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PACCAR PX-8 Operator`s Manual

1. PACCAR Pxs Operator s Manual Y53 1030A 12 09 2010 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 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 on page 5 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 e
2. 28 Tips for Operation on Level and Dry Pavement 36 Tips for Operation on Grades with Dry Pavement 37 Tips for Operation on Slick Roads 40 Engine Shutdown 42 Electromagnetic Interference EMI 42 Maintenance Guidelines OVEIVIOW zi ei ee i ee ees 45 Maintenance Schedule 45 Maintenance Record Form 51 Service Literature Additional Service Literature 53 Maintenance Specifications General Engine Specifications 55 Lubricating Oil System 56 Cooling System 57 Filter Specifications 58 Diesel Exhaust Fluid Recommendations and Specifications 59 Fuel Recommendations and Specifications 59 Lubricating Oil Recommendations and Specifications 62 E pm Contents PACCAR PX 8 Coolant Recommendations and Specifications 66 United States and Canada Fire Apparatus Truck Applications Coverage 76 WARRANTY Emission Warranty 79 TTT California Emission Control System Warranty PACCAR PX 8 Engine United States and On Highway 81 Canada Coverage 73 California Emissions Components Statement for the PX 8 Engine 2010 Emission Engine Coverage 82 2
3. 22 NOTE If the Engine Coolant Temperature warning light comes on and the audible alarm sounds show ing 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 park ing 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 maxi mum Return the engine speed to normal idle after two or three minutes Monitor the engine temperature After the temper ature 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 Y53 1030A 12 09 Operating Instructions e 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 f you must l
4. LOW activates the engine brake on three cylinders and HI activates the engine brake on six cylinders Signals from the on off switch clutch switch throttle sensor and the cruise PTO switches are fed into the ECM NOTE Any one of these switches can de activate n the engine brakes PACCAR Operating Instructions e ENGINE BRAKE o OFF 20200004 The ECM then electronically enables or disables the engine brakes d Engine brakes cannot be enabled e When cruise control is active and the Engine brakes in Cruise Control feature is turned off e When engine speed goes below 850 rpm e When the Engine Computer recognizes a system problem PACCAR ea8swva The throttle sensor is part of the accelerator pedal assembly located in the cab and will deactivate the engine brakes when the acceleration pedal is depressed Y53 1030A 12 09 Operating Instructions cl8swva eb8swvo The clutch switch uses the motion of the clutch linkage to The service brake pressure switch is attached to the service deactivate the engine brakes when the clutch pedal is brake air supply line depressed Applying the service brakes while in cruise control will disengage the cruise control and enable the engine brakes If the pedal activated engine brake feature is enabled the service brake pedal must be depressed tapped before the engine brakes will be activated the engine oil temperature is above 30 C 86 F Op
5. Monitor the oil pressure and coolant temperature gauges frequently Refer to Lubricating Oil System on page 56 and Cooling System on page 57 for recommended operating pressures and temperatures Shut off the engine if any pressure or temperature does not meet the specifications x lt OIL PRESSURE eg8gaba Continuous operation with engine coolant temperature above or below the engine coolant temperature specifications listed in Cooling System on page 57 can damage the engine PACCAR Operating Instructions Engine A H PACCAR Overheating CAUTION The cooling system may overheat if the engine coolant is the minimum level A sud den loss of coolant caused by a split hose or broken hose clamp could also lead to an over heat 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 e Climbing a hill on a hot day Stopping after high speed driving eg8gasm 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 Y53 1030A 12 09 21
