PACCAR MX Operator's Manual

Contents
Safety
Emergency
Controls
Driving
Maintenance
Information
Index
Contents
©2011PaccarInc-AllRightsReserved
Thismanualillustratesanddescribestheoperationoffeaturesorequipmentwhichmaybeeitherstandardoroptionalon thisvehicle.Thismanualmayalsoincludeadescriptionoffeaturesandequipmentwhicharenolongeravailableorwere notorderedonthisvehicle.Pleasedisregardanyillustrationsordescriptionsrelatingtofeaturesorequipmentwhichare notonthisvehicle.
PACCARreservestherighttodiscontinue,changespecications,orchangethedesignofitsvehiclesatanytimewithout noticeandwithoutincurringanyobligation.
TheinformationcontainedinthismanualisproprietarytoPACCAR.Reproduction,inwholeorinpart,byanymeansisstrictly prohibitedwithoutpriorwrittenauthorizationfromP ACCARInc.
Safety
Introduction
SafetyAlerts..............1-3
Foreword...............1-5
ImportantReferenceNumber.......1-6
Illustrations...............1-7
GeneralSafetyInstructions........1-7
1-1

Introduction

Introduction
SafetyAlerts
Pleasereadandfollowallofthe safetyalertscontainedinthismanual. Theyarethereforyourprotection andinformation.Thesealertscan helpyouavoidinjurytoyourself,your passengers,andhelppreventcostly damagetothevehicle.Safetyalerts arehighlightedbysafetyalertsymbols andsignalwordssuchas"WARNING", "CAUTION",or"NOTE".Pleasedonot ignoreanyofthesealerts.
WARNING
WARNING:
Thesafetyalertfollowingthissymbol andsignalwordprovidesawarning againstoperatingprocedureswhich couldcausedeathorinjury .Theycould alsocauseequipmentorproperty damage.Thealertwillidentifythe hazard,howtoavoidit,andthe probableconsequenceofnotavoiding thehazard.
Example:
WARNING:Donotcarry additionalfuelcontainersin yourvehicle.Fuelcontainers, eitherfullorempty,mayleak, explode,andcauseorfeeda re.Donotcarryextrafuel containers.Evenemptyones aredangerous.Failureto complymayresultindeath,
personalinjury,equipmentor propertydamage.
1-
3
Introduction
CAUTION
CAUTION:
Thesafetyalertfollowingthissymbol andsignalwordprovidesacaution againstoperatingprocedureswhich couldcauseequipmentorproperty damage.Thealertwillidentifythe hazard,howtoavoidit,andthe probableconsequenceofnotavoiding thehazard.
Example:
CAUTION:Continuingto operateyourvehiclewith insufcientoilpressure willcauseseriousengine damage.Failuretocomply mayresultinequipmentor propertydamage.
NOTE
NOTE:
Thealertfollowingthissymboland signalwordprovidesimportant informationthatisnotsafetyrelated butshouldbefollowed.Thealert willhighlightthingsthatmaynotbe obviousandisusefultoyourefcient operationofthevehicle.
Example:
NOTE:Pumpingtheaccelerator willnotassistinstartingthe engine.
1-4
Introduction
Foreword
Thismanualcontainsinformationfor thecorrectoperationandmaintenance ofyourPACCARengine.Readand followallsafetyinstructions.Refer totheWARNINGinthe“General SafetyInstructions”beginningon
page1-7.Keepthismanualwith
theequipment.Iftheequipmentis tradedorsold,givethemanualto thenewowner.Theinformation, specications,andrecommended maintenanceguidelinesinthismanual arebasedoninformationineffect atthetimeofprinting.PACCAR reservestherighttomakechanges atanytimewithoutobligation.Ifyou nddifferencesbetweenyourengine andtheinformationinthismanual, contactyourlocalPACCARAuthorized RepairLocationorwritetoPACCAR c/oP ACCAREngines,POBox1518, Bellevue,WA98009.Thelatest technologyandthehighestquality componentswereusedtoproducethis
engine.Whenreplacementpartsare needed,werecommendusingonly genuinepartsfromPACCAR.
1-5
Introduction
ImportantReference
Number
Fillinthepartnameandnumberintheblankspacesprovidedbelow .Thiswillgiveyouareferencewheneverserviceormaintenanceisrequired.
