indicator Condition Operator Actions

On

Any one or combination of these conditions:• Exhaust outlet temperature is elevated above

normal (at least 450° C / 842° F) and vehicleslows below 8 kph / 5 mph.

• Normal driving but engine is under heavyloading.

• Automatic Regeneration in process• Parked Regeneration in process

Follow all warnings listed below. Use the STOP orDISABLE function of the Regeneration Switch (Or turnthe ignition off) if the situation requires. Follow theinstructions described under Stop an Automatic orParked Regeneration.

WARNING

Temperature of the tail pipe, exhaust pipe, the diesel particular filter (DPF) / selective catalytic reduction (SCR) device and sur-rounding components including enclosures and steps, will be elevated during and shortly after a regeneration event or normal vehi-cle operation when engine is under high or heavy loading.

INTRODUCTION - Notification of High Exhaust System Temperature

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Notification Regenerationis Required

Level Warning Indicators Condition Operator Actions

1 OnThe soot level in the DPF is above thedesired level and requires regeneration.

How to Enable an AutomaticRegeneration of the DPF on page 21

2Flashing

The soot level in the DPF continues tostay above the desired level andrequires regeneration.

Regenerate the DPF as soon as safelypossible. How to Enable an AutomaticRegeneration of the DPF on page 21or How to Start a Parked Regenerationon page 22

3 Flashing

On

The soot level in the DPF continues tostay above the desired level andrequires regeneration. The enginepower will derate.

Regenerate the DPF immediately. Howto Enable an Automatic Regeneration ofthe DPF on page 21 or How to Start aParked Regeneration on page 22

4

Flashing (MX engine only)

On (MX engine only)

1 2 Stop Engine Lamp On –Dash chime

The soot level in the DPF is now at fullcapacity. Engine power derates(decrease rate depends on enginemake).

At this point, you CANNOT regeneratethe DPF. Tow your vehicle to anAuthorized PACCAR Dealer to have theDPF removed. They will either have toclean it or replace it.

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CAUTION

The engine derate sequence is enginespecific; therefore, to learn how thissystem works on your vehicle, refer tothe Engine Manufacturer's Operationand Maintenance Manual suppliedwith your vehicle. Failure to complymay result in equipment or propertydamage.

WARNING

If the Stop Engine warning lamp illumi-nates, it means you have a serious en-gine system problem. This should beconsidered an emergency. You shouldstop the vehicle as safely as possibleand turn OFF the ignition. The vehiclemust be serviced and the problem cor-rected before driving again. Failure tocomply may result in death, personalinjury, equipment or property damage.

Controlling RegenerationProcess

Regeneration SwitchesThe following information explains how tocontrol the regeneration process and usethe regeneration switch.

Your vehicle may be equipped with either atwo or three position Regeneration Switch,mounted on the dash.If equipped with a two-positionRegeneration Switch, the driver can initiatea Parked Regeneration when certainoperating conditions are suitable forregeneration; however, you will NOT beable to Stop a regeneration if the ATS hasinitiated one automatically. A vehicle with atwo-position DPF switch can stop aregeneration by turning the vehicle ignitionOFF.If your vehicle is equipped with a three-position Regeneration Switch, the drivercan control the regeneration process viathe MANUAL or DISABLE positions of theswitch. The DISABLE position should beused when certain operating conditions arenot suitable for regeneration.

WARNING

If you operate in environments thatcontain explosive vapors or flammablematerials, look to see if your vehicle’sRegeneration Switch is equipped witha DISABLE function. The DISABLEfunction must be activated prior to en-tering the above environment(s) toprevent automatic engine regenerationfrom occurring, which could cause anexplosion or fire. Failing to activate theDISABLE function before entering acombustible environment may causean explosion or fire that could lead todeath, personal injury, equipment orproperty damage.

