Engine Aftertreatment Systems - Operator's Manual Y53 … Manuals/Emission Manuals... · Safety SafetyAlerts Pleasereadandfollowallofthe safetyalertscontainedinthismanual. Theyarethereforyourprotection

Contents

Safety

Emergency

Controls

Driving

Maintenance

Information

Index

1

2

3

4

5

6

7

Contents

©2012 Paccar Inc - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or optional 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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1

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.

NOTEAfter you’ve read this manual, itshould be stored in the cab for con-venient reference and remain withthis truck when sold.

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 equipped

with special equipment or optionsnot 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 carry additional fuel contain-ers in your vehicle. Fuel containers,either full or empty, may leak, ex-plode, and cause or feed a fire. Donot carry extra fuel containers. Evenempty ones are dangerous. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

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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 to operate your vehi-cle with insufficient oil pressure willcause serious engine damage. Fail-ure to comply may result in equip-ment or property 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:

NOTEPumping the accelerator will not as-sist in starting the engine.

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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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1

CONTROLS

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

Diesel Particulate Filter (DPF) SystemIntroduction . . . . . . . . . . . . . . . . . . 3-4Controlling the Regeneration Process . . . . . . . 3-4Functionality / Notification Information . . . . . . . 3-7DPF Regeneration . . . . . . . . . . . . . . 3-13Stop an Automatic or Parked Regeneration. . . . 3-16Idling in Freezing Temperatures. . . . . . . . . 3-17

Selective Catalytic Reduction (SCR) SystemIntroduction . . . . . . . . . . . . . . . . . 3-18

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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 6-3 of this

manual for more detailed informationabout the aftertreatment process andits components.

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3

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 3-13.

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 3-16.

WARNING!

If you operate in environmentsthat contain explosive vapors orflammable materials, look to see ifyour vehicle’s Regeneration Switchis equipped with a STOP function.The STOP function must be acti-vated prior to entering the aboveenvironment(s) to prevent automaticengine regeneration from occurring,which could cause an explosion orfire. Failure to equip your vehiclewith the proper switch (function) orfailing to activate the STOP functionbefore entering a combustible en-vironment may cause an explosionor fire that could lead to death, per-sonal injury, equipment or propertydamage.

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NOTETo obtain a Regeneration Switchwith a STOP function, contact yournearest authorized PACCAR dealerto obtain the proper switch and re-programming of your engine’s ECU.

Two-Position Regeneration Switch

Two-Position Regeneration Switch

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

NOTERefer to DPF Regeneration on page3-13 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.

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NOTEParked regeneration requires thatyour vehicle is stopped with theparking brake set. See Parked Re-generation on page 3-13 for details.

Center (three-position switch only)

NOTEDuring normal vehicle driving, theRegeneration Switchmust be in theCENTER position.

CENTER is the normal position ofthe switch. Unless you are manuallyinitiating a Parked Regeneration orintentionally stopping a regeneration,the switch should be in this position.Placing the switch in the CENTERposition will allow an AutomaticRegeneration to occur if conditionsallow.

Stop (three-position switch only)

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

CAUTION

Do not leave the switch in the STOPposition unless you need to cancelor stop a regeneration. Running theengine with the switch in the STOPposition will result in increased sootlevels in the DPF and could eventu-ally cause 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

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Functionality / NotificationInformation

The ATS will regenerate the DPF byusing hot exhaust gases normallygenerated by the engine. This typicallyoccurs during highway operation(known as Passive Regeneration) andis transparent to the operation of thevehicle.

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 lasts30 minutes. During and shortly afterthe event, the exhaust gases fromthe DPF may reach temperatures inexcess of 650° C (1202° F). See theinformation in the following table onprobable causes and recommended

actions related to the warning lampsand indicator symbols 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, warninglamps and indicator symbols will alertthe operator to take action. Theoperator should be aware of whetherthe lamps are on unaccompanied 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

NOTIFICATION OF HIGH EXHAUST SYSTEM TEMPERATUREWarning

Indicator Condition Operator Actions

HEST lamp on

Any one or combination of these conditions:• Exhaust outlet temperature is elevated above normal (at least 450° C /

842° F) and vehicle slows below 8 kph / 5 mph.• Normal driving but engine is under heavy loading.• Automatic Regeneration in process• Parked Regeneration in process

Follow all warnings listed below. Use the DISABLEfunction of the Regeneration Switch if the situationrequires. Follow the instructions described underStop an Automatic or Parked Regeneration onpage 3-16.

