PX6 Manual (Paccar Engine)

Operator’s Manual Y53-1029 2/07

Foreword

FOREWORD This manual contains information for the correct operation and maintenance of your PACCAR engine. Read and follow all safety instructions. Refer to the WARNING in “General Safety Instructions” on page 5. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. PACCAR Inc reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local PACCAR Authorized Repair Location or write to PACCAR Inc c/o Medium Duty Engines, PO Box 1518, Bellevue, WA 98009. The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine parts from PACCAR. NOTE: Warranty information including the EPA and California Emission Warranty is located in the section entitled “WARRANTY,” beginning on page 69. Make sure you are familiar with the warranty or warranties applicable to your engine.

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Foreword

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PACCAR

Important Reference Numbers

IMPORTANT REFERENCE NUMBERS Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required. Part Name

Number

Engine Model Engine Serial Number (ESN) Control Parts List (CPL) Fuel Pump Part Number Electronic Control Module (ECM) Electronic Control Module Serial Numbers (ECM) Filter Part Numbers: • Air Cleaner Element • Lubricating Oil • Fuel • Fuel-Water Separator • Coolant

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Number

Important Reference Numbers Part Name

Number

Number

• Crankcase Ventilation • Particulate Filter Governor Control Module (GCM) (if applicable) Belt Part Numbers: • • • Clutch • Model • Serial Number • Part Number • Oil Type

- Model - Part Number

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PACCAR

PACCAR PX-6

Contents

Foreword

Operating Instructions

Important Reference Numbers Introduction Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Instructions . . . . . . . . . . . . . . . . . . . . . Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . .

3 4 5 8

Engine Identification Engine Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PACCAR Engine Nomenclature . . . . . . . . . . . . . . . . . . Fuel Pump Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . ECM Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Geometry Turbocharger . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 12 13 13 14 15 15

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Starting Procedure . . . . . . . . . . . . . . . . . . . . . Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . Starting Procedure After Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Unique Operating Characteristics of an Engine with Aftertreatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . Engine Operating Range . . . . . . . . . . . . . . . . . . . . . . . Engine Braking System . . . . . . . . . . . . . . . . . . . . . . . . Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Interference (EMI) . . . . . . . . . . . . . . .

17 19 22 22 23 26 27 34 38 39 41 42

Maintenance Guidelines Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Record Form . . . . . . . . . . . . . . . . . . . . .

43 43 50

Service Literature Additional Service Literature . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

51

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Contents

PACCAR PX-6

Maintenance Specifications General Engine Specifications . . . . . . . . . . . . . . . . . . . 53 Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . 54 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel Recommendations and Specifications . . . . . . . . . 58 Lubricating Oil Recommendations and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Coolant Recommendations and Specifications . . . . . . 64

WARRANTY PACCAR PX-6 Engine United States and Canada Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . United States and Canada Fire Apparatus Truck Applications Coverage . . . . . . . . . . . . . . . . . . Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . California Emission Control System Warranty, On-Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . California Emissions Components Statements for PX-6 Engine (2007) Emissions Engines Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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69 71 74 75

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Operator’s Manual

INTRODUCTION Safety Signals

WARNING When you see this symbol & word, the message that follows is especially vital. This signals something that can cause injury or even death. This message will tell you what the hazard is, what can happen if you don’t heed the warning, and how to avoid it.

A number of alerting messages are in this manual. Please read and follow them. They are there for your protection and information. These messages can help you avoid injury to yourself, your passengers, and help prevent costly damage to the vehicle.

Example:

Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to instructions prefaced by symbols and signal words “WARNING”, “CAUTION”, or “NOTE”. Please do not ignore any of these alerts.

WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or empty, may leak, explode, and cause or feed a fire. Do not carry extra fuel containers, even empty ones are dangerous.

CAUTION This symbol and word signals something that could damage your vehicle. Example:

CAUTION: Continuing to operate your vehicle with insufficient oil pressure will cause serious engine damage.

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Introduction NOTE

Illustrations

Gives you information we feel you would like to have. It could have to do with care of your vehicle or with driving more efficiently.

General Information

Example:

NOTE: Pumping the accelerator will not assist in starting the engine.

Please take the time to read these messages when you see them, and remember: WARNING! Something that could cause an injury or even death. CAUTION: Something that could cause damage to your vehicle. NOTE: Useful information.

Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

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Introduction

General Safety Instructions Important Safety Notice WARNING! Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. • Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. • Always wear protective glasses and protective shoes when working. • Rotating parts can cause cuts, mutilation or strangulation. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.

PACCAR

• Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the controls. • Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. • If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system. • Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported ONLY by lifting jacks or a hoist. • Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

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Introduction • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant. • To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. • Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

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• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. • To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas flow, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Use ONLY genuine replacement parts from PACCAR. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. • Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Liquefied petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas.

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Introduction • Natural gas is lighter than air and can accumulate under hood and awnings. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas and liquefied petroleum gas lines in a well ventilated area. • Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations. • The catalyst reagent contains urea. Do not get the substance in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is ingested, contact a physician immediately. • The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly. Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. PACCAR

• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local regulations. • California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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CAUTION: Corrosive chemicals can damage the engine. Do not expose the engine to corrosive chemicals.

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Introduction

Acronyms and Abbreviations General Information

EPA

Environmental Protection Agency

ESN

Engine Serial Number

°F

Fahrenheit

The following list contains some of the acronyms and abbreviations used in this manual.

FMI

Failure Mode Indentifier

API

American Petroleum Institute

GVW

Gross Vehicle Weight

ASTM

American Society of Testing and Materials

HEST

High Exhaust System Temperature

ATS

After-Treatment System

LPG

Liquified Petroleum Gas

°C

Celsius

Hg

Mercury

CARB

California Air Resources Board

hp

Horsepower

C.I.D.

Cubic Inch Displacement

H2O

Water

CNG

Compressed Natural Gas

ICM

Ignition Control Module

CPL

Control Parts List

km/l

Kilometers per Liter

cSt

Centistokes

kPa

Kilopascal

DPF

Diesel Particulate Filter

LNG

Liquid Natural Gas

ECM

Electronic Control Module

LTA

Low Temperature Aftercooling

EGR

Exhaust Gas Recirculation

MPa

Megapascal

ELC

Extended Life Coolant

mph

Miles Per Hour

EMI

Electromagnetic Interference

mpq

Miles Per Quart

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Introduction N•m

Newton-meter

NG

Natural Gas

OEM

Original Equipment Manufacturer

PID

Parameter Identification Descriptions

ppm

Parts Per Million

psi

Pounds Per Square Inch

PTO

Power Takeoff

rpm

Revolutions Per Minute

SAE

Society of Automotive Engineers

SCA

Supplemental Coolant Additive

STC

Step Timing Control

SID

Subsystem Identification Descriptions

VGT

Variable Geometry Turbocharger

VS

Variable Speed

VSS

Vehicle Speed Sensor

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Introduction

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ENGINE IDENTIFICATION Engine Dataplate

The dataplate is located on the top side of the gear housing. Have the following engine data available when communicating with a PACCAR Authorized Repair Location: • Engine serial number (ESN). • Engine model information. • Control parts list (CPL). • Valve lash (overhead) setting. • Horsepower and rpm rating. The engine dataplate provides important facts about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for service and ordering parts. The engine dataplate must not be changed unless approved by PACCAR Inc. PACCAR

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Engine Identification

If the engine dataplate (1) is not readable, the ESN (2) can be found on the engine block on top of the lubricating oil cooler housing. Additional engine information is on the electronic control module (ECM) dataplate.

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PACCAR Engine Nomenclature The PACCAR engine nomenclature provides the engine model and horsepower rating.

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Fuel Pump Dataplate

ECM Dataplate

The Bosch® fuel injection pump dataplate is located on the fuel pump. The dataplate contains the following information which will assist in servicing or replacement: • Pump serial number. • Part number. • Factory code.

Rear gear train engines covered by this manual are equipped with a CM2150 Electronic Control Module (ECM). A CM2150 ECM has two 60-pin connectors and an additional 4-pin connector. One 60-pin connector is for inputs and outputs only, while the other 60-pin connector is for aftertreatment and vehicle inputs and outputs. The 4-pin connector provides dedicated power to the ECM.

• Bosch® part number. • Date code.

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Engine Identification The electronic control module (ECM) dataplate shows information about the ECM and how the ECM was programmed. The dataplate is located on the ECM. The following information is available on the ECM dataplate which will assist in servicing or replacement: • ECM part number (PN). • ECM serial number (SN). • ECM date code (DC). • Engine serial number (ESN). • ECM code: Identifies the software in the ECM.

Air Compressor If your engine has an air compressor, it will have a dataplate located on the rear side of the air compressor. The dataplate contains the following information that assists in servicing or replacement: • Part number. • Date code. • Serial number. NOTE: Not all engines are equipped with an air compressor.

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Variable Geometry Turbocharger

Exhaust System

The variable geometry turbocharger (VGT) dataplate is located on the turbocharger inlet compressor housing. The dataplate contains the following information that will assist in servicing or replacement: • Assembly part number. • Serial number. • Customer number. • Model number.

The aftertreatment assembly has information stamped into the canister showing important information for servicing and replacement. There are three important stamping locations on the aftertreatment assembly:

NOTE: The electronic actuator on the VGT is a serviceable component and has a separate dataplate that assists in servicing or replacement. PACCAR

1. Aftertreatment diesel oxidation catalyst part number and serial number; located on the catalyst section. 2. Aftertreatment diesel particulate filter part number and serial number; located on the filter section. 3. Aftertreatment assembly part number; located on the outlet of the aftertreatment system.

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A typical aftertreatment information stamping can provide the: 1. 2. 3. 4. 5.

Section name. Part number. Date code. Assembly number (only located on the outlet section). Serial number.

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OPERATING INSTRUCTIONS General Information Correct care of your engine will result in longer life, better performance, and more economical operation. Follow the daily maintenance checks listed in“Maintenance Schedule” on page 43. The new PACCAR engine associated with this manual does not require a ”break-in” procedure. This section of the manual provides all of the necessary information required for proper engine operation.