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WARNING

Avoid operating the vehicle inside abuilding or in environments that con-tain explosive vapors or flammablematerials if your vehicle does NOThave a STOP or DISABLE regenera-tion switch. In an event where the re-generation needs to be stopped, turnthe vehicle ignition OFF and the sys-tem will temporarily stop the regenera-tion cycle. Failing to stop a regenera-tion cycle before entering a combusti-ble environment may cause an explo-sion or fire that could lead to death,personal injury, equipment or propertydamage.

CAUTION

Do not leave the switch in the DISA-BLE position unless you need to can-cel or stop a regeneration. Runningthe engine with the switch in the DISA-BLE position will result in increasedsoot levels in the DPF and could even-tually cause the engine to derate.

NOTE

Contact your nearest authorized PAC-CAR dealer to obtain a RegenerationSwitch with a DISABLE function. In-stalling the switch will require that theengine ECU be reprogrammed.

Two-Position Regeneration Switch

Two Position Regeneration Switch

Pressing the button for at least 4 -8seconds will initiate a ParkedRegeneration. Vehicles with this buttonmust turn off the ignition to stop anautomatic regeneration.

NOTE

Parked regeneration requires that yourvehicle is stopped with the parkingbrake set. See Parked Regenerationfor details.

Related concepts

Three-Position RegenerationSwitch

NOTE

The information in this section only ap-plies to vehicles equipped with a three-position Engine Regeneration Switch.

1

2

3

DISABLE

MANUAL

1. Disable

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2. Allow auto regeneration (centerposition)

3. ManualSee DPF Regeneration for instructions onhow to start or stop a ATS regeneration(three-position switch only).

DISABLE (Three Position Switch Only)When DISABLE (1) is pressed,the system will not regenerateunder any conditions.

CAUTION

Do not leave theswitch in the DISA-BLE position unlessyou need to cancel orstop a regeneration.Running the enginewith the switch in theDISABLE position willresult in increasedsoot levels in theDPF and could even-tually cause the en-gine to derate.

ALLOW AUTOREGENERATION

(Three Position Switch Only)This is the normal position (2) ofthe switch. Unless you are

manually initiating a ParkedRegeneration or intentionallystopping a regeneration, theswitch should be in this position.Placing the switch in the CENTER(2) position will allow an AutomaticRegeneration to occur if conditionsallow.

NOTE

During normal vehicledriving, the Regener-ation Switch must bein the CENTER posi-tion.

MANUAL (Three Position Switch Only)Depressing the button in theMANUAL direction (3) for at least4 -8 seconds will initiate a ParkedRegeneration.

NOTE

Parked regenerationrequires that your ve-hicle is stopped withthe parking brake set.See Parked Regener-ation for details.

Related concepts

How to Enable anAutomatic Regeneration ofthe DPF

Carefully read the following instructions toregenerate the DPF. If you have anyproblems or difficulties contact yournearest authorized PACCAR dealer forassistance. Make sure that any two orthree position switches for the DPF are notin a position that will prevent aregeneration from happening.The instrument cluster will illuminatevarious icons that indicate a regenerationis needed. See Notification Regeneration isRequired on page 18. The ATS requiresconditions typically found in highwaydriving to regenerate the DPF. If the DPFwarning lamp is illuminated, the easiestoption is to assist the ATS by proceeding tothe nearest highway.

1. Select a highway that has a postedlegal speed of more than 35 mph(56 kph).

2. Drive your vehicle until the DPFlamp goes off. This may take 30 –

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45 minutes of speeds greater than25 mph (40 kph).

If your operation or planned route in theimmediate future limits your ability to reachhighway speeds, proceed to the nextsection titled Parked Regeneration.Related concepts

How to Start a ParkedRegeneration

In very limited applications or operationsthe DPF must be regenerated by initiatinga Parked Regeneration. Follow these stepsto initiate a Parked Regeneration:

1. Pull the vehicle over to a safelocation.

2. Ensure no one is in the immediatevicinity of the tail pipe.

3. Maintain a minimum of 1.5 m (5 ft)of clearance to any combustiblematerials from the edge and top ofthe vehicle.

WARNING

Parking the vehicle too close to anycombustible materials or vapors maystart a fire, ignite an explosion or burnsomeone standing close by. Beforepushing the Regeneration Switch onthe dash, walk around your vehicleand ensure you have at least 1.5 m (5ft) clearance from the sides and top ofyour vehicle to any combustibles. En-sure no one is in the immediate vicinityof the tail pipe. Failure to comply couldignite a fire or cause an explosion, re-sulting in death, personal injury, equip-ment or property damage.

