paccar engine aftertreatment systems-operator's manual

Contents

Safety

Emergency

Controls

Driving

Maintenance

Information

Index

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2

3

4

5

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Contents

©2011 Paccar Inc - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or optional onthis vehicle. This manual may also include a description of features and equipment which are no longer available or werenot ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which arenot on this vehicle.

PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time withoutnotice and without incurring any obligation.

The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictlyprohibited without prior written authorization from PACCAR Inc.

SAFETY

SafetyAbout This Manual . . . . . . . . . . . 1-3Safety Alerts . . . . . . . . . . . . . . 1-4Illustrations. . . . . . . . . . . . . . . 1-6

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Safety

Safety

About This Manual

Please take the time to get acquaintedwith your vehicle by reading thisOperator’s Manual. We recommendthat you read and understand thismanual from beginning to end beforeyou operate your truck. This manualexplains the safe, efficient operationand maintenance of your vehicle.

NOTE: After you’ve read thismanual, it should be stored inthe cab for convenient referenceand remain with this truck whensold.

Your vehicle may not have all thefeatures or options mentioned in thismanual. Therefore, you should paycareful attention to the instructionsthat pertain to just your vehicle. Inaddition, if your vehicle is equippedwith special equipment or options

not discussed in this manual, consultyour dealer or the manufacturer of theequipment. All information containedin this manual is based on the latestproduction information available at thetime of publication. PACCAR reservesthe right to make changes at any timewithout notice.

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Safety

Safety Alerts

Please read and follow all of thesafety alerts contained in this manual.They are there for your protectionand information. These alerts canhelp you avoid injury to yourself, yourpassengers, and help prevent costlydamage to the vehicle. Safety alertsare highlighted by safety alert symbolsand signal words such as "WARNING","CAUTION", or "NOTE". Please do notignore any of these alerts.

WARNING

WARNING:

The safety message following thissymbol and signal word provides awarning against operating procedureswhich could cause injury or even death.They could also cause equipment orproperty damage. The alert will identifythe hazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

WARNING: Do not carryadditional fuel containers inyour vehicle. Fuel containers,either full or empty, may leak,explode, and cause or feed afire. Do not carry extra fuelcontainers. Even empty onesare dangerous. Failure tocomply may result in death,personal injury, equipment orproperty damage.

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Safety

CAUTION

CAUTION:

The safety alert following this symboland signal word provides a cautionagainst operating procedures whichcould cause equipment or propertydamage. The alert will identify thehazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

CAUTION: Continuing tooperate your vehicle withinsufficient oil pressurewill cause serious enginedamage. Failure to complymay result in equipment orproperty damage.

NOTE

NOTE:

The alert following this symbol andsignal word provides importantinformation that is not safety relatedbut should be followed. The alertwill highlight things that may not beobvious and is useful to your efficientoperation of the vehicle.

Example:

NOTE: Pumping the acceleratorwill not assist in starting theengine.

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Safety

IllustrationsGeneral Information

Some of the illustrations throughoutthis manual are generic and will notlook exactly like the engine or partsused in your vehicle.

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CONTROLS

Aftertreatment System (ATS)Introduction . . . . . . . . . . . . . . 3-3

Diesel Particulate Filter (DPF) SystemIntroduction . . . . . . . . . . . . . . 3-4Controlling the Regeneration Process . . . 3-4Functionality / Notification Information . . . 3-6DPF Regeneration . . . . . . . . . . 3-11Stop an Automatic or Parked Regeneration 3-13Idling in Freezing Temperatures. . . . . 3-14

Selective Catalytic Reduction (SCR) SystemIntroduction . . . . . . . . . . . . . 3-16

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Aftertreatment System (ATS)

Aftertreatment System(ATS)

Introduction

The Aftertreatment System (ATS)on your vehicle is made up of twosystems:

1. Diesel Particulate Filter (DPF)System

2. Selective Catalytic Reduction(SCR) System

They fulfill two primary functions;particulate reduction & nitrogen oxide(NOx) reduction.

This section of the manual describeshow to interact and control these twosystems. See the INFORMATIONsection starting on page 6-1 of thismanual for more detailed informationabout the aftertreatment process andits components.

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Diesel Particulate Filter (DPF) System

Diesel Particulate Filter(DPF) System

Introduction

The DPF system consists of aHydrocarbon (HC) Doser (may notapply to all engines), a Diesel OxidationCatalyst (DOC), and a DPF. The DPFfilters soot out of the exhaust. Whenactivated the HC Doser sprays a smallamount of diesel fuel (the HC) intothe exhaust. The catalyst in the DOCreacts with the HC to generate heat.The heat is used to clean (regenerate)the DPF by reducing the trapped sootto ash.