Check the oil pressure indicators, temperature indicators, warning lights, and other gauges daily to make sure they are operational.

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Operating Instructions WARNING! Combustible vapors near the air intake system could be ingested into the engine, causing the engine to suddenly accelerate and overspeed or explode. This condition could result in an unexpected increase in engine rpm and/or fire, resulting in personal injury or property damage. Do not operate your vehicle in area where combustible chemicals or vapors may be present. IT IS THE RESPONSIBILITY OF THE OWNER AND OPERATOR TO OPERATE THE VEHICLE IN A SAFE ENVIRONMENT. NOTE: Numerous safety devices (ie engine shutoff devices) are available to minimize the risk of engine overspeeding caused by combustible vapors being ingested into the air intake system. PACCAR has no way of knowing what environment your vehicle will be operated in.

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Normal Starting Procedure Starting Ensure the parking brake is set and the transmission is in neutral. With the accelerator pedal in the idle position, turn the key switch to the ON position.

With the key in the ON position, the engine indicator lamps will come on momentarily and then go out. The engine indicator lamps include: 1. Check engine lamp; yellow in color. 2. STOP engine lamp; red in color. 3. Diesel Particulate Filter (DPF) status indicator; yellow in color. 4. High Exhaust System Temperature (HEST); amber in color.

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Operating Instructions CAUTION: Engaging the starter motor for more than 30 seconds may cause it to overheat and can damage the starter motor. Never engage the starter motor for more than 30 seconds and wait 2 minutes between each attempt to start the engine to allow the starter motor to cool. This caution does not apply to air starters.

Under cold conditions, the Wait-to-Start lamp (generally a yellow lamp using a symbol similar to the graphic, or the words WAIT TO START) will also illuminate at key on, and will stay on for a period of up to 30 seconds. NOTE: The length of time the Wait-to-Start lamp remains illuminated depends on the ambient temperature. The lower the ambient temperature, the longer the lamp will be illuminated. Once the Wait-to-Start lamp turns off, turn the key to the starting position to start the engine.

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CAUTION: The engine must have adequate oil pressure within 15 seconds after starting the engine. If the oil pressure gauge does not register the minimum pressure, or drops below the minimum pressure, a red warning light in the gauge will come on, a warning buzzer will sound, and the Stop Engine Lamp will come on. This should be considered an emergency. Operating the engine is this condition may cause severe engine damage. You should stop the vehicle as safely as possible. The vehicle must be serviced and the problem corrected before driving again.

PACCAR

Operating Instructions For more information on the Fast Idle Warm Up feature, contact a PACCAR authorized repair location.

After starting a cold engine, increase the engine speed (rpm) slowly to provide adequate lubrication to the bearings and to allow the oil pressure to stabilize. Some engines are equipped with a Fast Idle Warm Up feature. When enabled, this feature elevates the idle speed of the engine in cold ambient conditions, in order to shorten the time necessary to warm up the engine. When the idle speed is elevated, the engine noise may change, this is normal. To bring the engine back to low idle speed: • For vehicles equipped with a manual transmission and clutch switch: Depress the clutch pedal. • For vehicles equipped with a brake switch: Depress the service brake pedal. • Depress the accelerator pedal. PACCAR

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CAUTION: Do not operate the engine at low idle for long periods with engine coolant temperature below the minimum specification as indicated in “Cooling System” on page 56. This can result in the following: • Fuel dilution of the lubricating oil. • Carbon build up in the cylinder. • Cylinder head valve sticking. • Reduced performance. If an engine must idle for an extended period of time, it should be done at fast idle (1,000 rpm or greater) until the coolant temperature meets the specification.

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Cold Weather Starting

Using Starting Aids

General Information Follow the Normal Starting Procedure in this section. If equipped with an intake air heater, the Wait-To-Start lamp will stay on longer.

This engine is equipped with an intake grid heater to help start the engine in cold weather conditions. Contact your authorized PACCAR repair location for other cold weather starting aid options. WARNING! Using starting fluid to help start the engine could cause a fire or explosion, resulting in personal injury, property damage and severe engine damage. Do not use starting fluid to start this engine.

Refer to the vehicle operator's manual instructions for any additional cold weather starting procedures.

This engine is equipped with an intake air heater. Cold weather starting aids are available for your engine. Contact a local PACCAR Authorized Repair Location for more information.

Starting Procedure After Extended Shutdown or Oil Change General Information Follow the Normal Starting Procedure in this section. The engine will run at idle only until the minimum oil pressure is detected by the ECM.

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PACCAR


Operating the Engine

Engine Overheating CAUTION: The cooling system may overheat if the engine coolant is the minimum level. A sudden loss of coolant, caused by a split hose or broken hose clamp could also lead to an overheat condition. Always inspect to ensure hoses and clamps are not cracked, worn or loose.

Normal

NOTE: The system may also temporarily overheat during severe operations conditions such as: • Climbing a hill on a hot day. • Stopping after high–speed driving.

Monitor the oil pressure and coolant temperature gauges frequently. Refer to “Lubricating Oil System,” page 54 and “Cooling System,” page 56 for recommended operating pressures and temperatures. Shut off the engine if any pressure or temperature does not meet the specifications. Continuous operation with engine coolant temperature above or below the engine coolant temperature specifications listed in “Cooling System,” page 56 can damage the engine.

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Operating Instructions NOTE: If the “Engine Coolant Temperature” warning light comes on and the audible alarm sounds showing an overheat condition, or if you have any other reason to suspect the engine may be overheating, DON'T TURN OFF THE ENGINE unless a low water warning device indicates a loss of coolant. Follow these steps: • Reduce engine speed or stop. When stopped, place the transmission in Neutral and set the parking brake. See the Truck Operator’s Manual for instructions on transmission shifting and parking brake information.

• If the overheating came from severe operating conditions, the temperature should have cooled by this time. • Check the sight gauge (glass level indicator) on the side of the coolant expansion tank. CAUTION: Never leave the engine idling when the vehicle is unattended. If the engine should overheat, immediate action is required to correct the condition. Failure to take immediate action may result in serious engine damage. If you must leave your vehicle unattended, shut down the engine.

• Check to ensure that the oil pressure gauge reads normal. • Increase the engine speed to about one–half of full operating speed, or 1,100 to 1,200 rpm, maximum. • Return the engine speed to normal idle after two or three minutes. • Monitor the engine temperature. After the temperature returns to normal, allow the engine to idle 3 to 5 minutes before shutting it off. This allows the engine to cool gradually and uniformly.

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Operating Instructions WARNING! Removing the radiator fill cap while the engine is hot can be dangerous. Never remove the caps of the expansion tank while the engine is still hot; you could be badly burned. • Scalding steam and fluid under pressure may escape and cause serious personal injuries. • Wait until the coolant temperature is below 122°F (50°C). • Protect your face, hands, and arms by covering the cap with a large, thick rag to protect against escaping fluid and steam. • Carefully and slowly turn cap one turn to allow excess pressure to escape, then push down and turn for final removal. See the Truck Operator’s Manual for instructions on checking and filling the coolant expansion tank.

PACCAR

Take the time to learn what normal operating conditions are for your engine so that when an abnormal condition arises, you will be able to recognize it as such and take the appropriate action. Most failures give an early warning. Look and listen for changes in performance, sound, or engine appearance that can indicate service or engine repair is needed. Some changes to look for are: • Engine misfires. • Vibration. • Unusual engine noises. • Sudden changes in engine operating temperatures or pressures. • Excessive smoke.

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Operating Instructions • • • •

Unique Operating Characteristics of an Engine with Aftertreatment

Loss of power. An increase in oil consumption. An increase in fuel consumption. Fuel, oil, or coolant leaks.

General Information

CAUTION: Do not allow your engine to idle, at low rpm's (400-600 rpm), longer than five minutes. Long periods of idling after the engine has reached operating temperatures can decrease engine temperature and cause gummed piston rings, clogged injectors, and possible engine damage from lack of lubrication. The normal torsional vibrations generated by the engine can also cause transmission wear. If an engine must idle for an extended period of time, it should be done at fast idle (1,000 rpm or greater).

The aftertreatment system is designed to decrease the exhaust particulate emissions from the vehicle tailpipe. It is composed of six main components:

NOTE: An idle shutdown feature, available on PACCAR Engines, can be programmed to shut the engine down after a period of low idle speed operation with no driver activity. A flashing warning lamp will inform the driver of an impending shutdown.

NOTE: The power take off (PTO) feature, available on PACCAR engines, can be programmed to adjust engine idle speed with the use of switches to pre-programmed set points.

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1. Aftertreatment inlet. 2. Aftertreatment particulate filter differential pressure sensor. 3. Aftertreatment diesel oxidation catalyst.

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Operating Instructions 4. Aftertreatment diesel particulate filter. 5. Aftertreament outlet. 6. Aftertreatment gas temperature sensors. CAUTION: Ultra-low-sulfur diesel fuel is required for an engine equipped with an aftertreatment diesel particulate filter. If ultra-low-sulfur fuel is not used, the engine might not meet emissions regulations, and aftertreatment diesel particulate filter or aftertreatment diesel oxidation catalyst can be damaged.

Emissions Aftertreatment System Description In order to meet 2007 EPA engine emission requirements, vehicles will have an exhaust After-Treatment System (ATS) which includes a Diesel Particulate Filter (DPF), Regeneration Switch and warning lights. The DPF will trap soot from the engine exhaust gases. The ATS will periodically clean the DPF.

PACCAR

The Regeneration Switch is mounted on the dash and can override the ATS. Various situations may require the operator to use the functions of this switch. Refer to “Parked Regeneration” on page 32 and “Stop an Automatic or Parked Regeneration” on page 34 for more information. ATS specific warning lights and indictor symbols are located on the dash panel.