WARNING

Never initiate a regeneration in aclosed building or enclosure. Alwayspark your vehicle outside and ensureno one is in the immediate vicinity.Failure to comply could ignite a fire orcause an explosion, resulting in death,personal injury, equipment or propertydamage.

NOTE

Typical operation areas or materials thatcan contain explosive vapors, flamma-ble materials or people in close proximi-ty of the vehicle are:

• Fuel depots• Grain elevators• Dry grass, leaves or trees• Transfer refuse stations/

dumps• Parking lots• Load/unload terminals

While the list above may appear com-prehensive, it is your responsibility totake the necessary precautions and beaware of your surroundings and ensurethat no combustibles (materials or va-pors) or bystanders are close by beforeinitiating a regeneration.

4. Verify that the following conditionsare met before proceeding. AParked Regeneration will notinitiate if any of these conditionsare not met:

• Parking brake is applied / set• Engine is at low idle

INTRODUCTION - How to Start a Parked Regeneration

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• DPF warning lamp isilluminated or flashing

• Coolant is at operatingtemperature

• No throttle, brake or clutchapplied

• PTO is disengaged 3

• Transmission is in neutral• Cruise control switch is off• Engine brake switch is off

5. Get out and walk all around vehicleto ensure that the vehicle is at least1.5 m (5 ft) away from allcombustible materials and no oneis in the immediate vicinity.

6. Climb back into the vehicle.7. Push the regeneration button at

least 4 -8 seconds to initiate aParked Regeneration.

NOTE

Acknowledgment that a Parked Re-generation has initiated will vary by en-gine. The most predominant acknowl-

edgement to you will be an increase inengine rpm and overall engine noise.

NOTE

A Parked Regeneration may take 30or more seconds to initiate as the Af-tertreatment System conducts variousself-checks to verify all the system re-quirements have been met.

Regeneration will automatically shut off ifany of the conditions (in step 4) change orbecome activated. Contact your nearestPACCAR dealer for assistance if you areunable to initiate a Parked Regenerationand the DPF warning lamp is illuminated.Related concepts

Stop an Automatic orParked Regeneration

Always stop or prevent the vehicle fromperforming an automatic or parkedregeneration ANYTIME you plan to driveyour vehicle into a building, enclosure or

sensitive area. Turn the vehicle ignition offto stop and prevent the DPF fromregenerating. Alternatively, if the vehiclehas a DPF switch to DISABLE or STOP aregeneration, depress this switch toprevent or stop a regeneration. Turn thevehicle ignition OFF if the regenerationswitch does not stop or the vehicle doesnot have a switch that can stop aregeneration.

WARNING

Never allow an Automatic Regenera-tion to automatically start while insidea building such as a service bay, shopor building of any kind. Anytime youare parking your vehicle inside a build-ing or enclosure, ALWAYS press theRegeneration STOP or DISABLESwitch prior to entering the building.Failure to comply could ignite a fire orcause an explosion, resulting in death,personal injury, equipment or propertydamage.

3 Parked regeneration with PTO engaged is dependant on vehicle configuration.

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WARNING

Never initiate a regeneration in aclosed building or enclosure. Alwayspark your vehicle outside and ensureno one is in the immediate vicinity.Failure to comply could ignite a fire orcause an explosion, resulting in death,personal injury, equipment or propertydamage.

WARNING

If you operate in environments thatcontain explosive vapors or flammablematerials, look to see if your vehicle’sRegeneration Switch is equipped witha STOP function. The STOP functionmust be activated prior to entering theabove environment(s) to prevent auto-matic engine regeneration from occur-ring, which could cause an explosionor fire. Failing to activate the STOPfunction before entering a combustibleenvironment may cause an explosionor fire that could lead to death, person-al injury, equipment or property dam-age.