6. Oil Pressure At Low Idle minimum allowable 69 kPa 10 psi At Rated Speed minimum allowable 207 kPa 30 psi Regulated Oil Pressure 517 kPa 75 psi Lubricating Oil Filter Capacity 3 78 liters 4 qt Oil Pan Capacity Low to High Standard Oil Pan 15 1 to 18 9 liters 16 to 20 qt Standard Oil Pan with Cylinder Block Stiffener Plate 16 1 to 19 9 liters 17 to 21 qt Total System Capacity Oil Pan and New Oil Filter Standard Oil Pan 22 7 liters 24 qt Standard Oil Pan with Cylinder Block Stiffener Plate 23 7 liters 25 qt 56 Y53 1030A 12 09 Maintenance Specifications Cooling System Coolant Capacity engine only 12 4 liters 13 1 qt Standard Modulating Thermostat Range 82 to 93 C 180 to 200 F Minimum Recommended Pressure Cap 103 kPa 15 psi Maxiumum Top Tank Coolant Temperature 107 C 225 F Winterfronts Minimum Allowed Air Passage Area PACCAR 774 cm 120 in 2 Y53 1030A 12 09 57 Maintenance Specifications Filter Specifications General Information Fleetguard filters are standard on new PACCAR engines PACCAR recommends their use Fleetguard products meet all PACCAR test standards to pro vide the quality filtration necessary to achieve the engine s design life If other brands are substituted the purchaser should ensure the filter specification mee
7. Operator s Manual INTRODUCTION Safety Signals 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 PACCAR Y53 1030A 12 09 WARNING When you see this symbol amp word the message that AN 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 ers 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 1 WARNING Do not carry additional fuel contain CAUTION This symbol and word signals something that could damage your vehicle Example with insufficient oil pressure will cause serious engine damage CAUTION Continuing to operate your vehicle NOTE This symbol and word gives you information we d feel you would like to have It could have to do with care of your vehicle or with driving more eff
8. ating in ambient temperature conditions consistently below 25 C 13 F Synthetic OW 30 oils that meet the require ments of API Group 111 or Group IV basestocks can be used in operations where the ambient temperature never exceeds 0 C 32 F Multiviscosity oils rated OW 30 do not offer the same level of protection against fuel dilution as do higher multigrade oils Higher cylinder wear can be experienced when using OW 30 oils in high load situations As these oils have directionally thinner oil films than 15W 40 oils top quality Fleetguard filters must be used above 20 C 70 F Some oil suppliers might claim better fuel economy for these oils PACCAR can neither approve nor disapprove any product not manufactured by PACCAR These claims are between the customer and oil supplier Obtain a commit ment from the oil supplier that the oil will give satisfactory performance in PACCAR engines or do not use the oil New Engine Break In Oils Special break in engine lubricating oils are not recom mended for new or rebuilt PACCAR engines Use the same lubricating oil that will be used during normal operation 65 CAUTION A sulfated ash limit of 1 85 percent A has been placed on all engine lubricating oils recommended for use in PACCAR engines Higher ash oils can cause valve and or piston damage and lead to excessive oil consumption not justify extended oil change intervals Extended oil change intervals can decrease
9. engine life due to factors such as corrosion deposits and wear A CAUTION The use of a synthetic base oil does Aftermarket Oil Additive Usage PACCAR does not recommend the use of aftermarket oil additives The present high quality fully additive engine lubri cating oils are very sophisticated with precise amounts of additives blended into the lubricating oil to meet stringent requirements These furnished oils meet performance char acteristics that conform to the lubricant industry standards Aftermarket lubricating oil additives are not necessary to enhance engine oil performance and in some cases can reduce the furnished oil s capability to protect the engine 66 Y53 1030A 12 09 Maintenance Specifications Coolant Recommendations and Specifications Fully Formulated Coolant Antifreeze The cooling system in your vehicle was factory filled with Extended Life Coolant ELC that meets or exceeds all ASTM D 6210 requirements PACCAR recommends only using a 50 50 mixture of distilled water and ELC when cool ing system service is required A 50 50 mixture of ELC and distilled water will provide freeze protection down to 34 F 36 7 C which is adequate for most locations in North America For extremely cold operating conditions a 60 40 mixture coolant water ratio can be used to provide freeze protection down to 62 F 52 2 C Your engine is also equipped with a Coolant Filter designed to capture and remove