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Operating Instructions Functionality / Notification Information The ATS will clean the DPF by using hot exhaust gases normally generated by the engine. This typically occurs during highway operation. This is referred to as a "Passive" Regeneration and is transparent to the operation of the vehicle. Occasionally, the exhaust gases are too cool for passive regeneration. When this occurs, the ATS will clean the DPF by increasing the exhaust temperature. This is referred to as an "Automatic" Regeneration and is also transparent to the operation of vehicle. An Automatic Regeneration event typically lasts 30 minutes. During and shortly after the event, the exhaust gases from the DPF may reach temperatures in excess of 650°C (1200°F). See the information in the following table on probable causes and recommended actions related to the warning lights and indicator symbols of the ATS. The ATS may not be able to clean the DPF when the vehicle is driven at extended low speeds or with frequent start and stops. In such cases, warning lights and indicator symbols will alert the operator to take action. The operator should be aware of whether the lights are on alone or in combination with others. The following table will describe each warning light(s) and what actions are needed from the operator.

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Operating Instructions Notification of High Exhaust System Temperature Indicator On steady

Information

What to Do

The High Exhaust Temperature (HEST) warning lamp will illuminate, regardless of ATS status, as your vehicle slows below 5 mph / 8 kph to warn the driver when the vehicle's exhaust outlet temperature is extremely hot (at least 450°C / 842°F). This will typically occur when:

Follow all warnings listed below. Use the STOP function of the Regeneration Switch if the situation requires. Follow the instructions described “Stop an Automatic or Parked Regeneration” on page 34.

An Automatic or Parked Regeneration is in process or During normal vehicle operation when engine is under high or heavy loading

WARNING! Temperatures of the exhaust pipes and at the outlets of the exhaust system during and shortly after a regeneration event will be extremely hot. If the High Exhaust System Temperature (HEST) warning lamp is on: • Do not park in an area of combustible vapors or materials. You must keep combustibles at least five (5) feet away from the exhaust (outlet) stream (as it exits the tail pipe) while the HEST light is illuminated. Always park your vehicle outside. Failure to do so could ignite an explosion or harm bystanders which could result in serious injury. • Do not park in an area where people are close by. You must keep bystanders at least five (5) feet away from the exhaust outlet while the HEST light is illuminated. Failure to do so could result in serious injury. • The exhaust piping, diesel particular filter (DPF) or tail pipe become extremely hot during engine operation or any regeneration event and can cause serious burns to the skin. Allow adequate cooling time before working on or near any part of the exhaust system.

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Operating Instructions Indicator On steady

Blink once every second

Blinking

On steady

– 30 –

Information

What to Do

The DPF status indicator symbol will illuminate when the soot level in the DPF is above the desired level and it needs cleaning.

The DPF needs cleaning soon. Follow the instructions described “Cleaning the DPF” on page 32.

The DPF status indicator symbol will blink when the soot level in the DPF continues to stay above the desired level and it needs cleaning.

Clean the DPF as soon as safely possible. Follow the instructions described “Cleaning the DPF” on page 32.

The DPF status indicator symbol will blink when the soot level in the DPF continues to stay above the desired level and it MUST be cleaned.

Clean the DPF immediately. Follow the instructions described “Cleaning the DPF” on page 32.

The engine will de-rate power.

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NOTE: If you ignore the warning lamp and do not initiate regeneration at the soonest, safest possible time, the DPF will become increasingly clogged with soot and can lead to engine shutdown.

CAUTION: If you do not initiate regeneration after the DPF Indicator lamp is blinking, you only have a short time before the check engine light will illuminate and the engine will go into protection mode and de-rate power.

CAUTION: If you do not initiate regeneration after the DPF Indicator lamp is blinking and the check engine light is illuminated, you only have a short time before the stop engine light will illuminate and the engine will automatically begin to shutdown.

PACCAR

Operating Instructions Indicator On steady

Information

What to Do

The Stop Engine light is illuminated when the soot level in the DPF continues to stay above the desired level. The soot level in the DPF is now at full capacity. The engine will begin to shutdown.

At this point, you CANNOT clean the DPF and the engine's ECU will shutdown the engine. WARNING! If the Stop Engine warning lamp illuminates, it means you have a serious engine system problem. This should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to do so may cause severe engine, DPF damage or personal injury. NOTE: The engine shutdown system is engine specific; therefore to learn how this system works on your vehicle, refer to the Engine Manufacturer's Operation and Maintenance Manual supplied with your vehicle.

PACCAR

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Operating Instructions Cleaning the DPF Carefully read the following instructions to clean the DPF. If you have any problems or difficulties contact your nearest authorized PACCAR Engine dealer for assistance. The ATS needs conditions typically found in highway driving to clean the DPF. If your DPF Indicator lamp is illuminated, the easiest option is to help the ATS by proceeding to the nearest highway. 7. Select a highway that has a posted legal speed of more than 35 mph. 8. Drive your vehicle until the DPF light goes off. This may take 30–45 minutes of speeds greater than 20 mph (32 kph). If your operation or planned route in the immediate future limits your ability to reach highway speeds, proceed to the next section titled Parked Regeneration.

WARNING! Parking the vehicle too close to any combustible materials or vapors may start a fire, ignite an explosion or burn someone standing close by. Before pushing the Regeneration switch on the dash, walk around your vehicle and ensure you have at least five (5) feet clearance from the sides and top of your vehicle to any combustibles. Ensure no one is in the immediate vicinity to the tailpipe. Failure to do so could cause a fire or lead to serious injury to you and/or bystanders. WARNING! Never initiate a regeneration in a closed building or enclosure. Always park your vehicle outside and ensure no one is in the immediate vicinity. Failure to do so could ignite an explosion or harm bystanders which could result in serious injury.

Parked Regeneration In very limited applications or operations the DPF must be cleaned by initiating a Parked Regeneration. Follow these seven steps to initiate a Parked Regeneration: 1. Pull the vehicle over to a safe location. 2. Ensure no one is in the immediate vicinity to the tailpipe. 3. Maintain a minimum of 5 feet of clearance to any combustible materials from the edge and top of the vehicle.

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PACCAR

Operating Instructions NOTE: Typical operation areas or materials that can contain explosive vapors, flammable materials or people in close proximity of the vehicle are: • Fuel depots. • Grain elevators. • Dry grass, leaves or trees. • Transfer refuse stations/dumps. • Parking lots. • Load/unload terminals.

5. Get out and walk all around vehicle to ensure that the vehicle is at least 5 feet away from all combustible materials and no one is in the immediate vicinity. 6. Climb back into the vehicle. 7. Push the Regeneration (START) Switch located on the dash for at least 4 seconds to initiate a Parked Regeneration.

NOTE: While the list above may appear comprehensive, it is your responsibility to take the necessary precautions and be aware of your surroundings and ensure that no combustibles (materials or vapors) or bystanders are close by before initiating a regeneration. 4. Verify that the following conditions are met before proceeding. A Parked Regeneration will not initiate if any of these conditions are not met. • Parking brake is applied / set • Engine is at low idle • No throttle, brake or clutch applied • PTO is disengaged • Transmission is in neutral

PACCAR

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NOTE: Acknowledgment that a Parked Regeneration has initiated will vary by engine. The most predominant acknowledgement to you will be an increase in engine RPM and overall engine noise. NOTE: A Parked Regeneration may take 30 or more seconds to initiate as the ATS system conducts various self-checks to verify all the system requirements have been met.

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Operating Instructions NOTE: A Parked Regeneration will initiate only if the DPF status light is illuminated or blinking.

WARNING! Never initiate a Parked Regeneration in a closed building or enclosure. Always park your vehicle outside. Failure to do so could ignite an explosion which could result in serious injury to you and/or bystanders.

If you are unable to initiate a Parked regeneration and the DPF status light is illuminated, contact your nearest authorized PACCAR Engine dealer for assistance.

Stop an Automatic or Parked Regeneration

Engine Indicator Lamps

If an Automatic or Parked Regeneration is in process and you want the regeneration to stop, OR you want to prevent a regeneration from occurring, your vehicle is equipped with a switch that can STOP an Automatic or Parked Regeneration. Since Automatic Regenerations can occur at any time with this engine, you must depress the STOP portion of the Regeneration Switch ANYTIME you plan to drive your vehicle into a building, enclosure or area where the activation of a regeneration is not allowed. If the regeneration does not stop, turn the vehicle ignition OFF. WARNING! Never allow an Automatic regeneration to automatically start while inside a building such as a service bay, shop or building of any kind. Any time you are parking your vehicle inside a building or enclosure, ALWAYS press the Regeneration (STOP) switch prior to entering the building. Failure to do so could ignite an explosion which could result in serious injury to you and/or bystanders.

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General Information The following engine indicator lamps cover only the lamps controlled by the engine's ECM. The vehicle manufacturer can provide additional indicator lamps. Please refer to the vehicle's operator's manual for additional lamp information.

Wait to Start Lamp The WAIT TO START lamp illuminates when the intake air heater needs to warm the intake air prior to starting the engine.

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PACCAR

Operating Instructions The WAIT TO START lamp on time will vary depending on the ambient air temperature. See “Normal Starting Procedure” on page 19.

When the DPF is at full capacity, the engine will begin to shutdown. The MAINTENANCE lamp could flash for any of the following reasons: • Maintenance required (if the Maintenance Monitor is enabled). • Water-in-fuel is detected. • Low engine lubricating oil level (if equipped with an engine lubricating oil level sensor). • Coolant level is low.

Check Engine Lamp The CHECK ENGINE lamp illuminates when the engine needs service at the first available opportunity. The CHECK ENGINE lamp is amber, and can look like: • The words WARNING or CHECK ENGINE spelled out. • A symbol of an engine, similar to the graphic. • DPF regeneration is required. Another function of the CHECK ENGINE lamp is to flash for 30 seconds at key-on when one of the following occurs. This flashing function is referred to as the MAINTENANCE lamp. The STOP ENGINE lamp will also illuminate when the soot level in the DPF continues to stay above the desired level.

PACCAR

Stop Engine Lamp The STOP ENGINE lamp indicates, when illuminated, the need to stop the engine as soon as it can be safely done. The engine must remain shut down until the engine can be repaired.