WARNING

Avoid operating the vehicle inside abuilding or in environments that con-tain explosive vapors or flammablematerials if your vehicle does NOThave a STOP or DISABLE regenera-tion switch. In an event where the re-generation needs to be stopped, turnthe vehicle ignition OFF and the sys-tem will temporarily stop the regenera-tion cycle. Failing to stop a regenera-tion cycle before entering a combusti-ble environment may cause an explo-sion or fire that could lead to death,personal injury, equipment or propertydamage.

NOTE

To obtain a Regeneration Switch witha STOP function, contact an author-ized PACCAR dealer to obtain theproper switch and reprogramming ofyour engine’s ECU.

What is a SelectiveCatalyst ReductionSystem?

The SCR system reduces Nitrogen Oxides(NOx) from the exhaust by mixing DieselExhaust Fluid (DEF) with a catalyst. TheDEF is contained in a separate tank on thevehicle and the level of fluid in the tank isshown in a gauge on the dash.DEF is consumable and needs to bereplenished, so monitor the DEF levelgauge as you would the fuel level gauge.

DEF Gauge

The SCR system reduces Nitrogen Oxides(NOx) from the exhaust by mixing DieselExhaust Fluid (DEF) with a catalyst. TheDEF is contained in a separate tank on the

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vehicle and the level of fluid in the tank isshown in a gauge on the dash.Diesel Exhaust Fluid (DEF) Gauge

211. DEF Symbol2. DEF Gauge Warning Lamp

DEF is consumable and needs to bereplenished, so monitor the DEF levelgauge as you would the fuel level gauge.

Why is the DEF WarningLight on?There is a warning lamp located in the DEFgauge. There may also be additional

warning lamps and information that willappear in the instrument cluster. Thesewarning lamps will illuminate for thefollowing reasons:

DEF Level The amount of DEF available in thetank is low. The warning lamp will turnon when the gauge needle is near or inthe red zone. There are 4 stages to thiswarning.

CAUTION

If the DEF warning lampturns on due to the DEFlevel, refill the DEF tank.Failure to refill maycause the engine to de-rate and limit vehiclespeed.

DEF Quality The engine detects that DEF quality isbelow acceptable levels. The gaugeneedle is in the upper region, indicatingthere is fluid, but the quality is poor.There are 3 stages to these warnings.

CAUTION

See your authorizedPACCAR dealer if theDEF warning lamp turnson due to DEF Quality.

Failure to correct maycause the engine to de-rate and limit vehiclespeed.

SCRComponentFailure

The system detects failures that may bethe result of tampering with theaftertreatment (DPF/SCR) system. Thegauge needle is in the upper region,indicating there is fluid, but systemfailure is detected. There are 3 stagesto this warning.

CAUTION

If the DEF warning lampturns on due to SystemTampering, see your au-thorized PACCAR dealerto have this repaired.Failure to repair the sys-tem may cause the en-gine to derate and limitvehicle speed.

INTRODUCTION - Why is the DEF Warning Light on?

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SCR System Status – Reference Chart

System Status Non-Emergency Vehicles Emergency Vehicles

DEF Level Warning DEF Level Warning – Non-EmergencyVehicles on page 26

DEF Level Warning – Emergency Vehicleson page 30

DEF Quality (except PX) DEF Quality Warning – Non-EmergencyVehicles on page 28

DEF Quality Warning – EmergencyVehicles on page 31

SCR Component Failure SCR Component Failure Warning – Non-Emergency Vehicles on page 29

SCR Component Failure Warning –Emergency Vehicles on page 32

NOTE

The malfunction indicator lamp (MIL) will illuminate if the on-board diagnostics (OBD)system detects a possible emissions system failure. The vehicle should be broughtin for service at the next opportunity to ensure the condition is corrected.