WARNING!

Temperature of the tail pipe, exhaust pipe, diesel particular filter (DPF), selective catalytic reduction (SCR) device andsurrounding components including enclosures and steps, will be elevated during and shortly after a regeneration event ornormal vehicle operation when engine is under high or heavy loading. If the High Exhaust System Temperature (HEST)

warning lamp is on:• Do not park in an area of combustible vapors or materials. You must keep combustibles at least 1.5 m (5 ft) away from the exhaust

(outlet) stream (as it exits the tail pipe) while the HEST lamp is illuminated. Always park your vehicle outside. Failure to do so couldignite an explosion or harm bystanders which could result in serious injury.

• Do not park in an area where people are close by. You must keep combustibles at least 1.5 m (5 ft) away from the exhaust outlet while theHEST lamp is illuminated. Failure to do so could result in serious injury.

• Temperature of the tail pipe, exhaust pipes, diesel particular filter (DPF), selective catalytic reduction (SCR) device and surroundingcomponents including enclosures and steps becomes elevated during engine 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 surrounding

components.

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Notification Regeneration is Required

NOTIFICATION REGENERATION IS REQUIREDWarningLevel

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 3-13.

NOTEIf you ignore the warning lamp and do not initi-ate regeneration at the soonest, safest possibletime, the DPF will become increasingly cloggedwith soot and can lead to severe engine derate.

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 3-13.

CAUTION

If you do not initiate regeneration after the DPFwarning lamp begins to flash, you only have a shorttime before the Check Engine lamp will illuminateand the engine will go into a protection mode andderate power.

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3

DPF lamp flashes

Check Engine lamp on

The soot level in the DPF continuesto stay above the desired level andrequires regeneration.The engine power will derate.

Regenerate the DPF immediately. Follow the instructionsdescribed under DPF Regeneration on page 3-13 for PACCARMX engines, Parked Regeneration on page 3-13 for PACCARPX and Cummins engines.

CAUTION

If you do not initiate regeneration after the DPFwarning lamp begins to flash and the Check En-gine lamp is on, you only have a short time beforethe Stop Engine lamp will illuminate and the en-gine power will derate severely. No regenerationwill be allowed at the next stage.

NOTEUnder some conditions after prolonged stationaryidling, a Parked Regeneration may be requiredwithout a Level 1 or Level 2 warning.

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4

DPF lamp flashes (MX engineonly)

Check Engine lamp on (MXengine only)

Stop Engine lamp on

Dash chime will sound

The soot level in the DPF is now at fullcapacity.Engine power derates (decrease ratedepends on engine make)

NOTEThe engine derate sequenceis engine specific; therefore, tolearn how this system workson your vehicle, refer to theEngine Manufacturer's Opera-tion and Maintenance Manualsupplied with your vehicle.

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

WARNING!

If the Stop Engine warning lamp illuminates, itmeans you have a serious engine system prob-lem. This should be considered an emergency.You should stop the vehicle as safely as possibleand turn OFF the ignition. The vehicle must beserviced and the problem corrected before drivingagain. Failure to comply may result in death,personal injury, equipment or property damage.

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Quick Reference Guide

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DPF Regeneration

Carefully 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 56 kph(35 mph).

• Drive your vehicle until the DPFlamp goes off. This may take 30 -45 minutes of speeds greater than32 kph (20 mph).

If your operation or planned route inthe immediate future limits your abilityto reach highway speeds, proceed

to 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 of the tail pipe.

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

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WARNING!

Parking the vehicle too close to anycombustible materials or vaporsmay start a fire, ignite an explosionor burn someone standing close by.Before pushing the RegenerationSwitch on the dash, walk aroundyour vehicle and ensure you haveat least 1.5 m (5 ft) clearance fromthe sides and top of your vehicle toany combustibles. Ensure no oneis in the immediate vicinity of thetail pipe. Failure to comply couldignite a fire or cause an explosion,resulting in death, personal injury,equipment or property damage.

WARNING!

Never initiate a regeneration in aclosed building or enclosure. Al-ways park your vehicle outside andensure no one is in the immediatevicinity. Failure to comply could ig-nite a fire or cause an explosion,resulting in death, personal injury,equipment or property damage.