Controlling theRegeneration Process

Your vehicle is equipped with eithera two-position or three-positionRegeneration Switch, mounted on thedash.

If equipped with a two-positionRegeneration Switch, the drivercan initiate a Parked Regenerationwhen certain operating conditions aresuitable for regeneration, however,you will NOT be able to Stop aregeneration if the ATS has initiatedone automatically. Refer to " ParkedRegeneration on page 3-11 "

If your vehicle is equipped with athree-position Regeneration Switch,the driver can control the regenerationby overriding the ATS when certainoperating conditions are not suitablefor regeneration. Refer to " Stop anAutomatic or Parked Regeneration onpage 3-13 "

WARNING: If you operatein environments thatcontain explosive vaporsor flammable materials,look to see if yourvehicle’s RegenerationSwitch is equipped witha STOP function. TheSTOP function must beactivated prior to enteringthe above environment(s)to prevent automatic engineregeneration from occurring,which could cause anexplosion or fire. Failure toequip your vehicle with theproper switch (function) orfailing to activate the STOPfunction before entering acombustible environmentmay cause an explosion orfire that could lead to death,personal injury, equipment orproperty damage.

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NOTE: To obtain a RegenerationSwitch with a STOP function,contact your nearest authorizedPACCAR dealer to obtainthe proper switch andreprogramming of your engine’sECU.

Two-Position Regeneration Switch

Two-Position Regeneration Switch

NOTE: Refer to " DPFRegeneration on page 3-11" for instructions on how to startor stop a ATS regeneration(three-position switch only).

Start

Depressing the button in the STARTdirection for at least 4 - 8 seconds willinitiate a parked regeneration.

Three-Position Regeneration Switch

Three-Position Regeneration Switches

Start

Depressing the button in the STARTdirection for at least 4 - 8 seconds willinitiate a parked regeneration.

Center (three position switch only)

NOTE: During normal vehicledriving, the regeneration switchmust be in the CENTERposition.

CENTER is the normal position ofthe switch. Unless you are manuallyinitiating a parked regeneration orintentionally stopping a regeneration,

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the switch should be in this position.Placing the switch in the center positionwill allow an automatic regeneration tooccur if conditions allow.

Stop (three position switch only)

When STOP is pressed the system willnot regenerate under any conditions.

CAUTION: Do not leave theswitch in the STOP positionunless you need to cancel orstop a regeneration. Runningthe engine with the switch inthe STOP position will resultin increased soot levels inthe DPF and could eventuallycause the engine to derate.

Aftertreatment System WarningLamps

ATS specific warning lamps andindicator symbols are located on themain gauge cluster.

Diesel ParticulateFilter (DPF) Warning

Lamp Symbol

High Exhaust SystemTemperature (HEST)Warning Lamp

Symbol

Functionality / NotificationInformation

The ATS will regenerate the DPF byusing hot exhaust gases normallygenerated by the engine. Thistypically occurs during highwayoperation, is referred to as a "Passive"Regeneration, and is transparent tothe operation of the vehicle.

Occasionally, the exhaust gasesare not hot enough for passiveregeneration. When this occurs,the ATS will regenerate the DPF byincreasing the exhaust temperature.This is referred to as an "Automatic"Regeneration and is also transparentto vehicle operation. An AutomaticRegeneration event typically lasts 30minutes. During and shortly after theevent, the exhaust gases from the DPFmay reach temperatures in excess of650° C (1200° F). See the informationin the table below on probable causesand recommended actions related

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to the warning lamps and indicatorsymbols of the ATS.

The ATS may not be able to regeneratethe DPF when the vehicle is driven atextended low speeds or with frequentstart and stops. In such cases,warning lamps and indicator symbolswill alert the operator to take action.The operator should be aware ofwhether the lamps are on alone or incombination with others. The followingtable will describe each warninglamp(s) and what actions are neededfrom the operator.

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Notification of High Exhaust System Temperature:

Warning Indicator Condition Operator Actions

HEST lamp on

Any one or combination of theseconditions:• Exhaust outlet temperature

is elevated above normal (atleast 450° C / 842° F) andvehicle slows below 5 mph /8 kph.

• Normal driving but engine isunder heavy loading.

• Automatic Regeneration inprocess

• Parked Regeneration inprocess

Follow all warnings listed below. Use the STOP function of the Regeneration Switch ifthe situation requires. Follow the instructions described under " Stop an Automatic orParked Regeneration on page 3-13 ".