10. ing oil specifications and confirm that the oil meets CES 20078 or CES 20081 Maintenance Specifications Also located on the lubricating oil bottle is the API service symbol which is shown in the illustration The upper half of the symbol displays the appropriate oil categories The cen ter section identifies the SAE oil viscosity grade The table below shows how the Cummins Engineering Stan dard CES compares to the American Petroleum Institute API classification Petroleum Institute API performance classification CJ 4 SL may not meet the CES 20081 requirement Always make sure the lubricating oil used meets the CES 20081 requirement in addition to the API per formance classification CJ 4 SL ij NOTE A lubricating oil that meets the American 64 Cummins Engine American Petroleum StandardClassification Institute Classification Comments CES API CES 20071 CES 20072 CH 4 SJ Not recommended Lubricating oil drain interval must be reduced by 50 Aftertreatment CES 20076 maintenance interval will be reduced CES 20077 CES 20078 Cl 4 SL Aftertreatment maintenance interval will be reduced CES 20081 CJ 4 SL Maximum aftertreatment maintenance interval No change in lubricating oil drain interval Y53 1030A 12 09 PACCAR recommends the use of high quality SAE 15W 40 heavy duty engine oil The primary PACCAR recommendation is for the use of 15W 40 multigrade lubricating oil for normal ope
11. 1030A 12 09 61 NOTE PACCAR requires all permissible fuels to di have adequate fuel lubricity Lubricity can be mea sured by ASTM specification D6079 ISO 12156 High Frequency Reciprocating Rig HFRR in which the fuel must have a wear scar diameter of 0 52 mm 0 02 in or less Warranty and the Use of Biodiesel Fuel PACCAR Inc approves the use of biodiesel fuel blends up to 5 by volume in diesel fuel that meets all of the following three conditions The biodiesel used in the blend meets ASTM Stan dard D 6751 or EN 14214 specifications The biodiesel used in the blend is sourced from a BQ 9000 Accredited Producer The finished blend meets the fuel properties of ASTM Standard D 975 or EN 590 specifications The use of approved biodiesel fuel does not affect the PACCAR engine warranty Failures caused by the use of non approved biodiesel fuels or other fuel additives that are of unacceptable quality or do not meet specified industry standards are not defects of PACCAR parts or workmanship and therefore will not be a covered by the PACCAR engine warranty 62 Y53 1030A 12 09 Maintenance Specifications Lubricating Oil Recommendations and Specifications General Information CAUTION Extending the oil and filter change A interval beyond the recommendations will decrease the engine life due to factors such as corrosion deposits and wear Engine oil filters capture dirt and remove deposits from the oil t
12. Complete Cleaning of filter using a DPF cleaning machine Replace filter if necessary SAF Every 1 200 000 km 750 000 mi 22 000 Hours or 6 years Maintenance Check il 48 Change extended life coolant See note 1 below NOTE 1 A heavy duty extended life coolant ELC that meets ASTM D 6210 chemical composition specifi cations must be used The change interval is 750 000 miles 1 200 000 km or 22 000 hours on road use 8 years or 15 000 hours off highway use on initial fill with no extender added The change interval is 1 000 000 miles 1 600 000 km 20 000 hours 8 years with an extender addition at 500 000 miles 800 000 km 10 000 hours 4 years Anti freeze is essential for freeze overheat and corro sion protection The use of supplemental coolant additives SCAs is not recommended 2 Follow the manufacturers recommended mainte nance procedures for the starter alternator batter ies electrical components radiator air compressor air cleaner refrigerant compressor and fan clutch 3 Reset valve lash if needed to nominal specifica tions 4 H Y53 1030A 12 09 Maintenance Guidelines The aftertreatment DPF clean replace interval is based on the use of lubricating oils that meet the CJ 4 15W40 oil specification NOTE 1 The lubricating oil and lubricating oil filter interval can be adjusted based on applica tion fuel consumption gross vehicle weight and idle time See the O