NOTETypical operation areas or materi-als that can contain explosive va-pors, flammable materials or peoplein close proximity of the vehicle are:

• Fuel depots

• Grain elevators

• Dry grass, leaves or trees

• Transfer refuse stations/dumps

• Parking lots

• Load/unload terminals

NOTEWhile the list above may appearcomprehensive, it is your respon-sibility to take the necessary pre-cautions and be aware of yoursurroundings and ensure that nocombustibles (materials or vapors)or bystanders are close by beforeinitiating a regeneration.

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

° Parking brake is applied / set

° Engine is at low idle

° DPF warning lamp isilluminated or flashing

° Coolant is at operatingtemperature

° No throttle

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° PTO is disengaged

° Transmission is in neutral

° Cruise control switch is off

5. Get out and walk all around vehicleto ensure that the vehicle is atleast 1.5 m (5 ft) away from allcombustible materials and no oneis in the immediate vicinity.

6. Climb back into the vehicle.

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

° After regeneration starts if anyof the conditions (in step 4)change or become activatedregeneration will automaticallyshut off.

Regeneration Switch

NOTEAcknowledgment that a Parked Re-generation has initiated will vary byengine. The most predominant ac-knowledgement to you will be an in-crease in engine RPM and overallengine noise.

NOTEA Parked Regeneration may take 30or more seconds to initiate as theATS system conducts various self-checks to verify all the system re-quirements have been met.

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

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Stop an Automatic or ParkedRegeneration

NOTEThe information in this section onlyapplies to vehicles equipped with athree-position Engine RegenerationSwitch with 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 an Automatic Regen-eration to automatically start whileinside a building such as a servicebay, shop or building of any kind.Anytime you are parking your vehi-cle inside a building or enclosure,ALWAYS press the Regeneration(STOP) Switch prior to entering thebuilding. Failure to comply couldignite a fire or cause an explosion,resulting in death, personal injury,equipment or property damage.

WARNING!

Never initiate a Parked Regenera-tion in a closed building or enclo-sure. Always park your vehicle out-side. Failure to comply could ignite afire or cause an explosion, resultingin death, personal injury, equipmentor property damage.

WARNING!

If you operate in environmentsthat contain explosive vapors orflammable materials, look to see ifyour vehicle’s Regeneration Switchis equipped with a STOP function.The STOP function must be acti-vated prior to entering the aboveenvironment(s) to prevent automaticengine regeneration from occurring,which could cause an explosion orfire. Failure to equip your vehiclewith the proper switch (function) orfailing to activate the STOP functionbefore entering a combustible en-vironment may cause an explosionor fire that could lead to death, per-sonal injury, equipment or propertydamage.

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NOTETo obtain a Regeneration Switchwith a STOP function, contact an au-thorized PACCAR dealer to obtainthe proper switch and reprogram-ming of your 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 underDPF Regeneration on page 3-13.

NOTEIf you ignore the warning lampand do not initiate regeneration atthe soonest, safest possible time,the DPF will become increasinglyclogged with soot and can lead toengine shutdown.

• PACCAR PX-7 and PX-9 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 to performan automated DPF cleaning.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 DieselExhaust Fluid (DEF) Doser and a SCRCatalyst. The DEF Doser sprays asmall amount of DEF into the exhaust.The SCR Catalyst reacts with the DEFto break down the Nitrogen Oxides(NOx) in the exhaust into nitrogen andwater 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 warn youto refill the DEF tank. The warninglamp will turn on when the gaugeneedle is near or in the red zone.There are 4 stages to this warning.

CAUTION

If the DEF warning lamp turns ondue to the DEF level, refill the DEFtank. Failure to refill may cause theengine to derate and limit vehiclespeed.

2. DEF Quality: The enginedetects that DEF quality is belowacceptable levels. The gaugeneedle is in the upper region,indicating there is fluid, but thequality is poor. There are 3 stagesto these warnings.

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CAUTION

If the DEF warning lamp turns ondue to DEF Quality, see Contamina-tion/Incorrect Fluid for corrective ac-tion. Failure to correct may causethe engine to derate and limit vehi-cle speed.

