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 were not
ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this
vehicle.
PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without
notice 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 strictly
prohibited without prior written authorization from PACCAR Inc.
Foreword
FOREWORD
This manual contains information for the correct operation and maintenance of your PACCAR engine.
Read and follow all safety instructions. Refer to the WARNING in the “General Safety Instructions
Keep this manual with the vehicle. If the vehicle is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at
the time of printing. PACCAR Inc reserves the right to make changes at any time without obligation. If you find differences
between your engine and the information in this manual, contact your local PACCAR Authorized Repair Location or write to
PACCAR Inc c/o Medium Duty Engines, PO Box 1518, Bellevue, WA 98009.
The latest technology and the highest quality components were used to produce this engine. When replacement parts are
needed, we recommend using only genuine parts from PACCAR.
NOTE: Warranty information including the EPA and California Emission Warranty is located in the section entitled
“WARRANTY
engine.
,” beginning on page 73. Make sure you are familiar with the warranty or warranties applicable to your
A number of alerting messages are in this manual. Please
read and follow them. They are there for your protection and
information. These messages can help you avoid injury to
yourself, your passengers, and help prevent costly damage
to the vehicle.
Key symbols and “signal words” are used to indicate what
kind of message is going to follow. Pay special attention to
instructions prefaced by symbols and signal words
“WARNING”, “CAUTION”, or “NOTE”. Please do not ignore
any of these alerts.
WARNING
When you see this symbol & word, the message that
follows is especially vital. This signals something
that can cause injury or even death. This message
will tell you what the hazard is, what can happen if
you don’t heed the warning, and how to avoid it.
Example:
WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or
empty, may leak, explode, and cause or feed a
fire. Do not carry extra fuel containers, even
empty ones are dangerous.
CAUTION
This symbol and word signals something that could
damage your vehicle.
Example:
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
engine damage.
PACCARY53-1030A 12/09– 3 –
Introduction
NOTE
This symbol and word gives you information we
feel you would like to have. It could have to do
with care of your vehicle or with driving more
efficiently
NOTE: Pumping the accelerator will not assist in
starting the engine.
Please take the time to read these messages when
WARNING!
S
omething that could cause an injury or even death.
CAUTION:
Something that could cause damage to your vehicle.
NOTE:
Useful information.
.
Example:
you see them, and remember:
Illustrations
General Information
Some of the illustrations throughout this manual are generic
and will not look exactly like the engine or parts used in your
application. The illustrations can contain symbols to indicate
an action required and an acceptable or not acceptable condition.
The illustrations are intended to show repair or replacement
procedures. The procedure will be the same for all applications, although the illustration can differ.
– 4 –
Y53-1030A 12/09PACCAR
Introduction
General Safety Instructions
Important Safety Notice
WARNING! Improper practices, carelessness, or
ignoring the warnings can cause burns, cuts,
mutilation, asphyxiation or other personal injury
or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide
personal safety. Special safety precautions are included in
the procedures when they apply.
• Work in an area surrounding the product that is dry, well
lit, ventilated, free from clutter, loose tools, parts, ignition
sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes
when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all
jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
• Disconnect the air starting motor if equipped to prevent
accidental engine starting. Put a "Do Not Operate" tag in
the operator's compartment or on the controls.
• Use ONLY the proper engine barring techniques for
manually rotating the engine. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot,
allow the engine to cool before slowly loosening the filler
cap to relieve the pressure from the cooling system.
• Always use blocks or proper stands to support the product before performing any service work. Do not work on
anything that is supported ONLY by lifting jacks or a
hoist.
• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure
when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal injury.
PACCARY53-1030A 12/09– 5 –
Introduction
• To reduce the possibility of suffocation and frostbite,
wear protective clothing and ONLY disconnect liquid
refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be
properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into
the atmosphere. Federal law requires capturing and
recycling refrigerant.
• To reduce the possibility of personal injury, use a hoist or
get assistance when lifting components that weigh 23 kg
[50 lb] or more. Make sure all lifting devices such as
chains, hooks, or slings are in good condition and are of
the correct capacity. Make sure hooks are positioned
correctly. Always use a spreader bar when necessary.
The lifting hooks must not be side-loaded.
• Corrosion inhibitor, a component of SCA and lubricating
oil, contains alkali. Do not get the substance in eyes.
Avoid prolonged or repeated contact with skin. Do not
swallow internally. In case of contact, immediately wash
skin with soap and water. In case of contact, immediately
flood eyes with large amounts of water for a minimum of
15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP
OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable
materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety
when using these materials. KEEP OUT OF REACH OF
CHILDREN.
• To reduce the possibility of burns, be alert for hot parts
on products that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compartments.