13. Owner or employees of Owner as a result of a Warrantable Condition Owner is responsible for downtime expenses cargo dam age fines all applicable taxes all business costs and other losses resulting from a Warrantable Condition 82 Y53 1030A 12 09 WARRANTY California Emissions Components Statement for the PX 8 Engine 2010 Emission Engine Coverage This list of emission control parts may be covered by the Emission Control System Warranty under certain failure modes Aftertreatment System Aftertreatment Diesel Oxidation Catalyst Aftertreatment Diesel Particulate Filter Aftertreatment Selective Catalyst Element Aftertreatment Decomposition Tube Exhaust Piping from Turbocharger Outlet to Diesel Par ticulate Filter Selective Catalyst Reduction Outlet Temperature Sen sor Pressure Protection Valve Plumbing between Pressure Protection Valve and HC Doser Crankcase Ventilation System Selective Catalyst Intake Temperature Sensor Crankcase Breather and Associated Plumbing Parts Crankcase Pressure Sensor PACCAR WARRANTY Dash Lamps Exhaust Gas Recirculation Valve and Associated Plumb Diesel Exhaust Fluid DEF Lamp ing Parts Diesel Exhaust Fluid DEF System Exhaust Gas Recirculation Cooler Outlet Temperature DEF Dosing Unit and Wiring Sensor DEF Tank and Associated Plumbing Exhaust Gas Recirculation Cooler and Associated DEF Solution Level Temperature Sensor Plumbing Par
14. authorized Cummins Distributor or an authorized PACCAR Engine facility where applicable sub ject to PACCAR s time mileage and hour limitations of the engine warranty The maximum time mileage and hour limi tations of the engine warranty begin running on the Date of Delivery to the First Purchaser The accrued time mileage or hours is calculated when the engine is brought into an Authorized Dealer for correction of warrantable failures PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect including but not limited to damage due to accident opera tion without adequate coolants or lubricants overfueling overspeeding lack of maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications of the Engine PACCAR is also not responsible for failures caused by incorrect oil or fuel or diesel exhaust fluid or by water dirt or other contaminants in the fuel oil or diesel exhaust fluid Failure of replacement parts used in repairs due to the above non warrantable conditions is not warrantable PACCAR WARRANTY This warranty does not apply to accessories supplied by the vehicle OEM which are covered by the OEM vehicle war ranty Failures resulting in excessive oil consumption are covered for the duration of the coverage or 250 000 miles 402 336 kilometers or 6 250 hours from the date of del
15. f CARB PX 8 BT CONS TR tate Pi Pe of Mig WARNING Lnjery may resol ond warrasly is voided aT fel cate or altitedes DIPTIET INFORMATION This engine conform with 0 5 CHACUS plih lw medel 20M exceed published marimen volves for Ibis This engine as for expect only end il is ml certified for sate in the f medel and application The dataplate is located on the top side of the gear housing Have the following engine data available when communicat ing with a PACCAR Authorized Repair Location Engine serial number ESN Control parts list CPL Model Horsepower and rpm rating Engine Identification Wo PX 8 240 Engine Wo Qum Medel m reet Rate of eo n ms Oh A lle Speed rpm YU Advertised WP XXX of REI rpm Family mixern FEL EPA CARB Bale of Wigs firing order Timing T 0 C ELECTRONIC Catalyst ho ur 1 mmm rr r IMPORTANT ENGINE INFORMATION This engine conforms with U S EPAICARB Regulations for model peor 2004 This engine is for exper only ond it is tol cerlified for sole in the U S gt 5 Cas Z D KA F ALLA 2 DAN 45 re KS CU 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 inform
16. harmfuil deposits from the cooling system to help prolong system life PACCAR Maintenance Specifications Good quality water is important for cooling system perfor mance Excessive levels of calcium and magnesium contrib ute to scaling problems and excessive levels of chlorides and sulfates cause cooling system corrosion Water Quality Calcuim Magnesium Maximum 170 ppm as hardness CaCO MgCO3 Chloride 40 ppm as Cl Sulfur 100 ppm as 504 Fully formulated antifreeze must be mixed with good quality water at a 50 50 ratio 40 to 60 percent working range A 50 50 mixture of antifreeze and water gives a 36 C 33 F freezing point and a 108 C 226 F boiling point which is adequate for locations in North America The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent Using higher concentrations of antifreeze will raise the freez ing point of the solution and increase the possibility of a silica gel problem PACCAR vehicle engine cooling systems are filled with fully formulated extended life coolant ELC PACCAR Y53 1030A 12 09 PACCAR recommends the use of fully formulated extended life coolant that meets the requirements of Cummins Engi neering Standard C E S 14603 for top off and service If the replacement coolant is Chevron Texaco Shell Rotella or their private label counterparts which do not meet the elas tomer compatibility section of CES 14603 the