Functionality / NotificationInformation

DEF Level Warning – Non-Emergency Vehicles

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Level Warnings \ Indicators Condition Effect on Engine

0 None DEF levelsufficient None

1 DEF warning lampOn

DEF level fallenbelow initialwarning

None

2 DEF warning lampflashing


None


Check enginelamp On


Engine powerderated 25%


Check enginelamp On

DEF level emptyContinue to 40%engine powerderate


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2


Final DEF warning lampflashing

Check enginelamp On

MIL may be On1 2

Stop engine lampmay be On

Engine has beenshut down, idledfor 1-hour or afuel re-fill hasoccurred

Engine powerderated and/orvehicle speedsignificantlylimited

DEF Quality Warning – Non-Emergency VehiclesThe DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX Engines.


0 None No DEF qualityissue None

1 DEF warninglamp On Check

engine lamp On MIL may be ON

Quality issuedetected None

2 DEF warninglamp flashing Check


80 km (50 mi) or1 hour afterdetected



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2




241 km (150 mi)or 3 hours afterdetected

Continue to 40%engine powerderate

Final DEF warninglamp flashing Check

engine lamp On MIL may be ON1 2



Engine powerderated and/orvehicle speedsignificantlylimited

SCR Component Failure Warning –Non-Emergency VehiclesThe DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX Engines.


0 None No Issue None



Failure detected None


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2




80 km (50 mi) or1 hour afterdetected




322 km (200 mi)or 4 hours afterdetected

Continue to 40%engine powerderate





Engine powerderated and/orvehicle speedreduced to 8 kph(5 mph)

DEF Level Warning – EmergencyVehicles


0 None DEF levelsufficient None

1 DEF warninglamp On


None


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2


2 DEF warninglamp flashing

DEF level fallenbelow criticalwarning

None


engine lamp On

DEF level lessthan 5%

Vehicle speedlimited to 88 kph(55 mph)


engine lamp OnMIL

may be On1 2


DEF Level emptyand vehicle hasbeen shut downor stationary for1-hour


DEF Quality Warning – EmergencyVehicles

The DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX Engines.

Level Warnings \ Indicator Condition Effect onEngine

0 None No DEF qualityissue None


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2

Level Warnings \ Indicator Condition Effect onEngine



Quality issuedetected None



10-hours afterdetected





20-hours afterdetected, enginehas been shutdown or idled for1-hour


SCR Component Failure Warning –Emergency VehiclesThe DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX Engines.


0 None No Issue None


32 Y53-6085-1B1 (11/17)

2




Failure detected None



10-hours afterdetected





40-hours afterdetected, enginehas been shutdown or idled for1-hour

Vehicle speedlimited to 40 kph(25 mph).


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Chapter 3 | MAINTENANCEIn this Chapter:

Aftertreatment System Power Requirements......................................................................................35Diesel Exhaust Fluid (DEF) Tank Straps.............................................................................................35

MAINTENANCE -

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Aftertreatment SystemPower Requirements

The aftertreatment system uses batterypower for up to 10 minutes after theignition is turned off. After the ignition turnsoff, the aftertreatment system circulatesDEF to help cool down the fluid andprevent overheating. For situations wherethe battery will be disconnected (ie forservice or maintenance of the vehicle),please wait 10 minutes beforedisconnecting battery power.

CAUTION

Wait at least 10 minutes after the keyswitch is turned OFF before discon-necting battery power. The systemuses battery power to circulate DEFand prevent overheating of the DEFsystem. Failure to comply may resultin equipment or property damage.

Diesel Exhaust Fluid (DEF)Tank StrapsMaintenance checks for the DEF tank.

During normal operation of the truck, theDEF tank straps may relax. Inspect thespring on top of the strap. If more than ½"(12.7mm) of the spring is exposed, the boltwill need to be re-torqued between 70 – 80in-lbs. (7.9 – 9 Nm). This distance (1) ismeasured from the washer at the end ofthe spring to the edge of the tube at the topof the straps.

1/2" (12.7 mm)

1

See Engine Operator's Manual for DEFfilter maintenance interval.