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Operating Instructions For engines with the Engine Protection Shutdown feature enabled, if the STOP ENGINE lamp begins to flash, the engine will automatically shut down after 30 seconds. The flashing STOP engine lamp aler ts the operator to the impending shutdown. The STOP ENGINE lamp is red in color, and can look like: • The words STOP or STOP ENGINE spelled out • A symbol of an engine with an exclamation point in the center, similar to the graphic.

1. Changing to a more challenging duty cycle, such as highway driving, for at least 20 minutes. 2. Performing a stationary regeneration. Follow the instructions in “Unique Operating Characteristics of an Engine with Aftertreatment” on page 26.

The DPF status indicator lamp will flash once every second when the soot level in the DPF continues to stay above the desired level and it needs cleaning. When this lamp is flashing, the operator should:

Aftertreatment Diesel Particulate Filter Lamp The DPF status indicator lamp will illuminate when the soot level in the DPF is above the desired level and it needs cleaning. An illuminated AFTERTREATMENT DIESEL PARTICULATE FILTER lamp indicates that the aftertreatment diesel particulate filter needs to be regenerated at the next possible opportunity. This can be accomplished by:

– 36 –

1. Change to a more challenging duty cycle, such as highway driving, for at least 20 minutes. 2. Performing a stationary regeneration. Follow the instructions in “Unique Operating Characteristics of an Engine with Aftertreatment” on page 26.

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PACCAR


High Exhaust System Temperature Lamp

The DPF status indicator will flash once every second and the Check Engine lamp will illuminate when the soot level in the DPF continues to stay above the desired level and it MUST be cleaned. The High Exhaust Temperature (HEST warning lamp will illuminate whenever the vehicle slows below 5mph/8kph to warn the driver when the vehicle's exhaust outlet temperature is extremely hot (at least 842F / 450C). The warning lamp will also illuminate when the exhaust outlet temperature is extremely hot during normal engine operation or during a stationary regeneration.

PACCAR

The HIGH EXHAUST SYSTEM TEMPERATURE lamp indicates, when illuminated, that exhaust temperatures are high due to regeneration of the aftertreatment diesel particulate filter. The lamp could illuminate during normal engine operation or during stationary regeneration. When this lamp is illuminated, ensure that the exhaust pipe outlet is not directed at any surface or material that will melt, burn, or explode.

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Operating Instructions WARNING! When this lamp is illuminated, the exhaust gas temperature could reach 800°C (1500°F), which is hot enough to ignite or melt common materials, and to burn people.

Engine Operating Range General Information CAUTION: Operating the engine at full throttle below 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 torque rpm (refer to engine dataplate for peak torque rpm) for more than 30 seconds.

• Keep the exhaust outlet away from people and anything that can burn, melt, or explode. • Nothing within 0.6 m [2 ft] of the exhaust outlet. • Nothing that can burn, melt, or explode within 1.5 m (5 ft) (such as gasoline, wood, paper, plastics, fabric, compressed gas containers, hydraulic lines). • In an emergency, turn off the engine to stop the flow of exhaust.

PACCAR engines are designed to operate successfully at full throttle under transient conditions down to peak torque engine speed. This is consistent with recommended operating practices.

NOTE: The HIGH EXHAUST SYSTEM TEMPERATURE lamp does not signify the need for any kind of vehicle or engine service; it merely alerts the vehicle operator to high exhaust temperatures. It will be common for the HIGH EXHAUST SYSTEM TEMPERATURE lamp to illuminate on and off during normal vehicle operation as the engine completes regeneration.

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CAUTION: Operating the engine beyond the maximum engine speed can cause severe engine damage. Do not operate the engine beyond the maximum engine speed. Use proper operating techniques for the vehicle to prevent engine overspeed. The maximum engine speed specification is listed in “General Engine Specifications” on page 53.

PACCAR

Operating Instructions exhaust brake works by retarding engine speed by creating high exhaust back pressure. This back pressure is obtained by restricting airflow through the turbine housing of the turbocharger. This restriction through the turbine housing of the turbocharger is created through positioning of the sliding nozzle (1) located internally to the variable geometry turbocharger (VGT). the position of the sliding nozzle is controlled by the engine electronic control module (ECM).

Engine Braking System Variable Geometry Turbo (VGT) Brake System General Information This engine is equipped with a variable geometry turbocharger (VGT) with an exhaust brake feature. This feature allows the variable geometry turocharger to act as an exhaust brake by retarding the speed of the engine to provide additional vehicle braking power and extend the life of the vehicle service brakes. The on/off function is controlled by a switch located on the dash of the vehicle. The engine (VGT) PACCAR

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WARNING! The exhaust brake is not intended as the primary brake for the vehicle, nor is it an emergency brake. The service brakes must be used in an emergency. Relying solely on the exhaust brake to stop the vehicle in an emergency could cause an accident and lead to personal injury. The exhaust brake only helps the service brakes by using pressure to slow the drive train. You must use the service brakes for quick or emergency stops. WARNING! Do not use the exhaust brake when operating on surface with poor traction (such as wet, icy, or snow covered roads gravel). Retarders can cause the wheels to skid on a slippery surface. You could lose control of the vehicle and jacknife if the wheels begin to skid, resulting in an accident.

– 39 –

Operating Instructions WARNING! Do not use an exhaust brake when driving bobtail or with an unloaded trailer. There may not be enough weight on the rear axle to provide traction. This could cause a lose of control and jackknife resulting in an injury accident. Make sure the exhaust brake is switched OFF when bobtailing or with an unloaded trailer.

NOTE: The exhaust brake can only be activated when the accelerator pedal is at its low idle position. With the throttle at low idle position, fueling commands to the cylinders will not detract from the braking power of the brake system. NOTE: The engine (VGT) exhaust brake is designed to assist the vehicle's service brakes when slowing the vehicle to a stop.

When the engine (VGT) exhaust brake switch is in the On position, the engine's electronic control module (ECM) monitors inputs (such as accelerator pedal position and engine speed). From these inputs, the ECM determines when to enable the engine (VGT) exhaust brake feature when the proper braking conditions are present. Other features/switches like cruise control, can also affect when the engine (VGT) exhaust brake activates. For more information on how the engine (VGT) exhaust brake functions, refer to vehicle operation manual or contact a PACCAR Authorized Repair Location. WARNING! To reduce the possibility of personal injury or property damage, always be prepared to use the vehicle service brakes for emergency stopping. The safe control speed of a vehicle will vary with the size of the load, the type of load, the grade, and the road conditions.

– 40 –

Vehicle service brakes must always be used. The engine brake is not intended to be used as the primary brake of the vehicle, nor is it an emergency brake. The engine retarder only helps the service brakes by using pressure to slow the divetrain. Use the service brakes for quick stops.

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PACCAR


CAUTION: Exceeding governed engine speed can cause engine damage. Operating the engine beyond the maximum engine speed may cause serious engine damage and considered engine abuse. Use the engine and vehicle braking systems to control engine speed.

Engine Shutdown General Information

The optimum braking power of the engine (VGT) exhaust brake is reached at rated engine speed. Correct gear selection, therefore, is critical.

NOTE: Allow the engine to idle 3 to 5 minutes before shutting it off after a full-load operation. This allows adequate cool down of pistons, cylinders, bearings, and turbocharger components.

Typically, on vehicles equipped with automatic transmissions, the engine electronic control module (ECM) and the transmission will determine the correct gear selection.

PACCAR

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Electromagnetic Interference (EMI)

System EMI Radiation Levels

General Information Some engine applications utilize accessories (CB radios, mobile transmitters, etc.) that generate and use radio frequency energy that, if not installed and used properly, can cause electromagnetic interference (EMI) conditions to exist between the accessory and PACCAR electronic controlled fuel system. PACCAR is not liable for any performance problems with either the fuel system or the accessory due to EMI. EMI is not considered by PACCAR to be an engine failure and therefore is not warrantable.

System EMI Susceptibility Your PACCAR product has been designed and tested for minimum sensitivity to incoming electromagnetic energy. Testing has shown that there is no engine performance degradation at relatively high energy levels; however, if very high energy levels are encountered, then some noncritical diagnostic fault code logging can occur. The fuel system EMI susceptibility level will protect your engine from most, if not all, electromagnetic energy-emitting devices that meet the Federal Communications Commission legal requirements.

– 42 –

Your PACCAR product has been designed to emit minimum electromagnetic energy. Electronic components are required to pass various PACCAR industry EMI specifications. Testing has shown that when the engine is properly installed, it will not interfere with onboard communication equipment or with the vehicle's ability to meet any applicable EMI standards and regulated specifications. If an interference condition is observed, follow the suggestions below to reduce the amount of interference: 1. Locate the receiving antenna as far away from the engine and as high as possible. 2. Locate the receiving antenna as far away as possible from all metal obstructions (e.g., exhaust stacks). 3. Consult a representative of the accessory supplier in your area to: • Calibrate accurately the device for proper frequency, power output, and sensitivity (both base and remote site devices must be properly calibrated) • Obtain antenna reflective energy data measurements to determine the optimum antenna location • Obtain optimum antenna type and mounting arrangement for your application • Make sure your accessory equipment model is built for maximum filtering to reject incoming electromagnetic noise.

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PACCAR

MAINTENANCE GUIDELINES Overview

Maintenance Schedule

General Information

General Information

PACCAR recommends that the engine be maintained according to the Maintenance Schedule in this section.

Perform maintenance at whichever interval occurs first.

If the engine is operating in ambient temperatures below 18°C [0°F] or above 38°C [100°F], perform maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a dusty environment or if frequent stops are made. Contact your local PACCAR Authorized Repair Location for recommended maintenance intervals. Some of these maintenance procedures require special tools or must be completed by qualified personnel. Contact your local PACCAR Authorized Repair Location for detailed information. If your engine is equipped with a component or accessory not manufactured by PACCAR, refer to the component manufacturer's maintenance recommendations. Use the chart provided in this section as a convenient way to record maintenance performed.