PartNameNumber
EngineModel
EngineSerialNumber(ESN)
OilType(UseAPICJ-4oilonly)
FilterPartNumbers:
AirCleanerElement
LubricatingOil
Fuel(Useultra-lowsulfurdieselfuelonly)
Coolant
BeltPartNumbers:
1-6
Introduction
Illustrations
GeneralInformation
Someoftheillustrationsthroughout thismanualaregenericandwillnot lookexactlyliketheengineorparts usedinyourapplication.
Theillustrationsareintendedtoshow repairorreplacementprocedures. Theprocedurewillbethesameforall applications,althoughtheillustration candiffer.
GeneralSafetyInstructions
ImportantSafetyNotice
WARNING:Improper practices,carelessness, orignoringanywarnings maycausedeath,personal injury,equipmentorproperty damage.
Beforeperforminganyrepair,readand understandallofthesafetyprecautions andwarnings.Thefollowingisalistof generalsafetyprecautionsthatmust befollowedtoprovidepersonalsafety . Failuretofollowtheseinstructions maycausedeathorinjury.Special safetyprecautionsareincludedinthe procedureswhentheyapply.
Usethepropertoolformanually
rotatingtheengine.Donotattempt torotatethecrankshaftbypulling orpryingonthefan.Thispractice cancausedeath,personalinjury, equipmentdamage,ordamageto
thefanblades,causingpremature fanfailure.
Workareasshouldbedry,welllit,
ventilated,freefromclutter,loose tools,parts,ignitionsourcesand hazardoussubstances.
Wearprotectiveglassesand
protectiveshoeswhenworking.
Donotwearloose-ttingortorn
clothing.Removealljewelrywhen working.
Beforebeginninganyrepair,
disconnectthebattery(negative [-]cable)anddischargeany capacitors.
Puta"DONOTOPERATE"tagin
theoperator’scompartmentoron thecontrols.
Allowtheenginetocoolbefore
slowlylooseningthecoolantller captorelievethepressurefrom thecoolingsystem.
1-
7
Introduction
Alwaysuseblocksorproper
standstosupportthevehicle orvehiclecomponentsbefore performinganyservicework. Donotworkonanythingthatis supportedonlybyliftingjacksor ahoist.
Beforeremovingordisconnecting
anylines,ttings,orrelateditems, relieveallpressureintheair,oil, fuel,andcoolingsystems.Remain alertforpossiblepressurewhen disconnectinganydevicefroma systemthatcontainspressure. Highpressureoilorfuelcancause deathorpersonalinjury .
Alwayswearprotectiveclothing
whenworkingonanyrefrigerant (Freon)linesandmakesurethat theworkplaceisinawellventilated area.Inhalationoffumescan causedeathorpersonalinjury. Toprotecttheenvironment, liquidrefrigerantsystemsmust beproperlyemptiedandlled
usingequipmentthatprevents thereleaseofrefrigerantgas. Federallawrequirescapturing andrecyclingrefrigerant.
Whenmovingorliftinganyheavy
equipmentorparts,makesure tousepropertechniquesand assistance.Ensurealllifting devicessuchaschains,hooks,or slingsareingoodconditionand areofthecorrectloadcapacity. Makesureanyliftingdevicesare positionedcorrectly .
Corrosioninhibitorsandlubricating
oilsmaycontainalkali.Donotget thesubstanceineyesandavoid prolongedorrepeatedcontact withskin.Donotswallow.In caseofcontact,immediatelywash skinwithsoapandwater.Incase ofharmfulcontact,immediately contactaphysician.Alwayskeep anychemicalsOUTOFREACH OFCHILDREN.
NapthaandMethylEthylKetone
(MEK)areammablematerials andmustbeusedwithcaution. Followthemanufacturer’s instructionstoensuresafetywhen usingthesematerials.Always keepanychemicalsOUTOF REACHOFCHILDREN.
Whenworkingonthevehicle,
bealertforhotpartsonsystems thathavejustbeenturnedoff, exhaustgasow,andhotuidsin lines,tubes,andcompartments. Contactwithanyhotsurfacemay causeburns.