WARNING: Temperature of the tail pipe, exhaust pipe, diesel particularfilter (DPF), selective catalytic reduction (SCR) device and surroundingcomponents including enclosures and steps, will be elevated during andshortly after a regeneration event or normal vehicle operation when engineis under high or heavy loading. If the High Exhaust System Temperature(HEST) warning lamp is on:• Do not park in an area of combustible vapors or materials. You must

keep combustibles at least five (5) feet away from the exhaust (outlet)stream (as it exits the tail pipe) while the HEST lamp is illuminated.Always park your vehicle outside. Failure to do so could ignite anexplosion or harm bystanders which could result in serious injury.

• Do not park in an area where people are close by. You must keepcombustibles at least five (5) feet away from the exhaust outlet whilethe HEST lamp is illuminated. Failure to do so could result in seriousinjury.

• Temperature of the tail pipe, exhaust pipes, diesel particular filter(DPF), selective catalytic reduction (SCR) device and surroundingcomponents including enclosures and steps becomes elevated duringengine operation or any regeneration event and can cause seriousburns to the skin. Allow adequate cooling time before approaching,working on or near any part of the exhaust system or surroundingcomponents.

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Notification That Regeneration Is Required:

WarningLevel

WarningIndicators Condition Operator Actions

1

DPF lamp on

The soot level in the DPF is abovethe desired level and requiresregeneration.

The DPF requires regeneration soon. Follow the instructionsdescribed under " DPF Regeneration on page 3-11 ".

NOTE: If you ignore the warning lamp and do notinitiate regeneration at the soonest, safest possibletime, the DPF will become increasingly clogged withsoot and can lead to engine shutdown.

2

DPF lamp flashes

The soot level in the DPF continuesto stay above the desired level andrequires regeneration.

Regenerate the DPF as soon as safely possible. Follow theinstructions described under "DPF Regeneration on page 3-11".

CAUTION: If you do not initiate regenerationafter the DPF warning lamp begins to flash, youonly have a short time before the Check Enginelamp will illuminate and the engine will go into aprotection mode and derate power.

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WarningLevel

WarningIndicators Condition Operator Actions

3

DPF lamp flashes

Check Engine lamp on

The soot level in the DPF continuesto stay above the desired level andrequires regeneration.The engine will derate power if actionis not taken.

Regenerate the DPF immediately. Follow the instructionsdescribed under "DPF Regeneration on page 3-11 " forPACCAR MX engines , "Parked Regeneration on page 3-11 "for PACCAR PX and Cummins engines.

CAUTION: If you do not initiate regenerationafter the DPF warning lamp begins to flash andthe Check Engine lamp is on, you only havea short time before the Stop Engine lamp willilluminate and the engine will automatically beginto shutdown.

NOTE: Under some conditions after prolongedstationary idling, a parked regeneration may berequired without a level 1 or level 2 warning.

4

DPF lamp flashes (MX engineonly)

Stop Engine lamp on

The soot level in the DPF is now at fullcapacity.The engine will derate power and ifthe engine is not an MX, it will begin ashutdown sequence.When shutdown sequence is complete,the system will allow a restart.

NOTE: The engine shutdownsequence is engine specific;therefore to learn howthis system works on yourvehicle, refer to the EngineManufacturer’s Operation andMaintenance Manual suppliedwith your vehicle.

At this point, you CANNOT regenerate the DPF. Take yourvehicle to an Authorized PACCAR Dealer to have the DPFremoved. They will either have to clean it or replaced it.

WARNING: If the Stop Engine warning lampilluminates, it means you have a serious enginesystem problem. This should be considered anemergency. You should stop the vehicle as safelyas possible and turn OFF the ignition. The vehiclemust be serviced and the problem correctedbefore driving again. Failure to comply may resultin death, personal injury, equipment or propertydamage.

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DPF RegenerationCarefully read the following instructionsto regenerate the DPF. If you have anyproblems or difficulties contact yournearest authorized PACCAR dealer forassistance.

The ATS requires conditions typicallyfound in highway driving to regeneratethe DPF. If the DPF warning lamp isilluminated, the easiest option is toassist the ATS by proceeding to thenearest highway.

• Select a highway that has a postedlegal speed of more than 35 mph.

• Drive your vehicle until the DPFlamp goes off. This may take 30 -45 minutes of speeds greater than20 mph (32 kph).

If your operation or planned route inthe immediate future limits your abilityto reach highway speeds, proceedto the next section titled ParkedRegeneration.

Parked Regeneration

In very limited applications oroperations the DPF must beregenerated by initiating a ParkedRegeneration. Follow these sevensteps to initiate a Parked Regeneration:

1. Pull the vehicle over to a safelocation.

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

3. Maintain a minimum of 5 feetof clearance to any combustiblematerials from the edge and topof the vehicle.

WARNING: Parking thevehicle too close to anycombustible materials orvapors may start a fire,ignite an explosion orburn someone standingclose by. Before pushingthe Regeneration switchon the dash, walk around

your vehicle and ensureyou have at least five(5) feet clearance fromthe sides and top ofyour vehicle to anycombustibles. Ensure noone is in the immediatevicinity to the tailpipe.Failure to comply couldignite a fire or cause anexplosion, resulting indeath, personal injury,equipment or propertydamage.