PACCAR

At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance. Daily or Refueling – Maintenance Check • Engine Lubrication Oil Level - Check/Correct To check engine oil level, park vehicle on level ground and wait 5 minutes after shutting engine OFF. • Remove dipstick and wipe it off with a clean, lint free rag. • Reinsert dipstick all the way in and pull it out again to check oil level. • Correct oil level is between the low (L) and high (H) marks on dipstick. • Fuel – Water Separator – Drain • Air Intake Piping – Inspect • Hose/Pipe condition – Chaffing, Deterioration, Leaks

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Maintenance Guidelines

•

•

• •

• Hose clamps for tightness • Clearance to other components Aftertreatment Exhaust Piping – Inspect • Cracks • Clearance to other components (i.e. electrical harnesses, etc) • Hose/pipe condition – cracks, chaffing, exhaust leaks. Cooling Fan – Inspect • Cracks • Clearance to other components Air Tank and Reservoirs (if equipped) Inspect Engine Coolant Level - Check/Correct With the engine off and temperature cool: • Check coolant level. It should be visible within the sight glass (glass level indicator) on the surge tank. • Add coolant as necessary by removing the pressure cap on the neck of the surge tank. • Replacement or top up coolant should have the same antifreeze concentration and corrosion inhibitor content as the original coolant in the cooling system. • Never add 100% antifreeze to the cooling system. Always dilute antifreeze to the correct concentration based on freeze protection prior to adding it to the

– 44 –

cooling system. Adding or using 100% antifreeze in a cooling system may result in cooling system plugging and overheating problems. Every 12,000 km (7500mi), 250 Hours, or 3 months – Maintenance Check • Air Cleaner Restriction - Check/Correct • Service filter element when Air Cleaner Restriction Gauge (option) locks in the extreme High position. • Hose/pipe condition - deterioration/signs of leaking • Hose clamp torque • Charge Air Piping – check/Correct • Hose/pipe condition – chaffing, deterioration, leaks • Hose clamps for tightness • Clearance to other components • Charge Air Cooler – Check/Correct • Cracked tubes or header • Clogged fins/tubes • Hose/pipe condition - deterioration/signs of leaking • Hose clamp torque • Air fuel, etc. Every 24,000 km (15,000mi), 500 Hours, or 6 months – Maintenance Check • Fuel Filter, Spin on type replace • Lubricating Oil – Change • Lubricating Oil filters – Replace

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PACCAR

Maintenance Guidelines • Cooling System Antifreeze Check • Supplemental additive/conditioner level • Coolant level • Coolant protection • Batteries – Check • Battery Cables and Connections – Check • Battery condition - electrolyte level, cracks, signs of leaking, overcharging • Harness/cables for loose connections, corrosion, chafing, broken retention clips • Battery hold-downs for tightness • Battery box mounting bolt torque Every 48,000 km [30,000 mi], 1000 Hours, or 1 Year Maintenance Check • Drive Belts - Check/Correct • Belt condition - signs of wear/deterioration • Belt alignment • Fan Belt Tensioner - Check/Correct • Mounting bolt torque • Tensioner maintains proper belt tension • Air Compressor Carbon Build-up - Check/Correct

• Radiator Hoses – Check • Hose condition - deterioration/signs of leaking • Hose clamp torque • Vibration Damper – Check • Damper for cracks, nicks, gouges • Condition of damper rubber isolator • Damper fastener torque • Crankcase Ventilation Filter – Replace Every 241,000 km [150,000 mi], 5000 Hours, or 4 Years Maintenance Check • Overhead Set – Adjust Every 321,500 km [200,000 mi], 6500 Hours - Maintenance Check • Aftertreatment Diesel Particulate Filter – Clean • Complete Cleaning of filter using a DPF cleaning machine • Replace filter if necessary

Every 96,000 km [75,000 mi], 2500 Hours, or 2 Years Maintenance Check • Cooling System - Drain/Flush/Fill

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Maintenance Guidelines NOTE:

1. If the oil drain interval being used is greater than 24,000 km [15,000 mi], as determined by the Oil Drain Intervals section below, the fuel filter change can be extended until the oil drain interval. 2. The oil drain intervals are based on an engine equipped with a 14.2 liter [15 qt] capacity lubricating oil pan and a normal duty cycle. For detailed information on oil drain intervals for a specific application/duty cycle, refer to the Oil Drain Intervals section of this procedure. 3. Extended coolant drain/flush/fill intervals may be followed when certain requirements are met. For information on these requirements, refer to the Coolant Requirements and Maintenance Bulletin 3666132. 4. The aftertreatment diesel particulate filter clean/replace interval is based on the use of lubricating oils that meet the Cummins Engineering Standard (C.E.S.) 20081 oil specification. If a non-low ash lubricating oil meeting the American Petroleum Institute (API) performance classification CI-4/SL and/or C.E.S.

– 46 –

20078 is used, the service intervals for the aftertreatment systems will be reduced to 241,000 km [150,000 mi] or 5000 Hours. 5. Follow the manufacturer's recommended maintenance procedures for the starter, alternator, generator, batteries, electrical components, exhaust brake, charge air cooler, radiator, air compressor, air cleaner, freon compressor, and fan clutch. Oil Drain Intervals See the following flowchart to determine the maximum recommended oil change and filter change intervals in kilometers [miles], hours, or months, whichever comes first. Is the vehicle one of those listed below? • Delivery truck. • Fire truck/emergency vehicle. If Yes Select the correct oil drain interval from Table 1. If No Is the vehicle one of those listed below? • Refuse truck. • Mixer/dumper.

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PACCAR

Maintenance Guidelines If Yes Select the correct oil drain interval from Table 2. If No If vehicle has not been listed, select the correct oil drain interval from Table 3. Table 1—Maximum Oil Drain Intervals (A) Severe Duty (If the Vehicle Meets Any of These Conditions)

(B) Normal Duty (If the Vehicle Meets Both Conditions)

Average fuel economy is less than 2.98 km/liter [7 mpg], or idle time is 40 percent or greater, or vehicle operates in dusty conditions, or gross vehicle weight is greater than 20,865 kg [46,000 lb].

Average fuel economy is greater than 2.98 km/liter [7 mpg] and gross vehicle weight is less than 20,865 kg [46,000 lb].

Vehicle uses the severe-duty oil drain interval (A).

Vehicle uses the normal-duty oil drain interval (B).

If equipped with a 14.2 liter [15 qt] oil pana: 14,500 km [9000 mi], 500 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 14.2 liter [15 qt] oil pan1: 24,000 km [15,000 mi], 500 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 17 liter [18 qt] oil pan1: 19,000 km [12,000 mi], 550 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 18 liter [19 qt] oil pan1: 32,000 km [20,000 mi], 550 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

a. If the type/oil capacity of the oil pan is not known (1) contact a PACCAR Dealer, (2) determine the capacity of the oil pan option for the engine being serviced using Quickserve Online and the engine serial number, or (3) for the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

PACCAR

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Maintenance Guidelines Table 2—Oil Drain Interval Refuse Truck, Mixer, or Dump Truck

With a 14.2 liter [15 qt] Oil Pana

With a 18 liter [19 qt] Oil Pana

Kilometers

Miles

Hours

Months

Kilometers

Miles

Hours

Months

10 to 15 mph average

9,650

6,000

500

6

12,500

8,000

550

6


13,700

8,500

500

6

17,750

11,000

550

6


14,500

9,000

500

6

19,000

12,000

550

6

Above 25 mph average

19,000

12,000

500

6

25,750

16,000

550

6


Table 3—Oil Drain Interval With a 14.2 liter [15 qt] Oil Pana

With a 18 liter [19 qt] Oil Pana

Vehicle/Equipment Kilometers

Miles

Hours

Months

Kilometers

Miles

Hours

Months

Truck Crane

14,500

9,000

500

6

19,000

12,000

550

6

Yard Spotter

14,500

9,000

500

6

19,000

12,000

550

6

All Others

14,500

9,000

500

6

19,000

12,000

550

6


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PACCAR

Maintenance Guidelines PACCAR bases its oil drain specifications on duty cycle and oil contamination. This contamination occurs in all engines at varying rates regardless of design. Maintaining the correct oil and filter change interval is a vital factor in preserving the integrity of an engine. Filters must be changed when the oil is changed. If the type/oil capacity of the oil pan is not known: • Contact a PACCAR dealer. • Determine the capacity of the oil pan option for the engine being serviced using Quickserve Online and the engine serial number. • For the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

PACCAR

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Maintenance Guidelines

Maintenance Record Form Engine Serial No.

Engine Model:

Owner’s Name:

Equipment Name/No.

Date

– 50 –

km (Miles), Hours, or Time Interval

Actual km (Miles) or Hours

Maintenance Check Performed

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Check Performed By

Comments

PACCAR

SERVICE LITERATURE Additional Service Literature General Information The following publications can be purchased from your authorized PACCAR Engine dealer. Bulletin Number

PACCAR

Title of Publication

4021578

Engine Service Manual

4021570

Electronic Control System Troubleshooting and Repair Manual

4021572

Engine Wiring Diagram

4021602

Operation and Maintenance Manual

3379000

Air for Your Engine

3379001

Fuel for Diesel Engines

3379009

Operation of Diesel Engines in Cold Climates

3810340

Engine Oil Recommendations

3666132

Coolant Requirements and Maintenance

3666255

Warranty Failcode Manual (Midrange Engines)

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Service Literature

– 52 –

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PACCAR

MAINTENANCE SPECIFICATIONS General Engine Specifications Horsepower

See engine dataplate

Firing Order

1, 5, 3, 6, 2, 4

Crankshaft Rotation (viewed from front of engine)

Clockwise

Displacement

6.7 liters (409 C.I.D.)

Bore and Stroke

107 mm (4.21 in.) × 124 mm (4.88 in.)

Approximate Dry Weight (with standard accesories)

519 kg (1,144 lb)

Intake

0.254 mm (0.010 in.)

Exhaust

0.660 mm (0.026 in.)