Alwaysusetoolsthatareingood
condition.Makesureyouhave theproperunderstandingofhow tousethetoolsbeforeperforming anyservicework.Useonly genuinereplacementpartsfrom PACCAR.
1-
8
Introduction
Alwaysusethesamefastener
partnumber(orequivalent)when replacingitems.Donotuse afasteneroflesserqualityif replacementsarenecessary.
Donotperformanyrepairwhen
impaired,tired,fatiguedorafter consumingalcoholordrugsthat canimpairyourfunctioning.
Somestateandfederalagencies
intheUnitedStatesofAmerica havedeterminedthatusedengine oilcanbecarcinogenicandcan causereproductivetoxicity.Avoid inhalationofvapors,ingestion, andprolongedcontactwithused engineoil.
Coolantistoxic.Ifnotreused,
disposeofcoolantinaccordance withlocalenvironmental regulations.
CaliforniaProposition65Warning
-Dieselengineexhaustandsome ofitsconstituentsareknownto theStateofCaliforniatocause cancer,birthdefects,andother reproductiveharm.
Thecatalystsubstratelocated
intheDieselParticulateFilter containsVanadiumPentoxide. VanadiumPentoxidehasbeen determinedbytheStateof Californiatocausecancer.Always wearprotectiveclothingandeye protectionwhenhandlingthe catalystassembly.Disposeofthe catalystinaccordancewithlocal regulations.Ifcatalystmaterial getsintotheeyes,immediately oodeyeswithwaterfora minimumof15minutes.Avoid prolongedcontactwithskin.In caseofcontact,immediatelywash skinwithsoapandwater.Incase ofharmfulcontact,immediately contactaphysician.
CAUTION:Corrosive chemicalscandamage theengine.Donotuse corrosivechemicalsonthe engine.Failuretocomply mayresultinequipmentor propertydamage.
1-9
WHATTODOIF...
YouNeedRoadsideAssistance......2-3
StopEngineLampTurnsOn.......2-3
EngineOilPressureLampTurnsOn....2-4
CheckEngineLampTurnsOn......2-5
EngineisOverheating..........2-5
EMERGENCY
2-1

WHATTODOIF...

WHATTODOIF ...
YouNeedRoadside Assistance
Calltoll-FREEtotalktosomeoneat theP ACCARCustomerCenter.The toll-FREEtelephonenumberislocated onthewindshielddecal.
Open24-7-365daysayear
Theycanhelpyougetroadside
assistance.
Theyhaveacustommapping
systemwhichlocatesauthorized PACCARenginedealersand IndependentServiceProviders (ISPs)nearyouandliststypes ofservicesoffered,hoursof operationandcontactinformation.
Theycanassistwithjumpand
pullstarts,tires,trailers,nesand permits,chains,towing,hazardous clean-up,outoffuel(roadside),
mechanicalrepairsandpreventive maintenanceservices.
Theyhavemultilingualagentsand
accesstoatranslationservice toensurequalityassistance forcustomerswhospeakany language.
Theycan’tansweryourwarranty
questionsbutcangetyouin contactwithanauthorizeddealer whocan.
ThePACCARCustomerCenter
serviceisFREE.
StopEngineLampTurnsOn
StopEngineLamp-Ifthe
StopEnginewarninglamp illuminates,itmeansyou haveaseriousenginesystem problem.
WARNING:Thisshouldbe consideredanemergency. Youshouldstopthevehicle assafelyaspossibleand turnOFFtheignition.The vehiclemustbeservicedand theproblemcorrectedbefore drivingagain.Failuretodo somayresultinpersonal injury,severeenginedamage, equipmentorproperty damage.
2-
3
WHATTODOIF...
EngineOilPressureLamp TurnsOn
CAUTION:Continuingto operateyourvehiclewith insufcientoilpressuremay causesevereenginedamage, equipmentorproperty damage.
Iftheoilpressurefailsto
SeeLubricatingOil
EngineOilPressureGauge
-Itisimportanttomaintain oilpressurewithinacceptable limits.Ifoilpressuredrops belowtheminimumpsia RedWarningLampontheoil pressuregaugeandtheStop EngineLampwillcomeON.
risewithin10seconds aftertheenginestarts, stoptheengineand determinethecause.