WARNING: Never initiatea regeneration in a closedbuilding or enclosure.Always park your vehicleoutside and ensure noone is in the immediatevicinity. Failure to complycould ignite a fire or causean explosion, resultingin death, personal injury,

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equipment or propertydamage.

NOTE: Typical operationareas or materials that cancontain explosive vapors,flammable materials orpeople in close proximity ofthe vehicle are:

• Fuel depots

• Grain elevators

• Dry grass, leaves ortrees

• Transfer refusestations/dumps

• Parking lots

• Load/unload terminals

NOTE: While the listabove may appearcomprehensive, it is yourresponsibility to take thenecessary precautionsand be aware of your

surroundings and ensurethat no combustibles(materials or vapors) orbystanders are closeby before initiating aregeneration.

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

° Parking brake is applied / set

° Engine is at low idle

° DPF warning lamp isilluminated or flashing

° Coolant is at operatingtemperature

° No throttle, brake or clutchapplied

° PTO is disengaged

° Transmission is in neutral

° Cruise control switch is off

° Engine brake switch is off

5. Get out and walk all aroundvehicle to ensure that the vehicleis at least 5 feet away from allcombustible materials and no oneis in the immediate vicinity.

6. Climb back into the vehicle.

7. Push the Regeneration (START)Switch located on the dash for atleast 4 - 8 seconds to initiate aParked Regeneration.

Regeneration Switch

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NOTE: Acknowledgmentthat a Parked Regenerationhas initiated will vary byengine. The most predominantacknowledgement to you will bean increase in engine RPM andoverall engine noise.

NOTE: A Parked Regenerationmay take 30 or more secondsto initiate as the ATS systemconducts various self-checksto verify all the systemrequirements have beenmet.

If you are unable to initiate aParked regeneration and the DPFwarning lamp is illuminated, contactyour nearest PACCAR dealer forassistance.

Stop an Automatic or ParkedRegeneration

NOTE: The information in thissection only applies to vehiclesequipped with a three-positionEngine Regeneration Switchwith a STOP position.

If an Automatic or Parked Regenerationis in process and you want theregeneration to stop, OR you want toprevent a regeneration from occurring,your vehicle is equipped with a switchthat can STOP an Automatic or ParkedRegeneration. Since AutomaticRegenerations can occur at any time,you must depress the STOP portionof the Regeneration Switch ANYTIMEyou plan to drive your vehicle intoa building, enclosure or area wherethe activation of a regeneration is notallowed. If the regeneration does notstop, turn the vehicle ignition OFF.

WARNING: Never allow anAutomatic regeneration toautomatically start whileinside a building such asa service bay, shop orbuilding of any kind. Anytime you are parking yourvehicle inside a building orenclosure, ALWAYS press theRegeneration (STOP) switchprior to entering the building.Failure to comply could ignitea fire or cause an explosion,resulting in death, personalinjury, equipment or propertydamage.

WARNING: Never initiate aParked Regeneration in aclosed building or enclosure.Always park your vehicleoutside. Failure to complycould ignite a fire or cause anexplosion, resulting in death,personal injury, equipment orproperty damage.

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WARNING: If you operatein environments thatcontain explosive vaporsor flammable materials,look to see if yourvehicle’s RegenerationSwitch is equipped witha STOP function. TheSTOP function must beactivated prior to enteringthe above environment(s)to prevent automatic engineregeneration from occurring,which could cause anexplosion or fire. Failure toequip your vehicle with theproper switch (function) orfailing to activate the STOPfunction before entering acombustible environmentmay cause an explosion orfire that could lead to death,personal injury, equipment orproperty damage.

NOTE: To obtain a RegenerationSwitch with a STOP function,contact an authorized PACCARdealer to obtain the properswitch and reprogramming ofyour engine’s ECU.

Idling in FreezingTemperatures

Idling the engine for 3 or more hoursin freezing temperatures causes thebuild up of soot and moisture in theDPF. Extra heat is required to oxidizethe soot and moisture by using thefollowing methods:

• DPF Regeneration:If the DPF Lamp turns on followthe instructions described under "DPF Regeneration on page 3-11 ".

NOTE: If you ignore thewarning lamp and do notinitiate regeneration at thesoonest, safest possibletime, the DPF will becomeincreasingly clogged withsoot and can lead to engineshutdown.