Valve Clearance Maximum Overspeed Capability (15 seconds maximum)

4,200 rpm

Minimum Ambient Temperature for Unaided Cold Start

-12.2°C (-10°F)

Maximum Engine Cranking Speed

150 rpm

Engine Idle Speed

Minimum 600 rpm to maximum 1,000 rpm

Altitude Limit

3658 m (12,000 ft)

PACCAR

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Maintenance Specifications

Lubricating Oil System At Low Idle (minimum allowable)

69 kPa (10 psi)

At Rated Speed (minimum allowable)

207 kPa (30 psi)

Oil Pressure Oil Regulating Valve Opening Pressure Range

448 kPa (65 psi) to 517 kPa (75 psi)

Oil Filter Differential Pressure to Open Bypass

345 kPa (50 psi)

Lubricating Oil Filter Capacity

0.950 liters (1 qt)

Standard Oil Pan

Pan Only

14.2 liters (15 qt)

Total System

16.7 liters (17.6 qt)

High to Low (on dipstick)

1.9 liters (2 qt)

Pan Only

18 liters (19 qt)

Total System

20.3 liters (21.4 qt)

High to Low (on dipstick)

1.9 liters (2 qt)

Lubricating Oil Capacity of Standard Engine High-Capacity Oil Pan

Maximum Oil Temperature

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138°C (280°F)

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PACCAR

Maintenance Specifications NOTE: if the type/oil capacity of the oil pan is not known:

• Contact a PACCAR dealer. • Determine the capacity of the oil pan option for the engine being serviced using Quickserve Online and the engine serial number. • For the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

PACCAR

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Cooling System Coolant Capacity (engine only)

11 liters (2.9 gal)

Standard Modulating Thermostat Range

86 to 97°C (186 to 207°F)

Minimum Recommended Pressure Cap

103 kPa (15 psi)

Maxiumum Allowed Operating Temperature

107°C (225°F)

Minimum Recommended Operating Temperature

71°C (160°F)

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PACCAR


Filter Specifications General Information

Filter Part Numbers

Fleetguard filters are standard on new PACCAR engines. PACCAR recommends their use.

Lubricating Oil Filter Fleetguard Part Number

LF3970

Fleetguard products meet all PACCAR test standards to provide the quality filtration necessary to achieve the engine's design life. If other brands are substituted, the purchaser should ensure the filter specification meet or exceed the Fleetguard specifications.

Fuel Filter (primary) Fleetguard Part Number

FF5632

Fuel Filter (prefilter with water-in-fuel sensor) Fleetguard Part Number

FS1065

Crankcase Ventilation Filter (rocker lever cover mounted) Fleetguard Part Number

CV5200000

Crankcase Ventilation Filter (rear engine mounted) Fleetguard Part Number

CV5060100

PACCAR can not be responsible for problems caused by non-genuine filters that do not meet PACCAR performance or durability requirements.

PACCAR

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Fuel Recommendations and Specifications

CAUTION: Using diesel fuels blended with lubricating may cause damage to your exhaust aftertreatment system. Service intervals for aftertreatment systems will be reduced. Do not use diesel fuel blended with lubricating oil in engines equipped with an aftertreatment system.

Fuel Recommendations WARNING! Mixing other fuels with diesel can cause an explosion. Do not mix gasoline, alcohol, or gasohol with diesel fuel. Make sure you know your fuel source and use the recommended diesel fuel as indicated in this section of the Operator's manual. CAUTION: Dirt or water in the fuel system can cause severe damage to both the fuel pump and the fuel injectors. Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Know your fuel source and make sure all steps are taken for dispensing or using clean fuel in your vehicle. CAUTION: Lighter fuel can reduce economy or possibly damage fuel system components. Lighter fuels typically do not have enough lubricity elements in the fuel to properly lubricate the fuel injection system. Be sure you follow the fuel recommendations as indicated in this section of the operator's manual.

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CAUTION: Do not use high sulfur diesel fuel as it will damage the exhaust aftertreatment system. Also, the engine will not meet emission regulations. Use only Ultra Low Sulfur Diesel (ULSD) fuel. NOTE: The engine has been optimized for use with an aftertreatment system together with ULSD fuel to meet the 2007 U.S. Environmental Protection Agency (EPA) regulations. PACCAR recommends the use of ASTM number 2D fuel. The use of number 2 diesel fuel will result in optimum engine performance. At operating temperatures below 0°C [32°F], acceptable performance can be obtained by using blends of number 2D and number 1D.

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PACCAR

Maintenance Specifications The following chart lists acceptable types of fuels for this engine. Acceptable Types of Fuels Number 1D

Number 2D

Dieselab

Dieselb

Number 1K Kerosene

Jet-A

Jet-A1

JP-5

JP-8

Jet-B

JP-4

CITE

OK

OK

NOT OK

NOT OK

NOT OK

NOT OK

NOT OK

NOT OK

NOT OK

NOT OK

48-34c

40-24c

50-35c

51-37c

51-37c

48-36c

51-37c

57-45c

57-45c

57-45c

a. Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable. b. Winter blend fuels, such as found at commercial fuel dispensing outlets, are combinations of number 1D and number 2D diesel fuel and are acceptable. c. BTU Content/Degree API Gravity - Low API gravity fuels have a higher thermal energy content (BTU). As a general rule, there is a 3 to 5 percent decrease in BTU content for every 10 degree increase in API gravity, there is also a 0.7 degree API gravity increase with an increase in fuel temperature. This decrease in energy content equates roughly to the same percentage of power loss. Use of fuels with higher API gravity will cause higher than normal fuel consumption.

NOTE: PACCAR recommends that the cetane number of diesel fuel be a minimum of 45 for engines that are expected to operate at temperatures below 0°C (32°F) and a minimum of 42 for engines that are operated at temperatures above 0°C (32°F).

PACCAR

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NOTE: Using diesel fuel with a lower than recommended cetane number can cause hard starting, instability, and excessive white smoke. To maintain satisfactory operation at low ambient temperatures, it is important to specify diesel fuel of the correct cetane number.

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Maintenance Specifications NOTE: PACCAR requires all permissible fuels to have adequate fuel lubricity. This means the BOCLE number is 3100 or greater as measured by ASTM specification D6078, Scuffing Load Ball On Cylinder Evaluator (SLBOCLE). Lubricity can also be measured by ASTM, specification D6079, ISO 12156, High Frequency Reciprocating Rig (HFRR) in which the fuel must have a wear scar diameter of 0.45 mm [0.02 in] or less.

caused by the use of biodiesel fuels or other fuel additives are not defects of PACCAR parts or workmanship and therefore will not be covered by PACCAR warranty.

NOTE: For information on alternative fuels, such as biodiesel, and additional information for fuel recommendations and specifications, please refer to the Fuel for PACCAR Engines, Bulletin 3379001. Warranty and the Use of Biodiesel Fuel PACCAR neither approves nor disapproves of the use of biodiesel fuel blends. There is a major difference between operating on pure (100% concentration) biodiesel fuels and biodiesel or petrodiesel fuel blends. Currently, there are no firm industry standards on the content and properties for biofuels. The consistency and predictability of bio-diesel operation is not well documented nor its variations to the long-term effects on performance, durability or emissions compliance of the PACCAR engine. The use of biodiesel fuel does not affect PACCAR materials and workmanship warranty. Failures

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PACCAR


Lubricating Oil Recommendations and Specifications General Information CAUTION: Extending the oil and filter change interval beyond the recommendations will decrease the engine life due to factors such as corrosion, deposits, and wear. Engine oil filters capture dirt and remove deposits from the oil to prolong the life of internal moving components. Follow the oil and filter change intervals as recommended in this section of the manual. The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical factor in maintaining engine performance and durability. Extending the oil and filter change interval beyond the recommendations will decrease engine life due to factors such as corrosion, deposits, and wear. Refer to “Oil Drain Intervals” on page 46 to determine which oil drain interval to use for an application. NOTE: The responsibility is with the owner. If recommendations are ignored, warranty could be affected. API: American Petroleum Institute

PACCAR allows, for midrange applications, the use of lubricating oils that meet or exceed CES 20078 or CES 20081 with no change in oil drain interval. But, if a non-low ash lubricating oil meeting the Cummins Engineering Standard (CES) classification CES 20078 is used, the service interval(s) for the aftertreatment system will be reduced.

To determine if the lubricating oil meets CES 20078 or CES 20081, review the label on the back of the lubricating oil bottle for the CES 20078 or CES 20081 reference. If acquiring the lubricating oil in bulk, contact the supplier for the lubricating oil specifications and confirm that the oil meets CES 20078 or CES 20081.

CES: Cummins Engineering Standard PACCAR

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Maintenance Specifications Also located on the lubricating oil bottle is the API service symbol which is shown in the illustration. The upper half of the symbol displays the appropriate oil categories. The center section identifies the SAE oil viscosity grade. The table

below shows how the Cummins Engineering Standard (CES) compares to the American Petroleum Institute (API) classification.

Cummins Engine Standard Classification (CES)

American Petroleum Institute Classification (API)

CES-20071 CES-20072 CES-20076 CES-20077

API CH-4/SJ

Not recommended. Lubricating oil drain interval must be reduced by 50%. Aftertreatment maintenance interval will be reduced.

CES-20078

CI-4/SL

Aftertreatment maintenance interval will be reduced.

CES-20081

CJ-4/SL

Maximum aftertreatment maintenance interval. No change in lubricating oil drain interval.

Comments

NOTE: A lubricating oil that meets the American Petroleum Institute (API) performance classification CJ-4/SL may not meet the CES 20081 requirement. Always make sure the lubricating oil used meets the CES 20081 requirement in addition to the API performance classification CJ-4/SL. PACCAR recommends the use of high-quality SAE 15W-40 heavy-duty engine oil.

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The primary PACCAR recommendation is for the use of 15W40 multigrade lubricating oil for normal operation at ambient temperatures above -15°C [5°F]. The use of multigrade oil reduces deposit formation, improves engine cranking in low temperature conditions and increases engine durability by maintaining lubrication during high temperature operating conditions. Since multigrade oils have been shown to provide approximately 30 percent lower oil consumption compared with monograde oils, it is important to use multigrade oils to be certain the engine will meet applicable emissions requirements.