• Always use tools that are in good condition. Make sure
you understand how to use the tools before performing
any service work. Use ONLY genuine replacement parts
from PACCAR.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lesser quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some state and federal agencies in the United States of
America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid
inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
– 6 –
Y53-1030A 12/09PACCAR
Introduction
• Liquefied petroleum gas is heavier than air and can
accumulate near the floor, in sumps, and low-lying
areas.
• Natural gas is lighter than air and can accumulate under
hood and awnings.
• To reduce the possibility of suffocation and frostbite,
wear protective clothing and ONLY disconnect natural
gas and liquefied petroleum gas lines in a well ventilated
area.
• Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
• Coolant is toxic. If not reused, dispose of in accordance
with local environmental regulations.
• The Diesel Exhaust Fluid contains urea. Do not get the
substance in your eyes. In case of contact, immediately
flood eyes with large amounts of water for a minimum of
15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do
not swallow internally. In the event the Diesel Exhaust
Fluid is ingested, contact a physician immediately.
• The catalyst substrate contains Vanadium Pentoxide.
Vanadium Pentoxide has been determined by the State
of California to cause cancer. Always wear protective
gloves and eye protection when handling the catalyst
assembly. Do not get the catalyst material in your eyes.
In Case of contact, immediately flood eyes with large
amounts of water for a minimum of 15 minutes. Avoid
prolonged contact with skin. In case of contact, immediately wash skin with soap and water.
• The Catalyst substrate contains Vanadium Pentoxide.
Vanadium Pentoxide has been determined by the State
of California to cause cancer. In the event the catalyst is
being replaced, dispose of in accordance with local regulations.
• California Proposition 65 Warning - Diesel engine
exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and
other reproductive harm.
CAUTION: Corrosive chemicals can damage the
engine. Do not expose the engine to corrosive
chemicals.
PACCARY53-1030A 12/09– 7 –
Introduction
Acronyms and Abbreviations
General Information
The following list contains some of the acronyms and abbreviations used in this manual.
APIAmerican Petroleum Institute
ASTMAmerican Society of Testing and Materials
ATSAfter-Treatment System
BTUBritish Thermal Unit
°CCelsius
CARBCalifornia Air Resources Board
C.I.D.Cubic Inch Displacement
CPLControl Parts List
cStCentistokes
DEFDiesel Exhaust Fluid
DPFDiesel Particulate Filter
ECMElectronic Control Module
EGRExhaust Gas Recirculation
ELCExtended Life Coolant
EMIElectromagnetic Interference
EPAEnvironmental Protection Agency
ESNEngine Serial Number
°FFahrenheit
FMIFailure Mode Indentifier
GVWGross Vehicle Weight
HESTHigh Exhaust System Temperature
LPGLiquified Petroleum Gas
HgMercury
hpHorsepower
H
OWater
2
ICMIgnition Control Module
km/lKilometers per Liter
kPaKilopascal
LTALow Temperature Aftercooling
MPaMegapascal
mphMiles Per Hour
mpqMiles Per Quart
– 8 –
Y53-1030A 12/09PACCAR
Introduction
N•mNewton-meter
NGNatural Gas
OEMOriginal Equipment Manufacturer
PIDParameter Identification Descriptions
ppmParts Per Million
psiPounds Per Square Inch
PTOPower Takeoff
RGTRear Gear Train
rpmRevolutions Per Minute
SAESociety of Automotive Engineers
SCASupplemental Coolant Additive
SCRSelective Catalytic Reduction
STCStep Timing Control
SIDSubsystem Identification Descriptions
VGTVariable Geometry Turbocharger
VSVariable Speed
VSSVehicle Speed Sensor
PACCARY53-1030A 12/09– 9 –
Introduction
– 10 –
Y53-1030A 12/09PACCAR
ENGINE IDENTIFICATION
Engine Dataplate
The engine dataplate provides important facts about the
engine. The engine serial number (ESN) and control parts list
(CPL) provide information for service and ordering parts. The
engine dataplate must not be changed unless approved by
PACCAR Inc.
The dataplate is located on the top side of the gear housing.
Have the following engine data available when communicating with a PACCAR Authorized Repair Location:
• Engine serial number (ESN).
• Control parts list (CPL).
• Model.
• Horsepower and rpm rating.
PACCARY53-1030A 12/09– 11 –
Engine Identification
If the engine dataplate (1) is not readable, the ESN (2) can be
found on the engine block on top of the lubricating oil cooler
housing. Additional engine information is on the electronic
control module (ECM) dataplate.
– 12 –
Y53-1030A 12/09PACCAR
PACCAR Engine Nomenclature
The PACCAR engine nomenclature provides the engine
model and horsepower rating.
OPERATING INSTRUCTIONS
General Information
Correct care of your engine will result in longer life, better
performance, and more economical operation.
Follow the daily maintenance checks listed in “Maintenance
Schedule” on page 45.