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• PACCAR PX-6 and PX-8 Enginesand Cummins ISL Engine:Regardless if the DPF lamp ison or off, the engine speed willautomatically increase to 1000to 1100 RPM and remain at thisspeed for 10 minutes.If necessary, the RPMs canbe lowered by depressing thethrottle, clutch, or brake pedal.If the engine continues to idle,the aftertreatment system will tryagain to raise the idle speed untilthe aftertreatment temperaturesare suitable.

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Selective Catalytic Reduction (SCR) System

Selective CatalyticReduction (SCR) System

Introduction

The SCR system consists of a DieselEmissions Fluid (DEF) Doser anda SCR Catalyst. The DEF Dosersprays a small amount of DEF into theexhaust. The SCR catalyst reacts withthe DEF to break down the NitrogenOxides (NOx) in the exhaust intonitrogen and water vapor.

Diesel Exhaust Fluid (DEF) Gauge

1 DEF Symbol

2 DEFWarning Lamp

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

The DEF warning lamp will illuminatefor the following 3 reasons:

1. DEF Level Warning: To warnyou to refill the DEF tank. There

are 4 stages to this warning (seeDEF Level Warning table on page3-18).

CAUTION: If the DEFwarning lamp turns ondue to the DEF level, refillthe DEF tank. Failureto refill may cause theengine to derate and limitvehicle speed.

2. DEF Quality: If the enginedetects that DEF quality is belowacceptable levels. There are 3stages to these warnings (seeDEF Quality Warning table onpage 3-19).

CAUTION: If the DEFwarning lamp turns ondue to DEF Quality, seeContamination/IncorrectFluid on page 6-11 forcorrective action. Failureto correct may cause the

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engine to derate and limitvehicle speed.

3. SCR System Tampering: to warnyou if the engine system detectsfailures that may be the result oftampering with the SCR system.There are 3 stages to this warning(see SCR System TamperingWarning table on page 3-20).

CAUTION: If the DEFwarning lamp turns ondue to System Tampering,see your authorizedPACCAR dealer to havethis repaired. Failureto repair the systemmay cause the engine toderate and limit vehiclespeed.

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DEF Level Warning

WarningLevel Warnings Indicators Condition Effect on Engine

0 None DEF Level greaterthan 10% (1/8 tank) None

1DEF Warning Lamp on

DEF Level at 10%(1/8 tank) None

2DEF Warning Lamp

flashing

DEF Level betweenempty and 10%

(1/8 tank)None

3 DEF Warning Lampflashing

Check Engine Lampon

DEF Levelalmost empty

Engine powerderated


Check Engine Lampon

Malfunction IndicatorLamp (MIL) on

(Not on MX engine)

Stop Engine Lampmay be on

DEF Level empty

Engine powerderated and/orvehicle speedsignificantlylimited

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DEF Quality


0 None No Quality Issue None

1 DEF Warning Lampon

(MX engine only)

Check Engine Lampon

(Not on ISX Engine)


(May not apply to allengines)

Quality IssueDetected None


(MX engine only)

Check Engine Lampon

MILon


Detected+ 1 hour

Engine powerderated


(MX engine only)

Check Engine Lampon

MILon



Detected+ 3 hours


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SCR Component Failure


0 None NoIssue None

1 DEF Warning Lampon

(MX engine only)

Check Engine Lampon



FailureDetected None


(MX engine only)

Check Engine Lampon

MILon


Detected+ 1 hour

Engine powerderated


(MX engine only)

Check Engine Lampon

MILon



Detected+ 5 hours


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INFORMATION

InformationIntroduction . . . . . . . . . . . . . . 6-3Tampering with Aftertreatment System . . . 6-4

Diesel Particulate Filter (DPF) SystemOverview . . . . . . . . . . . . . . . 6-5

Selective Catalytic Reduction (SCR) SystemOverview . . . . . . . . . . . . . . . 6-7Diesel Exhaust Fluid (DEF)Recommendations and Specifications . . 6-8

Storage . . . . . . . . . . . . . . . . 6-9Handling . . . . . . . . . . . . . . . 6-10Disposal . . . . . . . . . . . . . . . 6-11Contamination/Incorrect Fluid. . . . . . 6-11Freezing . . . . . . . . . . . . . . . 6-12

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Information

Information

Introduction

The Aftertreatment System (ATS)on your vehicle is made up of twosystems:

1. Diesel Particulate Filter (DPF)System

2. Selective Catalytic Reduction(SCR) System

They fulfill two primary functions;particulate reduction & nitrogen oxide(NOx) reduction.

This section of the manual providesmore detailed information aboutthe aftertreatment process and itscomponents.