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PACCAR

Maintenance Specifications Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is permitted subject to the same performance and viscosity limitations of petroleum (mineral) based engine oils. The same oil change intervals must be applied to synthetic oils that are applied to petroleum (mineral) based engine oils.

same level of protection against fuel dilution as do higher multigrade oils. Higher cylinder wear can be experienced when using 0W-30 oils in high-load situations. As these oils have directionally thinner oil films than 15W-40 oils, top-quality Fleetguard® filters must be used above 20°C [70°F]. Some oil suppliers might claim better fuel economy for these oils. PACCAR can neither approve nor disapprove any product not manufactured by PACCAR. These claims are between the customer and oil supplier. Obtain a commitment from the oil supplier that the oil will give satisfactory performance in PACCAR engines or do not use the oil.

New Engine Break-In Oils Special “break-in” engine lubricating oils are not recommended for new or rebuilt PACCAR engines. Use the same lubricating oil that will be used during normal operation. While the preferred viscosity grade is 15W-40, lower viscosity multigrade oils can be used in colder climates. See the accompanying chart. Any viscosity grade lower than 15W-40 must still meet CES 20081. Synthetic engine oils, API Group III and Group IV basestocks, are recommended for use in PACCAR engines operating in ambient temperature conditions consistently below 25°C [-13°F]. Synthetic 0W-30 oils that meet the requirements of API Group III or Group IV basestocks, can be used in operations where the ambient temperature never exceeds 0°C [32°F]. Multiviscosity oils rated 0W-30 do not offer the PACCAR

Aftermarket Oil Additive Usage PACCAR does not recommend the use of aftermarket oil additives. The present high-quality fully additive engine lubricating oils are very sophisticated, with precise amounts of additives blended into the lubricating oil to meet stringent requirements. These furnished oils meet performance characteristics that conform to the lubricant industry standards. Aftermarket lubricating oil additives are not necessary to enhance engine oil performance and in some cases can reduce the furnished oil's capability to protect the engine.

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Coolant Recommendations and Specifications Fully Formulated Coolant/Antifreeze PACCAR recommends the use of fully formulated antifreeze/ coolant meeting Cummins Engineering Standards (C.E.S.) 14603. Ty p i c a l l y, a n t i f r e e ze / c o o l a n t s m e e t i n g A S T M 4 9 8 5 (GM6038M specification) or ASTM D6210 criteria are acceptable antifreeze/coolants for engines covered by the manual. Low-silicate antifreeze/coolants meeting ASTM D4985 (GM6038M specification) are not adequate for extended service intervals. PACCAR recommends using either a 50/50 mixture of goodquality water and fully formulated antifreeze, or fully formulated coolant when filling the cooling system.

Good-quality water is important for cooling system performance. Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of chlorides and sulfates cause cooling system corrosion. Water Quality

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Calcuim Magnesium (hardness)

Maximum 170 ppm as (CaCO3 + MgCO3)

Chloride

40 ppm as (Cl)

Sulfur

100 ppm as (SO4)

PACCAR

Maintenance Specifications Fully formulated antifreeze must be mixed with good quality water at a 50/50 ratio (40- to 60-percent working range). A 50/50 mixture of antifreeze and water gives a -36°C [-33°F] freezing point and a 108°C [226°F] boiling point, which is adequate for locations in North America. The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent. Using higher concentrations of antifreeze will raise the freezing point of the solution and increase the possibility of a silica gel problem. PACCAR vehicle engine-cooling systems are filled with fully formulated extended-life coolant (ELC). PACCAR recommends the use of fully formulated extended life coolant that meets the requirements of Cummins Engineering Standard (C.E. S.) 14603 for top off and service. If the replacement coolant is Chevron Texaco, Shell Rotella or their private label counterparts which do not meet the elastomer compatibility section of CES 14603, the coolant must be treated by adding 0.24 liter (8oz) of liquid silicate fluid for every 45 liters (12 gal) of total coolant system volume. It is critical to not over treat the coolant with silicate fluid. If overtreatment is suspended, drain the cooling system and discard the filter. Clean the cooling system immediately. Symptoms of silicate over-treatment can be thickened coolant in the lower radiator tank, water pump seal leakage soon after silicate addition, reduced heater output and/or elevated engine temperatures.

PACCAR

To obtain order forms or ask questions relative to ordering the silicate fluid, contact: Silicate Fluid Order Program P.O. Box 27388 Houston, TX 77277-7388 Phone: 800-346-9041 Fax: 800-876-5317 If the replacement coolant is Chevron Texaco, Shell Rotella or their private label counterparts the coolant must be replaced with new coolant whenever the engine is overhauled or repairs involve the replacement of the following components: • Rocker lever housing gasket. • Lubricating oil cooler housing gasket. • Cylinder head gasket. • Thermostat housing gasket. For further details of engine coolant for PACCAR PX-6 engines, refer to Cummins Coolant Requirements and Maintenance Bulletin 3666132.

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A refractometer must be used to measure the freezing point of the coolant accurately. Use Fleetguard ® refractometer, Part Number C2800.

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CAUTION: Do not use a floating ball hydrometer. The use of floating ball hydrometers can give an incorrect reading. Using a floating ball hydrometer for testing the freezing point of the coolant is an inaccurate test and will cause a false reading of the coolant freezing point. Use a refractometer to obtain an accurate test of the coolant freezing point.

PACCAR

Maintenance Specifications Cooling System Sealing Additives CAUTION: The use of sealing additives in the cooling system will cause damage to the engine. Sealing additives will plug various areas of the radiaters and oil cooler. The plugging of the cooling system will hamper heat transfer thus, causing internal engine damage. Do not use sealing additives in the cooling system. The use of sealing additives will: • Buildup in coolant low-flow areas • Plug the radiator and oil cooler • Possibly damage the water pump seal.

Cooling System Soluble Oils CAUTION: Do not use soluble oils in the cooling system. The use of soluble oils in the cooling system will cause damage to the engine. Soluble oils in the cooling system will: • Corrode brass and copper • Damage heat transfer surfaces • Damage seals and hoses.

PACCAR

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PACCAR

WARRANTY PACCAR PX-6 Engine United States and Canada Coverage

PACCAR Responsibilities PACCAR will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure.

Products Warranted This warranty applies to new PACCAR PX-6 Engines sold by PACCAR and delivered to the first purchaser that are used in on-highway applications in the United States1 or Canada with one exception. PACCAR provides different warranty coverage for engines used in fire apparatus truck applications.

PACCAR will pay for the lubricating oil, antifreeze, filter elements, belts, hoses, and other maintenance items that are not reusable due to the Warrantable Failure. PACCAR will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure.

Base Engine Warranty This warranty covers any failures of the Engine which result, under normal use and service, from a defect in material or factory workmanship (Warrantable Failure). This coverage begins on the date of delivery and ends two years after the date of delivery of the Engine to the first purchaser. Additional coverage is outlined in the Emission Warranty section.

PACCAR will pay reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair station for the first year from the date of delivery of the Engine to the first purchaser or the duration of the warranty, whichever occurs first. In lieu of the towing expense, PACCAR will pay reasonable costs for mechanics to travel to and from the location of the vehicle, including meals, mileage, and lodging when an engine repair is performed at the site of the failure.

1. United States includes American Samoa, the Commonwealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.

PACCAR

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WARRANTY Owner Responsibilities

Limitations

Owner is responsible for the operation and maintenance of the Engine as specified in the applicable PACCAR Operator’s Manual. Owner is also responsible for providing proof that all recommended maintenance has been performed.

PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the Engine. PACCAR is also not responsible for failures caused by incorrect oil or fuel or catalytic reagent or by water, dirt or other contaminants in the fuel, oil, or catalytic reagent.

Before the expiration of the applicable warranty, Owner must notify a PACCAR authorized dealer or an authorized Cummins Distributor of any Warrantable Failure and make the engine available for repair by such facility. Except for Engines disabled by Warrantable Failure during the first year from the date of delivery to the first purchaser or the duration of the warranty, whichever occurs first, Owner must also deliver the Engine to the authorized repair facility. Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure. Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of a Warrantable Failure. Owner is responsible for non-Engine repairs and for "downtime" expenses, cargo damage, fines, all applicable taxes, all business costs and other losses resulting from a Warrantable Failure.

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This warranty does not apply to accessories supplied by the vehicle OEM which are covered by the OEM vehicle warranty. Failures resulting in excessive oil consumption are covered for the duration of the coverage or 100,000 miles (160,935 kilometers) or 6,250 hours from the date of delivery of the Engine to the first purchaser, whichever of the three occurs first. Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that consumption exceeds PACCAR published standards. Failures of belts and hoses supplied by PACCAR are covered for the first year from the date of delivery of the Engine to the first purchaser.

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PACCAR

WARRANTY Parts used to repair a Warrantable Failure may be new parts, approved rebuilt parts, or repaired parts. PACCAR is not responsible for failures resulting from the use of parts not approved by PACCAR. A new approved rebuilt part used to repair a Warrantable Failure assumes the identity of the part it replaced and is entitled to the remaining coverage hereunder. PACCAR reserves the right to interrogate Electronic Control Module (ECM) data for purposes of failure analysis. PACCAR DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS. THIS WARRANTY AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY PACCAR IN REGARD TO THESE ENGINES. PACCAR MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. PACCAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

United States and Canada Fire Apparatus Truck Applications Coverage Products Warranted This warranty applies to new PACCAR Engines sold by PACCAR and delivered to the first purchaser that are used in fire apparatus truck applications in the United States 1 or Canada.

Base Engine Warranty The Base Engine Warranty covers any failures of the Engine which result, under normal use and service, from a defect in material or factory workmanship (Warrantable Failure). This coverage begins on the date of delivery to the first purchaser and ends five years or 100,000 miles (160,935 kilometers), whichever occurs first. Engine aftertreatment components included in the PACCAR Critical Parts List (CPL) and marked with a PACCAR part number are covered under Base Engine Warranty. Additional coverage is outlined in the Emission Warranty section.