Systemonpage5-1 1,for
thecorrectoilpressure rangesforyourvehicle’s engine.
Iftheoilpressure suddenlydrops,orthe audiblealarmandengine oilpressurewarninglight comeonwhiledriving,do thefollowing:
1.Slowdowncarefully.
2.Moveasafedistanceoff theroadandstop.
3.Placethetransmission inneutralandsetthe parkingbrake.(See ParkingBrakeValve andOPERATINGTHE TRANSMISSIONin yourvehicleOperator’s Manual,fortransmission shiftingandparkingbrake information.)
4.TurnOFFtheengine.
5.TurnONtheemergency asheranduseother warningdevicestoalert othermotorists.
6.Waitafewminutesto allowoiltodrainintothe engineoilpan,andthen checktheoillevel.(See InspectionoftheEngine OilLevelonpage5-4.)
7.Addoilifnecessary.Ifthe problempersists,contact anauthorizedP ACCAR enginedealerassoonas possible.
2-
4
WHATTODOIF...
CheckEngineLampTurns On
CheckEngineLamp-Turns
onwhenaproblemexists,but thevehiclecanstillbesafely driven.Vehicleshouldbe servicedtocorrecttheproblem butthesituationshouldnotbe consideredanemergency.
EngineisOverheating
CAUTION:Thecooling systemmayoverheatifthe enginecoolantisatthe minimumlevel.Asudden lossofcoolant,causedby asplithoseorbrokenhose clampcouldalsoleadtoan overheatcondition.Always inspecttoensurehosesand clampsarenotcracked,worn, orloose.Failuretocomply mayresultinequipmentor propertydamage.
NOTE:Thesystemmayalso temporarilyoverheatduring severeoperatingconditions suchas:
Climbingahillonahotday.
Stoppingafter high-speed/high-load driving.
Debrisblockingairow throughthecoolingmodule (radiator).
NOTE:Iftheenginecoolant temperaturewarninglamp comesonandtheaudiblealarm soundsshowinganoverheat condition,orifyouhaveany otherreasontosuspectthe enginemaybeoverheating, DONOTTURNOFFTHE ENGINEunlessalowwater warningdeviceindicatesaloss ofcoolant.Followthesesteps:
Reduceenginespeedor stop.Whenstopped,place thetransmissioninneutral andsettheparkingbrake. Seethevehicleoperator’s manualforinstructionson transmissionshiftingand parkingbrakeinformation.
2-
5
WHATTODOIF...
Checktoensurethatthe oilpressuregaugereads normal.
Increasetheenginespeed
to1,100to1,200rpm maximumfor2-3minutes.
Monitortheengine temperature.Afterthe temperaturereturnsto normal,allowtheengine toidle3–5minutesbefore shuttingitoff.Thisallows theenginetocoolgradually anduniformly .
Iftheoverheatingcame fromsevereoperating conditions,thetemperature shouldhavecooledbythis time.
Checkthecoolantlevelat thecoolingmodulesurge tank.
WARNING:Toreduce thechanceofpersonal injuryand/orvehicle damagecausedbyengine overheating,neverleave theengineidlingwhenthe vehicleisunattended.Ifthe engineoverheats,immediate actionisrequiredtocorrect thecondition.Continued unattendedoperationofthe engine,evenforashorttime, mayresultinseriousengine damageorare.Failureto complymayresultindeath, personalinjury,equipmentor propertydamage.
WARNING:Removingthe surgetankllcapwhile theengineishotcanbe dangerous.Neverremove thesurgetankcapwhilethe engineisstillhot;youcould bebadlyburned.Failureto complymayresultindeath,
personalinjury,equipmentor propertydamage.
Scaldingsteamanduid underpressuremay escapeandcauseserious personalinjuries.
Waituntilthecoolant temperatureisbelow 122°F(50°C).
Protectyourface,hands, andarmsbycoveringthe capwithalarge,thick ragtoprotectagainst escapinguidandsteam.
Carefullyandslowly turnthecaponeturnto allowexcesspressureto escape,thenpushdown andturnfornalremoval. Seethevehicleoperator’s manualforinstructions oncheckingandlling thecoolingmodulesurge tank.
2-
6
WHATTODOIF...