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Information

Tampering withAftertreatment System

The aftertreatment system for yourvehicle as installed from the factorywas specifically designed to meet theemissions requirements of the USEnvironmental Protection Agency andCalifornia Air Resources Board. Anychanges of component locations ormodifications of any aftertreatmentsystem components may reduce theemission effectiveness and you maybe subject to fines under the UnitedStates Clean Air Act.

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Diesel Particulate Filter(DPF) System

OverviewThe DPF system consists of aHydrocarbon (HC) Doser (maynot apply to all engines), a DieselOxidation Catalyst (DOC), and a DPF.

The components of the DPF systemperform the following functions:

• The ATS inlet and outlet adaptthe vehicle exhaust piping to theATS,and also provide a mountinglocation for the aftertreatment gastemperature sensors.

• The DPF differential pressuresensor measures the restrictionacross the DPF.

• The DPF filters soot out of theexhaust.

• When activated the HC Dosersprays a small amount of diesel

fuel (the HC) into the exhaust. Thecatalyst in the DOC reacts withthe HC to generate heat. The heatis used to clean (regenerate) theDPF by reducing the trapped sootto ash.

• Soot is composed of the partiallyburned particles of fuel that occurduring normal engine operation(black smoke).

• Over time, both soot and ashaccumulate in the DPF and mustbe removed. Soot is removed bya process called regeneration.Ash is removed by removing theDPF and cleaning it at specifiedintervals.

• A vehicle with a DPF has up totwo additional indicator lamps onthe dashboard. The two additionallamps, along with the checkengine lamp, alert the operator ofthe status of the DPF.

CAUTION: Do not submergeor allowwater to enter the DPFassembly. Components of theassembly can be damagedand effect the performanceof the aftertreatment system.Failure to comply may resultin equipment or propertydamage.

NOTE: Refer to your enginemanufacturer’s Operator’sManual for diesel particulatefilter (DPF) maintenanceinformation.

NOTE: Refer to your vehicleor engine manufacturer’sOperator’s Manual for additionalinformation on the engineindicator lamps.

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NOTE: Ultra low sulfur diesel(ULSD) fuel is required forengines equipped with anaftertreatment diesel particulatefilter. If ULSD is not used,the engine may not meetemissions regulations, and theDPF or aftertreatment dieseloxidation catalyst (DOC) can bedamaged.

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Selective CatalyticReduction (SCR) System

Overview

The SCR system is composed ofseveral main components:

1. Diesel Emissions Fluid (DEF)Controller

2. DEF Dosing Unit (DEF Module)

3. DEF Dosing Valve

4. SCR Catalyst

NOTE: It is unlawful to tamperwith, modify, or remove anycomponent of the SCR system.It is also unlawful to useDEF that does not meet thespecifications provided or tooperate the vehicle/equipmentwith no DEF.

DEF is required for an engine equippedwith a SCR system. DEF is a fluid that

is sprayed into the exhaust gas prior tothe SCR catalyst. The DEF vaporizesand decomposes to form carbondioxide and ammonia. The ammoniareacts with the NOx emissions over theaftertreatment SCR catalyst to formnitrogen and water.

DEF:

• may have a slight ammonia smell

• is colorless

• is non-toxic and non-polluting

• is non-flammable

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Diesel Exhaust Fluid (DEF)Recommendations andSpecifications

WARNING: It is unlawfulto tamper with or removeany component of theaftertreatment system. It isalso unlawful to use a DieselExhaust Fluid (DEF) that doesnot meet the specificationsprovided or to operate thevehicle/equipment with noDiesel Exhaust Fluid (DEF).

WARNING: Diesel ExhaustFluid (DEF) contains urea.Do not get the substance inyour eyes. In case of contact,immediately flush eyes withlarge amounts of water fora minimum of 15 minutes.Do not swallow internally. Inthe event the diesel exhaustfluid is ingested, contact

a physician immediately.Reference the MaterialsSafety Data Sheet (MSDS) foradditional information.

CAUTION: Never attempt tocreate Diesel Exhaust Fluid(DEF) by mixing agriculturalgrade urea with water.Agricultural grade urea doesnot meet the necessaryspecifications required andthe aftertreatment systemmay be damaged.

CAUTION: PACCAR Increquires the use of DEFmeeting ISO 22241-1. Thereis NO acceptable substitute.Failure to use the correct DEFmay cause engine damageand/or void the warranty.

NOTE: Some locations mayreference the DIN 70070standard. DEF specification

limits of this standard areidentical to ISO 22241-1.

PACCAR Inc is not responsible forfailures or damage resulting fromwhat PACCAR Inc determines to beabuse or neglect, including but notlimited to: operation without correctlyspecified DEF; lack of maintenanceof aftertreatment; improper storage,or shutdown practices; unauthorizedmodifications of the engine andaftertreatment. PACCAR is also notresponsible for failures caused byincorrect DEF or by water, dirt or othercontaminants in the DEF. Refer toyour engine and vehicle operator’smanuals for maintenance, storage,and shutdown information.