PACCAR

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WARRANTY PACCAR Responsibilities PACCAR will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure. PACCAR will pay for the lubricating oil, antifreeze, filter elements, belts, hoses and other maintenance items that are not reusable due to the Warrantable Failure. PACCAR will pay for reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure. PACCAR will pay reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair location. In lieu of the towing expense, PACCAR will pay reasonable costs for mechanics to travel to and from the location of the vehicle, including meals, mileage, and lodging when its engine repair is performed at the site of the failure.

Owner Responsibilities Owner is responsible for the operation and maintenance of the Engine as specified in PACCAR Operator’s Manual. Owner is also responsible for providing proof that all recommended maintenance has been performed. Before the expiration of the applicable warranty, Owner must notify a PACCAR authorized dealer or an authorized Cummins Distributor of any Warrantable Failure and make the engine available for repair by such facility. Except for

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Engines disabled by a Warrantable Failure, Owner must also deliver the Engine to the repair facility. Owner is responsible for the cost of lubricating oil, antifreeze, filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure. Owner is responsible for communication expenses, meals, lodging and similar costs incurred as a result of a Warrantable Failure. Owner is responsible for non-Engine repairs and for downtime expenses, cargo damage, fines, all applicable taxes, all business costs and other losses resulting from a Warrantable Failure. Owner is responsible for a $100 (U.S. Dollars) deductible per each service visit under this plan in the 3rd, 4th, and 5th years of base engine warranty. The deductible will not be charged during the first 2 years of the base engine warranty.

Limitations PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect, including but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the Engine. PACCAR is also

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PACCAR

WARRANTY not responsible for failures caused by incorrect oil, fuel or catalytic reagent or by water, dirt or other contaminants in the fuel, oil or catalytic reagent. This warranty does not apply to accessories supplied by PACCAR which are covered by the OEM vehicle warranty. Failures resulting in excessive oil consumption are not covered beyond the duration of the coverage or 100,000 miles (160,935 kilometers) or 6,250 hours from the date of delivery of the Engine to the first purchaser, whichever of the three occurs first. Before a claim for excessive oil consumption will be considered, Owner must submit adequate documentation to show that consumption exceeds PACCAR published standards.

PACCAR DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS. THIS WARRANTY AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY PACCAR IN REGARD TO THESE ENGINES. PACCAR MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. PACCAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Failures of belts and hoses supplied by PACCAR are not covered beyond the first year from the date of delivery of the Engine to the first purchaser. Parts used to repair a Warrantable Failure may be new parts, approved rebuilt parts, or repaired parts. PACCAR is not responsible for failures resulting from the use of parts not approved by PACCAR. A new approved rebuilt part used to repair a Warrantable Failure assumes the identity of the part it replaced and is entitled to the remaining coverage hereunder. PACCAR reserves the right to interrogate Electronic Control Module (ECM) data for purposes of failure analysis.

PACCAR

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WARRANTY

Emission Warranty

If the vehicle in which the Engine is installed is registered in the state of California, a separate California Emission Warranty also applies.

Products Warranted This emission warranty applies to new PACCAR Engines marketed by PACCAR that are used in the United States1 in vehicles designed for transporting persons or property on a street or highway.

Coverage PACCAR warrants to the first purchaser and each subsequent purchaser that the Engine is designed, built and equipped so as to conform at the time of sale by PACCAR with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in material or factory workmanship which would cause it not to meet these regulations within the longer of the following periods: (A) Five years or 100,000 miles (160,935 kilometers) of operation, whichever occurs first, as measured from the date of delivery of the Engine to the first purchaser or (B) The Base Engine Warranty.

Limitations Failures, other than those resulting from defects in material or factory workmanship, are not covered by this Warranty. PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the Engine. PACCAR is also not responsible for failures caused by incorrect oil, fuel or catalytic reagent or by water, dirt or other contaminants in the fuel, oil or catalytic reagent. PACCAR is not responsible for non-Engine repairs, downtime expenses, cargo damage, fines, all applicable taxes, all business costs or other losses resulting from a Warrantable Failure. PACCAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.


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PACCAR

WARRANTY

California Emission Control System Warranty, On-Highway

If an emission-related part on your engine is found to have a defect in material or factory workmanship that produces a measurable increase in emissions (Warrantable Condition), the part will be repaired or replaced by PACCAR. This is your emission control system defects warranty.

Products Warranted This Emission Control System Warranty applies to diesel engines (hereafter, engines) certified with the California Air Resources Board beginning with the year 2007, marketed by PACCAR, and registered in California for use in on-highway applications.

Your Warranty Rights and Obligations The California Air Resources Board and PACCAR are pleased to explain the emission control system warranty on your 2007 and subsequent model year diesel engine. In California, new motor vehicle engines must be designed, built and equipped to meet the States stringent anti-smog standards. PACCAR must warrant the emission control system on your diesel engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your diesel engine. Your emission control system may include parts such as the fuel injection system and engine electronic control module. Also included may be hoses, connectors and other emission related assemblies.

PACCAR

Manufacturer's Warranty Coverage This warranty coverage is provided for five years or 100,000 miles (160,935) km or 3,000 hours of engine operation, whichever first occurs from the date of delivery of the engine to the first purchaser. Where a Warrantable Condition exists, PACCAR will repair your engine at no cost to you including diagnosis, parts and labor.

Owner's Warranty Responsibilities As the engine owner, you are responsible for the performance of the required maintenance listed in your PACCAR Operator’s Manual. You are responsible for presenting your engine to an authorized PACCAR Dealer or an authorized Cummins Distributor as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the engine owner, you should also be aware that PACCAR may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

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WARRANTY If you have any questions regarding your warranty rights and responsibilities, you should contact PACCAR Medium Duty Engine Department or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.

California Emissions Components Statements for PX-6 Engine (2007) Emissions Engines Coverage

A warranted part which is scheduled for replacement as required maintenance is warranted up to the first scheduled replacement point.

The emission control system warranty applies to the following emission control parts which are subject to the failure qualifications as communicated in Cummins Warranty Alert 0141, titled "Emissions Warranty Qualification."

Prior to the expiration of the applicable warranty, Owner must give notice of any warranted emission control failure to an authorized PACCAR Engine dealer or an authorized Cummins Distributor and deliver the engine to such facility for repair. Owner is responsible for incidental costs such as: communication expenses, meals, lodging incurred by Owner or employees of Owner as a result of a Warrantable Condition. Owner is responsible for downtime expenses, cargo damage, fines, all applicable taxes, all business costs, and other losses resulting from a Warrantable Condition.

Intake System • Intake connection • Charge Air Cooler • Turbocharger Exhaust Gas Recirculation System • Exhaust Gas Recirculation Valve • Exhaust Gas Recirculation Cooler (and associated plumbing) Exhaust Manifold Fueling System • Injector • Fuel Pump Actuator

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WARRANTY Electronic Control System • Engine Control Module • Barometric Air Pressure Sensor • Coolant Temperature Sensor • Rail fuel Pressure Sensor • Intake manifold pressure and temperature sensor • Compressor Inlet Temperature Sensor • Exhaust Gas Temperature Sensor • Exhaust Gas Recirculation Differential Pressure Sensor • Ambient air temperature/Barometric Air Pressure Sensor Aftertreatment System • Aftertreatment diesel particulate filter • Aftertreatment diesel oxidation catalyst • Aftertreatment exhaust gas temperature sensors • Aftertreatment diesel particulate filter differential pressure sensor (and related plumbing)

Replacement Parts PACCAR recommends that any service parts used for maintenance, repair or replacement of emission control systems be new, genuine approved rebuilt parts and assemblies, and that the engine be serviced by an authorized PACCAR Engine dealer or an authorized Cummins Distributor. The owner may elect to PACCAR

have maintenance, replacement or repair of the emission control parts performed by a facility other than a PACCAR authorized dealer or an authorized Cummins Distributor and may elect to use parts other than new genuine approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the cost of such service or parts and subsequent failures resulting from such service or parts will not be covered under this emission control system warranty, except for Emergency Repairs as described below.

PACCAR Responsibilities The warranty coverage begins when the engine is delivered to the first purchaser. Repairs and service will be performed by any authorized PACCAR Engine, dealer or an authorized Cummins Distributor using new, genuine approved rebuilt parts and assemblies. PACCAR will repair any of the emission control parts found by PACCAR to be defective without charge for parts or labor (including diagnosis which results in determination that there has been a failure of a warranted emission control part).

Emergency Repairs In the case of an emergency where an authorized PACCAR Engine dealer or an authorized Cummins Distributor is not available, repairs may be performed by any available repair location or by any individual using any replacement parts. A part not being available within 30 days or a repair not being

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WARRANTY complete within 30 days constitutes an emergency. PACCAR will reimburse the Owner for expenses (including diagnosis), not to exceed the manufacturers suggested retail price for all warranted parts replaced and labor charges based on the manufacturers recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. Replaced parts and paid invoices must be presented at an authorized PACCAR Engine dealer or authorized Cummins Distributor as a condition of reimbursement for emergency repairs not performed by an authorized PACCAR Engine dealer or an authorized Cummins Distributor.

Warranty Limitations PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; overfueling; overspeeding; lack of maintenance of cooling, lubricating or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications to the engine. PACCAR is also not responsible for failures caused by incorrect oil or fuel or by water, dirt or other contaminants in the fuel or oil.

PACCAR is not responsible for the material and labor costs of emission control parts and assemblies replaced during Scheduled Maintenance of the engine as specified in PACCAR Operator’s Manuals. THIS WARRANTY, TOGETHER WITH THE EXPRESS COMMERCIAL WARRANTIES ARE THE SOLE WARRANT I E S M A D E B Y PAC C A R I N R E G A R D TO T H E S E ENGINES. PACCAR MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. PACCAR is not responsible for other incidental or consequential damages. Incidental or consequential damages include but are not limited to fines, theft, vandalism or collisions.

PACCAR is not responsible for failures resulting from improper repair or the use of parts which are not genuine approved parts.

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PX6 Manual (Paccar Engine)

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