3. SCR System Tampering: To warnyou when the engine systemdetects failures that may be theresult of tampering with the SCRsystem. The gauge needle isin the upper region, indicatingthere is fluid, but system failure isdetected. There are 3 stages tothis warning.

CAUTION

If the DEF warning lamp turns ondue to System Tampering, see yourauthorized PACCAR dealer to havethis repaired. Failure to repair thesystem may cause the engine to de-rate and limit vehicle speed.

System Status Non-Emergency Vehicles Emergency VehiclesDEF Level Warning See table on page 3-20. See table on page 3-23.DEF Quality (except PX) See table on page 3-21. See table on page 3-24.SCR System Tampering See table on page 3-22. See table on page 3-25.

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DEF Level Warning – Non-Emergency Vehicles

DEF LEVEL WARNING – NON-EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on Engine

0 None DEF Level sufficient None

1DEF Warning Lamp on

DEF Level fallenbelow initial warning None

2DEF Warning Lamp

flashing

DEF Level fallenbelow critical

warningNone

3DEF Warning Lamp

flashingCheck Engine Lamp

on

DEF Level empty Engine powerderated

4DEF Warning Lamp


onMalfunction IndicatorLamp (MIL) on (Not on

MX engine)

Stop Engine Lampmay be on

DEF level emptyand either enginehas been shut downor a fuel re-fill has

occurred

Engine powerderated and /or vehicle speedsignificantly limited

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DEF Quality – Non-Emergency Vehicles

DEF QUALITY – NON-EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on

Engine

0 None No QualityIssue None


(MX engine only)Check Engine Lamp on

(Not on ISX Engine)Malfunction Indicator Lamp(MIL) on (May not apply to

all engines)

QualityIssueDetected

None

2DEF Warning Lampflashing (MX engine only)

Check Engine Lamp on MIL on (May not apply to allengines)

Detected +1 hour

Engine powerderated 25%



Detected +2 hours

Engine powerderated 40%,additional 1%per minute



Stop Engine Lamp maybe on

Detected +3 hours

Engine powerderatedand / orvehicle speedreduced to 8kph (5 mph)

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SCR Component Failure – Non-Emergency Vehicles

SCR COMPONENT FAILURE – NON-EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on

Engine0 None No Issue None

1DEF Warning Lamp on (MX

engine only)Check Engine Lamp on Malfunction Indicator

Lamp (MIL) on (May notapply to all engines)

FailureDetected None

2DEF Warning Lamp flashing

(MX engine only)Check Engine Lamp on MIL on (May not apply

to all engines)

Detected + 1hour

Engine powerderated

3DEF Warning Lamp flashing

(MX engine only)Check Engine Lamp on MIL on (May not apply

to all engines)Stop Engine Lamp

may be on

Detected + 5hours

Engine powerderatedand / orvehicle speedsignificantly

limited

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DEF Level Warning – Emergency Vehicles

DEF LEVEL WARNING – EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on Engine

0 None DEF Level Sufficient None


DEF Level fallenbelow initial warning None

2DEF Warning Lamp

flashing

DEF Level fallenbelow critical

warningNone

3DEF Warning Lamp


on

DEF Level less than5%

Vehicle speedlimited to 88 kph

(55 mph)

4DEF Warning Lamp


onMalfunction Indicator

Lamp (MIL) onStop Engine Lamp

may be on

DEF Level emptyand vehicle hasbeen shut down


(25 mph)

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DEF Quality – Emergency Vehicles

DEF QUALITY – EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on Engine

0 None No DEF QualityIssue None


(MX engine only)Check Engine Lampon (Not on ISX Engine)

MIL on (May not applyto all engines)

Quality IssueDetected None

2DEF Warning Lampflashing (MX engine

only)

Check Engine Lampon


Detected + 10 hoursVehicle speedlimited to 88 kph

(55 mph)


only)

Check Engine Lampon


Stop Engine Lamp maybe on

Detected + 20 hoursand the engine hasbeen shut down


(25 mph)

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SCR Component Failure – Emergency Vehicles

SCR COMPONENT FAILURE – EMERGENCY VEHICLESWarningLevel Warnings Indicators Condition Effect on Engine

0 None No Issue None

1 DEF Warning Lamp on(MX engine only)

Check Engine Lampon

Malfunction IndicatorLamp (MIL) on (Maynot apply to all

engines)

Failure Detected None


only)

Check Engine Lampon


Detected + 10 hoursVehicle speedlimited to 88 kph

(55 mph)


only)

Check Engine Lampon


Stop Engine Lampmay be on

Detected + 40 hoursand the engine hasbeen shut down


(25 mph)

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3

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 andSpecifications . . . . . . . . . . . . . . . . 6-8

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

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6

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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6

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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6


Diesel Particulate Filter(DPF) System

Overview

The 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 dieselfuel (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 check

engine lamp, alert the operator ofthe status of the DPF.