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

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NOTE: To ensure the correctDEF is used, PACCAR Increcommends the use of TRPCleanBlue Diesel Exhaust Fluidwhich is available in differentquantity options from small tobulk containers.

• DEF is readily available at truckstops and at all PACCAR Enginedealers. For assistance locatingDEF contact your local PACCARauthorized repair location.

• If your vehicle is out of DEFand you are unable to locate asource to purchase DEF, please

contact the vehicle OEM customercare center at the telephonenumber provided in the vehicleoperator’s manual. The vehicleOEM customer care center will beable to contact the nearest dealerlocation to you and arrange for anemergency shipment of DEF toyour location 24 hours a day.

The following are other commonnames used for Diesel Exhaust Fluid(DEF):

• AUS 32 (Aqueous Urea Solution32)

• AdBlue

• NOx Reduction Agent

• Catalyst Solution

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

Storage

NOTE: The following informationis for reference and is to beused as a guideline only.There are many factors thatdetermine Diesel ExhaustFluid (DEF) shelf life, withtemperature and duration beingtwo of the major determiningcontributors. If in doubt,replace the fluid with knownquality DEF. DEF has a limitedshelf life, both in the vehicle’sdiesel exhaust fluid tank andin storage/bulk/transportationcontainers.

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

• Storage temperature between23°F and 77°F (-5°C and 25°C)

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• Store in sealed containers to avoidcontamination

• Avoid direct sunlight

In these conditions, Diesel ExhaustFluid (DEF) has a minimum expectedshelf life of 18 months. If stored athigher temperatures for extendedperiods of time, the shelf life willbe reduced by approximately 6months for every 5°C (9°F) abovethe highest storage temperaturelisted above. Long term storage in avehicle (in excess of 6 months) is notrecommended.

NOTE: To assist in preventingDEF from deteriorating whenstored in the vehicle’s DEFtank, locate and plug thetank’s venting to seal the tankexposure to the atmosphere.

Handling

CAUTION: If Diesel ExhaustFluid (DEF) is spilled onmetal surfaces (for examplethe steps, fuel tanks or grabhandles) rinse and cleanimmediately with water.Failure to do so may leavepermanent corrosive stainson the metal surfaces whichcan not be removed.

• Make sure to only use approvedcontainers to transport andstore DEF. Containers made ofpolyethylene and polypropyleneare recommended.

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

• Avoid prolonged contact with skin.In case of contact, wash withimmediately with soap and water.If not washed immediately, whenthe DEF dries, a white film will be

left that can be more difficult towash off.

NOTE: Spilled DEF if left todry or wiped away with a clothonly will leave a white residue.Failure to clean the spilled DEFmay result in an incorrectlydiagnosed leak of the DEFDosing system.

Before using containers, funnels,etc. that will be used to dispense,handle or store DEF, make sureto wash thoroughly to remove anycontaminants and then rinse withdistilled water.

NOTE: Do not use tap water torinse components that will beused to deliver diesel exhaustfluid. Tap water will contaminatethe DEF. If distilled water is notavailable, rinse with tap waterand then rinse with DEF.

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6


Disposal

If disposing of Diesel Exhaust Fluid(DEF), always check with the localauthority regulations on properdisposing process and requirements.

Contamination/IncorrectFluid

CAUTION: Never add water orany other fluid besides whatis specified to the DEF tank.The aftertreatment systemmay be damaged.

In the event that the incorrect fluidis added to the Diesel Exhaust Fluidtank, such as, but not limited to:

• Water

• Diesel Fuel

• Hydraulic Fluid

• Coolant

• Windshield Washer Fluid

Contact a local PACCAR AuthorizedRepair location to determine theappropriate repair direction. If onlywater has been added to the DEF tank,drain the DEF tank, flush with distilledwater and refill with new and/or knowngood DEF.

6-11

6


Freezing

CAUTION: The Diesel ExhaustFluid (DEF) system purgesto prevent damage fromfreezing. If your vehicleis equipped with batterydisconnect switches doNOT disconnect batterypower within two minutes ofswitching the ignition keyoff. Failure to comply mayresult in vehicle or propertydamage.

CAUTION: Do NOT add anychemicals/additives to theDiesel Exhaust Fluid (DEF) inan effort to prevent freezing.If chemicals/additives areadded to the DEF, theaftertreatment system may bedamaged.

DEF will freeze around -12°C (11°F).The DEF system on the vehicle isdesigned to accommodate this anddoes not require any intervention.