CAUTION:Donotallow yourenginetoidle,atlow RPMs(400–600rpm),longer than5minutes.Prolonged periodsofidlingafterthe enginehasreachedoperating temperaturescandecrease enginetemperatureandcould causeenginedamagefrom inadequatelubrication.The normaltorsionalvibrations generatedcanalsocause transmissionwear.Anidle shutdownfeature,available onPACCARengines,can beprogrammedtoshut theenginedownaftera periodoflowidleoperation withnodriveractivity.A ashingwarninglampwill informthedriverofan impendingshutdown.If thetruckisequippedwith PTOequipment,theengine shutdownsystemcanbe deactivatedwhenthePTOis
operational;however ,engine idleperiodsshouldnot exceed5minuteswhenever possible.Failuretocomply mayresultinequipmentor propertydamage.
2-7
Controls
OperatingInstructions
EngineWarningLamps.........3-3
EngineOperatingRange.........3-6
EngineBrakingSystem.........3-6
3-1

OperatingInstructions

OperatingInstructions
EngineWarningLamps
GeneralInformation
Thefollowingenginewarninglamps coveronlythelampscontrolledbythe engine’sElectronicControlModule (ECM).Pleaserefertothevehicle operator’smanualforadditional warninglampinformation.
CheckEngineLamp
Thecheckenginewarninglampwill illuminatewhenaproblemexists, butthevehiclecanstillbesafely driven.Thevehicleshouldbeserviced tocorrecttheproblem,butthe situationshouldnotbeconsideredan emergency.
Thelampwillalsoilluminatewhena DPFregenerationoradditionofDiesel ExhaustFluidisrequired.Another functionofthecheckenginelampisto warntheoperatorofanimpendingidle shutdown.Whentheidleshutdown timeris30secondsfromexpiring,the engineECMbeginsashingthecheck enginewarninglamponcepersecond. Whenthetimerexpires,theECMwill
turnoffthewarninglampandshut downtheengine.
3-
3
OperatingInstructions
StopEngineLamp
Thestopenginewarninglampwill
illuminate,andanaudibletonewill sound,whenamajorengineproblem exists.
WARNING:Thisshouldbe consideredanemergency. Youshouldstopthevehicle assafelyaspossibleand turnOFFtheignition.The vehiclemustbeserviced andtheproblemcorrected beforedrivingagain.Failure tocomplymayresultin personalinjury,severe enginedamage,equipmentor propertydamage.
Forengineswiththeengineprotection shutdownfeatureenabled,the stopenginelampwillbeginto ash30secondsbeforetheengine automaticallyshutsdown.The warninglampalertstheoperatortothe impendingshutdown.
Thelampwillalsoilluminatewhen theDieselExhaustFluid(DEF)tank isalmostemptyorthesootlevelin theDPFisatfullcapacity .Atthis levelwarning,regenerationcannotbe performedandenginepowerwillbe derated.
DieselParticulateFilter(DPF) WarningLamp
DPFWarningLamp
RefertoEngineAftertreatment SystemsOperator’sManualfor additionalinformation.
3-
4
OperatingInstructions
HighExhaustSystemT emperature (HEST)WarningLamp
HESTWarningLamp
RefertoEngineAftertreatment SystemsOperator’sManualfor additionalinformation.
CheckEngineLamp(CEL)
CheckEngineLamp
RefertoEngineAftertreatment SystemsOperator’sManualfor additionalinformation.
DieselEmissionFluid(DEF)Lamp
DieselEmissionFluid(DEF)Lamp
RefertoEngineAftertreatment SystemsOperator’sManualfor additionalinformation.
3-
5
OperatingInstructions
EngineOperatingRange
GeneralInformation
CAUTION:Operatingthe engineatfullthrottlebelow peaktorquewillshorten enginelifetooverhaul, cancauseseriousengine
damage,andisconsidered engineabuse.Donot operatetheengineatfull throttleoperationbelowpeak torquerpmformorethan30 seconds.Failuretocomply mayresultinequipmentor propertydamage.
PACCARenginesaredesignedto operateatfullthrottleundermomentary conditionsdowntopeaktorqueengine speed.Thisisconsistentwith recommendedoperatingpractices.