The new PACCAR engine associated with this manual does
not require a ”break-in” procedure. This section of the manual
provides all of the necessary information required for proper
engine operation.
Check the oil pressure indicators, temperature indicators,
warning lights, and other gauges daily to make sure they are
operational.
PACCARY53-1030A 12/09– 13 –
Operating Instructions
WARNING! Combustible vapors near the air
intake system could be ingested into the engine,
causing the engine to suddenly accelerate and
overspeed or explode. This condition could
result in an unexpected increase in engine rpm
and/or fire, resulting in personal injury or property damage. Do not operate your vehicle in area
where combustible chemicals or vapors may be
present.
IT IS THE RESPONSIBILITY OF THE OWNER
AND OPERATOR TO OPERATE THE VEHICLE IN
A SAFE ENVIRONMENT.
NOTE: Numerous safety devices (ie engine shutoff
devices) are available to minimize the risk of engine
overspeeding caused by combustible vapors being
ingested into the air intake system.
– 14 –
Y53-1030A 12/09PACCAR
Operating Instructions
PACCAR recommends the installation of an air intake shutoff
device or a similar safety device to minimize the risk of
overspeeding, as can occur when the vehicle, is being
operated in a combustible environment, such as from a fuel
spill or gas leak.
Normal Starting Procedure
Starting
Ensure the parking brake is set and the transmission is in
neutral.
With the accelerator pedal in the idle position, turn the key
switch to the ON position.
PACCARY53-1030A 12/09– 15 –
With the key in the ON position, the engine indicator lamps
will come on momentarily and then go out. The engine
indicator lamps include:
1. Check engine lamp; amber in color.
2. STOP engine lamp; red in color.
3. Diesel Particulate Filter (DPF) status indicator; amber in
color.
4. High Exhaust System Temperature (HEST); amber in
color.
Operating Instructions
The DEF Warning screen is displayed when the DEF Fluid
level has reached a critically low level. It may be suppressed
by pushing enter on the MCS (Menu Control Switch). This
warning may be accompanied by the DEF Level in the low
range, DEF Lamp on solid or flashing, the Check Engine
lamp, the Stop Engine lamp, the MIL lamp, and/or engine derate.
If any of the lamps remain on or begin to flash, refer to
“Engine Indicator Lamps
” on page 25.
– 16 –
Under cold conditions, the Wait-to-Start lamp will illuminate
at key on, and will stay on for a period of up to 30 seconds.
Y53-1030A 12/09PACCAR
Operating Instructions
NOTE: The length of time the Wait-to-Start lamp
remains illuminated depends on the ambient temperature. The lower the ambient temperature, the
longer the lamp will be illuminated.
Once the Wait-to-Start lamp turns off, turn the key to the
starting position to start the engine.
CAUTION: Engaging the starter motor for more
than 30 seconds may cause it to overheat and
can damage the starter motor. Never engage the
starter motor for more than 30 seconds and wait
2 minutes between each attempt to start the
engine to allow the starter motor to cool. This
caution does not apply to air starters.
CAUTION: The engine must have adequate oil
pressure within 15 seconds after starting the
engine. If the oil pressure gauge does not register the minimum pressure, or drops below the
minimum pressure, a red warning light in the
gauge will come on, a warning buzzer will
sound, and the Stop Engine Lamp will come on.
This should be considered an emergency. Operating the engine in this condition may cause
severe engine damage. You should stop the
vehicle as safely as possible. The vehicle must
be serviced and the problem corrected before
driving again.
PACCARY53-1030A 12/09– 17 –
Operating Instructions
Idle the engine 3 to 5 minutes before operating with a load.After starting a cold engine, increase the engine speed (rpm)
slowly to provide adequate lubrication to the bearings and to
allow the oil pressure to stabilize.
Some engines are equipped with a Fast Idle Warm Up
feature. When enabled, this feature elevates the idle speed
of the engine in cold ambient conditions, in order to shorten
the time necessary to warm up the engine. When the idle
speed is elevated, the engine noise may change, this is
normal. To bring the engine back to low idle speed:
• For vehicles equipped with a manual transmission and
clutch switch: Depress the clutch pedal.
• For vehicles equipped with a brake switch: Depress the
service brake pedal.
• Depress the accelerator pedal.
– 18 –
Y53-1030A 12/09PACCAR
Operating Instructions
For more information on the Fast Idle Warm Up feature,
contact a PACCAR authorized repair location.
CAUTION: Do not operate the engine at low idle
for long periods with engine coolant temperature below the minimum specification in “Cool-
ing System” on page 57. This can result in the
following:
• Fuel dilution of the lubricating oil.
• Carbon build up in the cylinder.
• Cylinder head valve sticking.
• Reduced performance.