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6

Index

Index

AAbout This Manual 1-3Aftertreatment Information

aftertreatment inlet and outlet 6-5alternate DEF names 6-9contamination or incorrectfluid 6-11DEF controller 6-7DEF dosing unit 6-7DEF dosing valve 6-7DEF Module 6-7diesel oxidation catalyst 6-5diesel particulate filter 6-5diesel particulate filter (DPF)differential pressure sensor 6-5freezing 6-12indicator lamps 6-5recommendations andspecifications 6-8regeneration 6-5SCR catalyst 6-7

selective catalytic reduction(SCR) 6-7soot 6-5storage, handling and disposal 6-8ultra low sulfur diesel (ULSD)fuel 6-6

Aftertreatment System (ATS) 3-3, 6-3diesel particulate filter (DPF)system 3-4, 6-5

Aftertreatment System DescriptionDPF regeneration 3-11functionality / notificationinformation 3-6high exhaust systemtemperature 3-8notification that regeneration isrequired 3-9parked regeneration 3-11regeneration (START) switch 3-12stopping an automatic or parkedregeneration 3-13

Aftertreatment System Tampering 6-4Aftertreatment System WarningLamps 3-6diesel particulate filter (DPF)warning lamp symbol 3-6high exhaust system temperature(HEST) warning lamp symbol 3-6

Automatic Regeneration 3-4

CCaution 1-5Cleaning 3-4, 6-5Consumer information 6-3Contamination/Incorrect Fluid 6-11Controlling the RegenerationProcess 3-4regeneration switch(three-position) 3-5regeneration switch(two-position) 3-5warning lamps 3-6

Index-1

7

Index

Controlsaftertreatment system (ATS) 3-3controlling the regenerationprocess 3-4DEF level warning table 3-18DEF quality 3-19diesel particulate filter (DPF)system 3-4DPF regeneration 3-11functionality / notificationinformation 3-6high exhaust systemtemperature 3-8notification that regeneration isrequired 3-9parked regeneration 3-11regeneration (START) switch 3-12regeneration switch(three-position) 3-5regeneration switch(two-position) 3-5SCR component failure 3-20SCR system 3-16stopping an automatic or parkedregeneration 3-13

three-position regenerationswitch 3-4two-position regenerationswitch 3-4warning lamps 3-6

DDEF Level Warning Table 3-18DEF Quality 3-19Diesel Exhaust Fluid

alternate DEF names 6-9contamination or incorrectfluid 6-11disposal 6-11freezing 6-12handling 6-10recommendations andspecifications 6-8storage 6-9

Diesel Exhaust Fluid (DEF)Gauge 3-16

Diesel Exhaust Fluid (DEF)Recommendations andSpecifications 6-8

Diesel Particulate Filter (DPF)System 3-3, 3-4, 6-5diesel oxidation catalyst (DOC) 3-4DPF 3-4hydrocarbon (HC) doser 3-4

Diesel Particulate Filter (DPF) WarningLamp Symbol 3-6

Disposaldiesel exhaust fluid 6-11

Doser 3-16Doser 3-4, 6-5DPF Regeneration 3-11

FFreezing 6-12Functionality / NotificationInformation 3-6

GGeneral Information 1-6

HHandling

diesel exhaust fluid 6-10

Index-2

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Index

High Exhaust System Temperature(HEST) Warning Lamp Symbo 3-6

High Exhaust System TemperatureNotification 3-8

Hydrocarbon (HC) 3-4, 6-5

IIdle 3-10Idling in Freezing Temperatures 3-14Illustrations 1-6Information

aftertreatment description 6-3

NNote 1-5Notification of High Exhaust SystemTemperature 3-8

Notification That Regeneration IsRequired 3-9

PParked Regeneration 3-11Passive Regeneration 3-6

RRegeneration (START) Switch 3-12Regeneration Is RequiredNotification 3-9

Regeneration Switchthree-position 3-5two-position 3-5

SSafety

about this manual 1-3caution example 1-5general information 1-6illustrations example 1-6introduction 1-3note example 1-5safety alerts 1-4warning example 1-4

Safety Alerts 1-4SCR Component Failure 3-20Selective Catalytic Reduction (SCR)System 3-16, 6-7diesel exhaust fluid (DEF)gauge 3-16

Soot 3-4, 6-5

Specificationsdiesel exhaust fluid (DEF) 6-8

Stop an Automatic or ParkedRegeneration 3-13

Storagediesel exhaust fluid 6-9

Switchesregeneration switch(three-position) 3-5regeneration switch(two-position) 3-5

TTampering

Aftertreatment System 6-4SCR 3-17

Three-Position RegenerationSwitch 3-5

Two-Position Regeneration Switch 3-5

WWarning 1-4

Index-3

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paccar engine aftertreatment systems-operator's manual

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