CAUTION:Operatingthe enginebeyondthemaximum enginespeedcancause severeenginedamage.Use properoperatingtechniques forthevehicletoprevent engineoverspeed.The maximumenginespeed specicationislisted inthe“GeneralEngine Specications”onpage5-10. Failuretocomplymayresult inequipmentorproperty damage.
EngineBrakingSystem
WARNING:Donotoperate theenginecompression brakewhendriving/operating yourvehiclebobtailorwith aloadedorunloadedtrailer onroadsurfaceswithpoor traction(wet,icy,orsnow coveredroads)orinheavy trafc.Brakingcausedby thenormaloperationof theenginecompression brakecouldcauseyouto losecontrolofthevehicle resultinginaninjuryaccident. Failuretocomplymayresult indeath,personalinjury, equipmentorproperty damage.
WARNING:Theservice brakesmustbeusedinan emergency.Theengine compressionbrakealone mightnotstopthevehicle
3-
6
OperatingInstructions
fastenoughtoprevent anaccident.Theengine compressionbrakeisNOT intendedastheprimarybrake forthevehicle,norisitan emergencybrake.Theengine compressionbrakeonly helpstheservicebrakesby usingenginebackpressure toslowthedrivetrain.Use theservicebrakesforquick stops.Youcouldbeseriously injuredifyoureliedonly ontheenginecompression braketostopthevehicleinan emergency.Failuretocomply mayresultindeath,personal injury,equipmentorproperty damage.
WARNING:Donotuse thecompressionbrake whenoperatingonroad surfaceswithpoortraction (suchaswet,icy,orsnow coveredroadsorgravel).
Compressionbrakescan causethewheelstoskidon aslipperysurface.Youcould losecontrolofthevehicle and/orjackknifeifthewheels begintoskid,resultinginan accident.Failuretocomply mayresultindeath,personal injury,equipmentorproperty damage.
NOTE:Ifyourvehicleis equippedwithanti-lock brakes(ABS),operationof thecompressionbrake(ifturned ON)maybeinterruptedifthe ABSsystemdetectswheelslip duetooperationonslippery surfaces.
Anenginecompressionbrakeis standardonthePACCARMX engine.Whenactivated,theengine compressionbrakecreatesabraking effectonthedrivewheels.This deviceusesenginepowertoslow
thevehicledown.Becauseitcan helpkeepyourvehicle’sbrakesfrom overheating,itcansavewearandtear ontheservicebrakes.However,the enginecompressionbrakeisnotan emergencybrake.
Ideally(onnormalroadsurfaces), youshouldslowyourvehiclewiththe compressionbrake(wherepermitted bylaw)andusetheservicebrakesonly forstoppingcompletely.Operatingthis waywillgreatlyprolongthelifeofthe servicebrakes.
3-
7
OperatingInstructions
CompressionBrake
Withthecompressionbrakeswitch ON,thebrakeautomaticallycreatesits brakingeffectwhenyouremoveyour footfromtheacceleratorpedal.
Thebrakeswitchislocatedonthe accessorydashpanel.Itcontrols
whetherthebrakeisON(readytoslow thevehicledown)orOFF(nobraking action).
Donotusetheengine
compressionbraketoslow thevehicledownwhenyouare bobtailingorpullinganempty trailer.
MakesurethebrakeisOFFbefore
startingtheengine.
Aftertheengineisstarted,warmed
up,andyouarereadytogetunder way,turntheenginecompression brakeswitchONforaddedbraking effect.
NOTE:Ifyourvehicleis equippedwiththeEaton Vorad®system,operationof thecompressionbrakemaybe automaticallyactivated.
CompressionBrakeControls
Two(2)switchesonthedashpanel controltheenginecompressionbrake. AmasterswitchturnsthesystemON orOFF .Asecondswitch,located nexttothemasterswitch,controls thebrakingeffect.Thisswitchallows youtochooseprogressivelystronger brakingtoslowthevehicledown.
Enginecompressionbrakecontrols include:
On/Offswitch.
3-positionselectorswitch.
Clutchswitch.
Throttlesensor.
Servicebrakepressureswitch.
EatonVorad®Anti-LockBraking
System
Engagingconditionsfortheengine compressionbrakeare:
3-
8
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