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CAUTIONDo not submerge or allow water toenter the DPF assembly. Compo-nents of the assembly can be dam-aged and effect the performance ofthe aftertreatment system. Failure tocomply may result in equipment orproperty damage.

NOTERefer to your engine manufacturer’sOperator’s Manual for diesel partic-ulate filter (DPF) maintenance infor-mation.

NOTERefer to your vehicle or engine man-ufacturer’s Operator’s Manual foradditional information on the engineindicator lamps.

NOTEUltra low sulfur diesel (ULSD) fuel isrequired for engines equipped withan aftertreatment diesel particulatefilter. If ULSD is not used, the enginemay not meet emissions regula-tions, and the DPF or aftertreatmentDiesel Oxidation Catalyst (DOC)can be damaged.

6-6

6


Selective CatalyticReduction (SCR) System

Overview

The SCR system is composed ofseveral main components:

1. Diesel Exhaust Fluid (DEF)Controller (Except PX)

2. DEF Dosing Unit (DEF Module)

3. DEF Dosing Valve

4. SCR Catalyst

NOTEIt is unlawful to tamper with, modify,or remove any component of theSCR system. It is also unlawful touse DEF that does not meet thespecifications provided or to operatethe vehicle/equipment with 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 unlawful to tamper with or re-move any component of the af-tertreatment system. It is also un-lawful to use a Diesel Exhaust Fluid(DEF) that does not meet the spec-ifications provided or to operate thevehicle/equipment without DieselExhaust Fluid (DEF).

WARNING!

Diesel Exhaust Fluid (DEF) containsurea. Do not get the substancein your eyes. In case of contact,immediately flush eyes with largeamounts of water for a minimum of15 minutes. Do not swallow inter-nally. In the event the diesel exhaustfluid is ingested, contact a physicianimmediately. Reference the Mate-rials Safety Data Sheet (MSDS) foradditional information.

CAUTIONNever attempt to create Diesel Ex-haust Fluid (DEF) by mixing agricul-tural grade urea with water. Agricul-tural grade urea does not meet thenecessary specifications requiredand the aftertreatment system maybe damaged.

CAUTION

PACCAR Inc requires the use ofDEF meeting ISO 22241-1 (DIN70070) specifications. There is NOacceptable substitute. Failure to usethe correct DEF may cause enginedamage and/or void the warranty.

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NOTESome locations may reference theDIN 70070 standard. DEF specifica-tion limits of this standard are identi-cal 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).

NOTETo ensure the correct DEF is used,PACCAR Inc recommends the useof TRP® CleanBlue Diesel ExhaustFluid which is available in differentquantity options from small to bulkcontainers.

• 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, pleasecontact 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.

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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 22241-1(DIN 70070) specifications.

Storage

NOTEThe following information is for ref-erence and is to be used as a guide-line only. There are many factorsthat determine Diesel Exhaust Fluid(DEF) shelf life, with temperatureand duration being two of the majordetermining contributors. If in doubt,replace the fluid with known qualityDEF. DEF has a limited shelf life,both in the vehicle's diesel exhaustfluid tank and in storage/bulk/trans-portation containers.

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

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

• Storage in sealed containers toavoid contamination

• Avoidance of 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.

NOTETo assist in preventing DEF from de-teriorating when stored in the vehi-cle's DEF tank, locate and plug thetank's venting to seal the tank expo-sure to the atmosphere.

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Handling

CAUTION

If Diesel Exhaust Fluid (DEF) isspilled on metal surfaces (for exam-ple the steps, fuel tanks or grab han-dles) rinse and clean immediatelywith water. Failure to do so mayleave permanent corrosive stains onthe metal surfaces which can not beremoved.

• 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, a whitefilm will be left when the DEF dries

that can be more difficult to washoff.