MAINTENANCE - Aftertreatment System Power Requirements

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3

Chapter 4 | INFORMATIONIn this Chapter:

Tampering with Aftertreatment System............................................................................................... 37Diesel Particulate Filter (DPF) System................................................................................................37Selective Catalytic Reduction (SCR) System......................................................................................38Diesel Exhaust Fluid (DEF).................................................................................................................38

INFORMATION -

36 Y53-6085-1B1 (11/17)

4

Tampering withAftertreatment System

The aftertreatment system for your vehicleas installed from the factory wasspecifically designed to meet the emissionsrequirements of the US EnvironmentalProtection Agency and California AirResources Board. Any changes ofcomponent locations or modifications ofany aftertreatment system componentsmay reduce the emission effectiveness andyou may be subject to fines under theUnited States Clean Air Act.

Diesel Particulate Filter(DPF) System

The DPF system consists of aHydrocarbon (HC) Doser (may not apply toall engines), a Diesel Oxidation Catalyst(DOC), and a DPF. During normaloperation the DPF filters soot out of theexhaust and constantly monitors inlet andoutlet pressure. When the DPF is full, thesystem will activate (via automatic or aparked regeneration) the HC Doser which

sprays a small amount of diesel fuel (theHC) into the exhaust stream which thenreacts with the DOC to generate heat. Thisheat will turn the trapped soot into ash untilthe filter is completely cleaned(regenerated). Over time, both soot andash accumulate in the DPF unit. While thesoot is cleaned by the system, the resultingash must be removed by servicing thevehicle at an authorized PACCAR dealer. Avehicle with a DPF has up to two additionalindicator lamps on the dashboard. The twoadditional lamps, along with the checkengine lamp, alert the operator of thestatus of the DPF.

CAUTION

Do not submerge or allow water to en-ter the DPF assembly. Components ofthe assembly can be damaged and af-fect the performance of the aftertreat-ment system. Failure to comply mayresult in equipment or property dam-age.

NOTE

Refer to your engine manufacturer’sOperator’s Manual for diesel particu-late filter (DPF) maintenance informa-tion.

NOTE

Refer to your vehicle or engine manu-facturer’s Operator’s Manual for addi-tional information on the engine indica-tor lamps.

NOTE

Ultra low sulfur diesel (ULSD) fuel isrequired for engines equipped with anaftertreatment diesel particulate filter. IfULSD is not used, the engine may notmeet emissions regulations, and theDPF or aftertreatment Diesel OxidationCatalyst (DOC) can be damaged.

INFORMATION - Tampering with Aftertreatment System

Y53-6085-1B1 (11/17) 37

4

Selective CatalyticReduction (SCR) System

The SCR system is composed of severalmain components:

1. Aftertreatment Control Module4

2. DEF Dosing Unit (DEF Module)3. DEF Dosing Valve4. SCR Catalyst

CAUTION

It is unlawful to tamper with, modify, orremove any component of the SCRsystem. Failure to comply may resultin equipment or property damage.

The system uses DEF from the DEF tankand delivers it to the DEF Doser. This DEFdoser sprays a small amount of DEF intothe exhaust upstream of the SCR Catalyst.The DEF vaporizes and decomposes toform carbon dioxide and ammonia. Theammonia and SCR catalyst reacts with theNOx in the exhaust to break down the

Nitrogen Oxides (NOx) to form nitrogenand water.DEF:

• may have a slight ammonia smell• is colorless• is non-toxic and non-polluting• is non-flammable

Diesel Exhaust Fluid (DEF)

Diesel Exhaust FluidRecommendations andSpecifications

CAUTION

It is unlawful use Diesel Exhaust Fluid(DEF) that does not meet the specifi-cations provided or to operate the ve-hicle/equipment without DEF. Failureto comply may result in equipment orproperty damage.

WARNING

Diesel Exhaust Fluid (DEF) containsurea. Do not get the substance in youreyes. In case of contact, immediatelyflush eyes with large amounts of waterfor a minimum of 15 minutes. DO NOTswallow internally. In the event the die-sel exhaust fluid is ingested, contact aphysician immediately. Reference theMaterials Safety Data Sheet (MSDS)for additional information. Failure tocomply may result in personal injury.