If an engine must idle for an extended period of
time, it should be done at fast idle (1,000 rpm or
greater) until the coolant temperature meets the
specification.
Cold Weather Starting
General Information
Follow the Normal Starting Procedure in this section. If
equipped with an intake air heater, the Wait-To-Start lamp
will stay on longer.
Refer to the vehicle operator's manual instructions for any
additional cold weather starting procedures.
PACCARY53-1030A 12/09– 19 –
Operating Instructions
Using Starting Aids
This engine is equipped with an intake grid heater to help
start the engine in cold weather conditions. Contact your
authorized PACCAR repair location for other cold weather
starting aid options.
WARNING! Using starting fluid to help start the
engine could cause a fire or explosion, resulting
in personal injury, property damage and severe
engine damage. Do not use starting fluid to start
this engine.
Starting Procedure After Extended
Shutdown or Oil Change
General Information
Follow the Normal Starting Procedure in this section. The
engine will run at idle only until the minimum oil pressure is
detected by the ECM. It can take more cranking time to start
the engine after an extended shut down or oil change.
Operating the Engine
Normal
Monitor the oil pressure and coolant temperature gauges
frequently. Refer to “Lubricating Oil System
“Cooling System
pressures and temperatures. Shut off the engine if any
pressure or temperature does not meet the specifications.
Continuous operation with engine coolant temperature above
or below the engine coolant temperature specifications listed
in “Cooling System
” on page 57 for recommended operating
” on page 57 can damage the engine.
” on page 56 and
– 20 –
Y53-1030A 12/09PACCAR
Operating Instructions
Engine Overheating
CAUTION: The cooling system may overheat if
the engine coolant is the minimum level. A sudden loss of coolant, caused by a split hose or
broken hose clamp could also lead to an overheat condition. Always inspect to ensure hoses
and clamps are not cracked, worn or loose.
NOTE: The system may also temporarily overheat
during severe operations conditions such as:
• Climbing a hill on a hot day.
• Stopping after high–speed driving.
If an overheating condition starts to occur, reduce the power
output of the engine by releasing the accelerator pedal or
shifting the transmission to a lower gear, or both, until the
temperature returns to the normal operating range. If the
engine temperature does not return to normal, shut off the
engine, and refer to Troubleshooting Symptoms, or contact a
PACCAR Authorized Repair Location.
PACCARY53-1030A 12/09– 21 –
Operating Instructions
NOTE: If the “Engine Coolant Temperature” warning
light comes on and the audible alarm sounds showing an overheat condition, or if you have any other
reason to suspect the engine may be overheating,
DON'T TURN OFF THE ENGINE unless a low water
warning device indicates a loss of coolant. Follow
these steps:
• Reduce engine speed or stop. When stopped,
place the transmission in Neutral and set the parking brake. See the Truck Operator’s Manual for
instructions on transmission shifting and parking
brake information.
• Check to ensure that the oil pressure gauge reads
normal.
• Increase the engine speed to about one–half of
full operating speed, or 1,100 to 1,200 rpm, maximum.
• Return the engine speed to normal idle after two
or three minutes.
• Monitor the engine temperature. After the temperature returns to normal, allow the engine to idle 3
to 5 minutes before shutting it off. This allows the
engine to cool gradually and uniformly.
• If the overheating came from severe operating
conditions, the temperature should have cooled by
this time.
• Check the sight gauge (glass level indicator) on
the side of the coolant expansion tank.
CAUTION: Never leave the engine idling when
the vehicle is unattended. If the engine should
overheat, immediate action is required to correct
the condition. Failure to take immediate action
may result in serious engine damage. If you
must leave your vehicle unattended, shut down
the engine.
– 22 –
Y53-1030A 12/09PACCAR
Operating Instructions
WARNING! Removing the radiator fill cap while
the engine is hot can be dangerous. Never
remove the caps of the expansion tank while the
engine is still hot; you could be badly burned.
• Scalding steam and fluid under pressure may
escape and cause serious personal injuries.
• Wait until the coolant temperature is below
122°F (50°C).
• Protect your face, hands, and arms by covering
the cap with a large, thick rag to protect
against escaping fluid and steam.
• Carefully and slowly turn cap one turn to allow
excess pressure to escape, then push down
and turn for final removal. See the Truck Operator’s Manual for instructions on checking and
filling the coolant expansion tank.
Take the time to learn what normal operating conditions are
for your engine so that when an abnormal condition arises,
you will be able to recognize it as such and take the
appropriate action.
Most failures give an early warning. Look and listen for
changes in performance, sound, or engine appearance that
can indicate service or engine repair is needed. Some
changes to look for are:
• Engine misfires.
• Vibration.
• Unusual engine noises.
• Sudden changes in engine operating temperatures or
pressures.
• Excessive smoke.
– 23 –
Y53-1030A 12/09PACCAR
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