NOTESpilled DEF, if left to dry or wipedaway with a cloth only, will leavea white residue. Failure to cleanthe spilled DEF may result in an in-correctly diagnosed 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.

NOTEDo not use tap water to rinse com-ponents that will be used to deliverdiesel exhaust fluid. Tap water willcontaminate the DEF. If distilled wa-ter is not available, rinse with tap wa-ter and then rinse with DEF.

Disposal

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

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Contamination/IncorrectFluid

CAUTION

Never add water or any other fluidbesides what is specified to the DEFtank. 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.

Freezing

CAUTION

The Diesel Exhaust Fluid (DEF) sys-tem purges to prevent damage fromfreezing. If your vehicle is equippedwith battery disconnect switches,do NOT disconnect battery powerwithin two minutes of switching theignition key off. Failure to complymay result in vehicle or propertydamage.

CAUTION

Do NOT add any chemicals/addi-tives to the Diesel Exhaust Fluid(DEF) in an effort to prevent freez-ing. If chemicals/additives areadded to the DEF, the aftertreatmentsystem may be damaged.

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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Index

Index

AAbout This Manual 1-3Aftertreatment Information

aftertreatment inlet and outlet 6-5alternate DEF names 6-10contamination or incorrectfluid 6-12DEF 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 3-13functionality / notificationinformation 3-7high exhaust systemtemperature 3-8notification regeneration isrequired 3-9parked regeneration 3-13regeneration (START) switch 3-15stopping an automatic or parkedregeneration 3-16

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 6-12Controlling the RegenerationProcess 3-4regeneration switch(three-position) 3-5regeneration switch(two-position) 3-5warning lamps 3-6

Index-1

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Index

Controlsaftertreatment system (ATS) 3-3controlling the regenerationprocess 3-4DEF level warning table –emergency vehicles 3-23DEF level warning table –non-emergency vehicles 3-20DEF quality – emergencyvehicles 3-24DEF quality – non-emergencyvehicles 3-21diesel particulate filter (DPF)system 3-4DPF regeneration 3-13functionality / notificationinformation 3-7high exhaust systemtemperature 3-8notification regeneration isrequired 3-9parked regeneration 3-13regeneration (START) switch 3-15regeneration switch(three-position) 3-5

regeneration switch(two-position) 3-5SCR component failure –emergency vehicles 3-25SCR component failure –non-emergency vehicles 3-22SCR system 3-18stopping an automatic or parkedregeneration 3-16three-position regenerationswitch 3-4two-position regenerationswitch 3-4warning lamps 3-6

DDEF Level Warning Table – EmergencyVehicles 3-23

DEF Level Warning Table –Non-Emergency Vehicles 3-20

DEF Quality – EmergencyVehicles 3-24

DEF Quality – Non-EmergencyVehicles 3-21

Diesel Exhaust Fluid

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

Diesel Exhaust Fluid (DEF)Gauge 3-18

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 3-4, 3-18Doser 6-5DPF Regeneration 3-13

Index-2

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Index

FFreezing 6-12Functionality / NotificationInformation 3-7

GGeneral Information 1-6

HHandling

diesel exhaust fluid 6-11High 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 3-17Illustrations 1-6Information

aftertreatment description 6-3

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

Notification Regeneration isRequired 3-9

PParked Regeneration 3-13Passive Regeneration 3-7

QQuick Reference Guide 3-12

RRegeneration (START) Switch 3-15Regeneration 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 – EmergencyVehicles 3-25

SCR Component Failure –Non-Emergency Vehicles 3-22

Selective Catalytic Reduction (SCR)System 3-18, 6-7diesel exhaust fluid (DEF)gauge 3-18

Soot 3-4, 6-5Specifications

diesel exhaust fluid (DEF) 6-8Stop an Automatic or ParkedRegeneration 3-16

Storagediesel exhaust fluid 6-10

Switches

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Index

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

TTampering

Aftertreatment System 6-4SCR 3-19

Three-Position RegenerationSwitch 3-5

Two-Position Regeneration Switch 3-5

WWarning 1-4

Index-4

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Documents

Engine Aftertreatment Systems - Operator's Manual Y53 … Manuals/Emission Manuals... · Safety SafetyAlerts Pleasereadandfollowallofthe safetyalertscontainedinthismanual. Theyarethereforyourprotection