CAUTION

Never attempt to create Diesel Ex-haust Fluid (DEF) by mixing agricultur-al grade urea with water. Agriculturalgrade urea does not meet the neces-sary specifications required and the af-tertreatment system may be damaged.Failure to comply may result in equip-ment damage.

4 Only for PACCAR MX powered vehicles.

INFORMATION - Selective Catalytic Reduction (SCR) System

38 Y53-6085-1B1 (11/17)

4

CAUTION

PACCAR Inc requires the use of DEFmeeting ISO 22241-1 (DIN 70070) spec-ifications. There is NO acceptable sub-stitute. Failure to use the correct DEFmay cause engine damage and/or voidthe warranty.

• Some locations may referencethe DIN 70070 standard. DEFspecification limits of this stand-ard are identical to ISO 22241-1.

PACCAR Inc is not responsible for failuresor damage resulting from what PACCARInc determines to be abuse or neglect,including but not limited to: operationwithout correctly specified DEF; lack ofmaintenance of the aftertreatment system;improper storage, or shutdown practices;unauthorized modifications of the engineand aftertreatment system. PACCAR isalso not responsible for failures caused byincorrect DEF or by water, dirt or othercontaminants in the DEF. Refer to yourengine and vehicle operator's manuals formaintenance, storage, and shutdowninformation.

For engines using SCR operating in theUnited States and Canada, it isrecommended that the DEF used becertified by the American PetroleumInstitute (API).

NOTE

To ensure the correct DEF is used,PACCAR Inc recommends the use ofTRP® CleanBlue Diesel Exhaust Fluidwhich is available in different quantityoptions from small to bulk containers.

DEF Availability• DEF is readily available at truck

stops and at all PACCAR Engine

dealers. For assistance locatingDEF, contact your local PACCARauthorized repair location.

• If your vehicle is out of DEF andyou are unable to locate a sourceto purchase DEF, please contactthe vehicle OEM customer carecenter at the telephone numberprovided in the vehicle operator’smanual. The vehicle OEMcustomer care center will be able tocontact the nearest dealer locationto you and arrange for anemergency shipment of DEF toyour location 24 hours a day.

The following are other common namesused for Diesel Exhaust Fluid (DEF):

• AUS 32 (Aqueous Urea Solution32)

• AdBlue• NOx Reduction Agent• Catalyst Solution

Regardless of what the DEF is called, theDEF must meet the ISO 22241-1 (DIN70070) specifications.

INFORMATION - Diesel Exhaust Fluid (DEF)

Y53-6085-1B1 (11/17) 39

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Related concepts

DEF Storage

NOTE

The following information is for refer-ence and is to be used as a guidelineonly. There are many factors that de-termine Diesel Exhaust Fluid (DEF)shelf life, with temperature and dura-tion being two of the major determiningcontributors. If in doubt, replace thefluid with known quality DEF. DEF hasa limited shelf life, both in the vehicle'sdiesel exhaust fluid tank and in stor-age/bulk/transportation containers.

The following conditions are ideal formaintaining DEF quality and shelf lifeduring prolonged transportation andstorage:

• Storage temperature between -5°Cand 25°C (23°F and 77°F)

• Storage in sealed containers toavoid contamination

• Avoidance of direct sunlightIn these conditions, Diesel Exhaust Fluid(DEF) has a minimum expected shelf life of

18 months. If stored at higher temperaturesfor extended periods of time, the shelf lifewill be reduced by approximately 6 monthsfor every 5°C (9°F) above the higheststorage temperature listed above. Longterm storage in a vehicle (in excess of 6months) is not recommended.

NOTE

To assist in preventing DEF from dete-riorating when stored in the vehicle'sDEF tank, locate and plug the tank'sventing to seal the tank exposure tothe atmosphere.

DEF Tank

1. DEF Tank VentRelated concepts

DEF Handling

CAUTION

If Diesel Exhaust Fluid (DEF) is spilledon metal surfaces (for example thesteps, fuel tanks or grab handles) rinseand clean immediately with water. Fail-ure to do so may leave permanent cor-rosive stains on the metal surfaceswhich can not be removed.• Make sure to only use approved

containers to transport and storeDEF. Containers made of poly-ethylene and polypropylene arerecommended.

• If DEF is spilled, rinse and cleanimmediately with water.

• Avoid prolonged contact withskin. In case of contact, washimmediately with soap and wa-ter. If not washed immediately, awhite film will be left when theDEF dries.


40 Y53-6085-1B1 (11/17)

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NOTE

Spilled DEF, if left to dry or wipedaway with a cloth only, will leave awhite residue. Failure to clean the spil-led DEF may result in an incorrectly di-agnosed leak of the DEF Dosing sys-tem.

Before using containers, funnels, etc. thatwill be used to dispense, handle or storeDEF, make sure to wash thoroughly toremove any contaminants and then rinsewith distilled water.

NOTE

Do not use tap water to rinse compo-nents that will be used to deliver dieselexhaust fluid. Tap water will contami-nate the DEF. If distilled water is notavailable, rinse with tap water andthen rinse with DEF.

DEF DisposalIf disposing Diesel Exhaust Fluid (DEF),always check with the local authority

regulations on proper disposal process andrequirements.Related concepts

Contamination / Incorrect FluidThe following guidelines are available ifDEF gets contaminated or the level of DEFthe tank is significantly different than whatthe gauge reads.

CAUTION

Never add water or any other fluid be-sides what is specified to the DEFtank. The aftertreatment system maybe damaged.

The system monitors the DEF fluid qualityunder normal operating temperatures andwhen the vehicle is moving 8 kph (5 mph).In some situations, the system may notcheck DEF quality because of reducedoperating temperatures. A service tool maybe required to temporarily allow the systemto check the DEF quality at operatingtemperatures regardless of vehicle speed.In the event that the incorrect fluid is addedto the Diesel Exhaust Fluid tank, such as,but not limited to:

• Water

• Diesel Fuel• Hydraulic Fluid• Coolant• Windshield Washer Fluid

Contact a local PACCAR AuthorizedRepair location to determine theappropriate repair direction. If only waterhas been added to the DEF tank, drain theDEF tank, flush with distilled water andrefill with new and/or known good DEF.Related concepts


Y53-6085-1B1 (11/17) 41

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Index

AAftertreatment System Warning Lamps 12

CContamination / Incorrect Fluid 41

DDEF Handling 40DEF Level Warning – Emergency Vehicles 30DEF Level Warning – Non-Emergency Vehicles 26DEF Quality Warning – Emergency Vehicles 31DEF Quality Warning – Non-Emergency Vehicles 28DEF Storage 40Diesel Exhaust Fluid (DEF) Lamp 12Diesel Exhaust Fluid tank maintenance 35Diesel Particulate Filter (DPF) System 37Diesel Particulate Filter (DPF) Warning Lamp 12DPF Regeneration 21

FFunctionality / Notification Information 14

HHigh Exhaust System Temperature (HEST) Warning Lamp 13

IIdling in Freezing Temperatures, Extended 15Illustrations 8Introduction 24

MMalfunction Indicator Lamp 13

NNotification of High Exhaust System Temperature 17Notification Regeneration is Required 18

PParked Regeneration 22

RRecommendations and Specifications 38Regeneration Switches 19Regeneration SwitchThree-Position 20Regeneration SwitchTwo-Position 20

Index

SSafety 7Safety Alerts 7SCR Component Failure Warning – Emergency Vehicles 32SCR Component Failure Warning – Non-Emergency Vehicles 29Selective Catalytic Reduction (SCR) System 38Stop an Automatic or Parked Regeneration 23Stop Engine Lamp 14

TTampering with Aftertreatment System 37

WWarning Symbols Quick Reference 15What is a Diesel Partilculate Filter 14

Index

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PACRI Bo

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