17. kilometers or 6 250 hours from the date of delivery of the Engine to the first purchaser whichever of the three occurs first Before a claim for excessive oil consumption will be considered Owner must submit adequate documentation to show that consumption exceeds PACCAR published stan dards Failures of belts and hoses supplied by PACCAR are not covered beyond the first year from the date of delivery of the Engine to the first purchaser PACCAR does not warrant antifreeze lubricants filters filter elements or any other part which is considered a mainte nance item Parts used to repair a Warrantable Failure may be new parts approved rebuilt parts or repaired parts PACCAR is not responsible for failures resulting from the use of parts not approved by PACCAR A new approved rebuilt part used to repair a Warrantable Failure assumes the identity of the part it replaced and is entitled to the remaining coverage hereun der PACCAR is not responsible for damage or loss resulting from Engine horsepower torque upgrades PACCAR Inc reserves the right to interrogate Electronic Con trol Module ECM data for purposes of failure analysis 78 Y53 1030A 12 09 WARRANTY PACCAR DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS THIS WARRANTY AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY PACCAR IN REGARD TO THESE ENGINES THIS LIMITED WARRANTY IS THE SOLE WARRANTY MADE BY PACCAR AND THE SEL
18. ACCAR Engine dealer PACCAR Bulletin Number Title of Publication 4022257 Engine Service Manual 4022225 Electronic Control System Troubleshooting and Repair Manual 2883353 Operation and Maintenance Manual 2883352 Owners Manual 3666255 Warranty Fail Code Manual Midrange Engines 3379000 Air for Your Engine 3379001 Fuel for Diesel Engines 3379009 Operation of Diesel Engines in Cold Climates 3666132 Coolant Requirements and Maintenance 3810340 Engine Oil and Oil Analysis Recommendations 4021566 Diesel Exhaust Fluid Specifications for Selective Catalytic Reduction Systems Y53 1030A 12 09 EN ie 54 Y53 1030A 12 09 Service Literature PACCAR p e MAINTENANCE SPECIFICATIONS General Engine Specifications Horsepower See engine dataplate Firing Order 1 5 3 6 2 4 Crankshaft Rotation viewed from front of engine Clockwise Displacement 8 3 liters 504 5 in3 Bore and Stroke 114 mm 4 49 in x 185 mm 5 32 in Dry Weight 754 kg 1 662 Ib Wet Weight 788 kg 1 737 Ib Intake Valve Adjustment 0 305 mm 0 012 in Overhead Adjustment Exhaust Valve Adjustment 0 559 mm 0 022 in Engine Brake Adjustment 2 286 mm 0 090 in Maximum Overspeed Capability 3 600 rpm 15 seconds maximum PACCAR Y53 1030A 12 09 55 Lubricating Oil System Maintenance Specifications
19. ACCAR is not responsible for non Engine repairs down time expenses cargo damage fines all applicable taxes all business costs or other losses resulting from a Warrantable Failure 80 Y53 1030A 12 09 WARRANTY THIS LIMITED EMISSION WARRANTY IS THE SOLE WARRANTY MADE BY PACCAR RELATING TO THE EMISSION EQUIPMENT EXCEPT FOR THE ABOVE LIM ITED WARRANTY PACCAR MAKES NO OTHER WAR RANTIES EXPRESS OR IMPLIED PACCAR EXPRESSLY DISCLAIMS ANY WARRANTY OF MER CHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OF INCOME OR LOST PROFITS ENGINE OR VEHICLE DOWNTIME THIRD PARTY DAMAGE INCLUDING DAM AGE OR LOSS TO OTHER ENGINES VEHICLES OR PROPERTY ATTACHMENTS TRAILERS AND CARGO LOSS OR DAMAGE TO PERSONAL CONTENTS COM MUNICATION EXPENSES LODGING AND OR MEAL EXPENSES FINES APPLICABLE TAXES OR BUSINESS COSTS OR LOSSES ATTORNEYS FEES AND ANY LIA BILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY PACCAR WARRANTY California Emission Control System Warranty On Highway Products Warranted This Emission Control System Warranty applies to diesel engines hereafter engines certified with the California Air Resources Board beginning with the year 2009 marketed by PACCAR and registered in California for use in on highway applications Your Warranty Rights and O
20. LING DEALER EXCEPT FOR THE ABOVE LIMITED WARRANTY PACCAR AND THE SELLING DEALER MAKE NO OTHER WARRANTIES EXPRESS OR IMPLIED PACCAR AND THE SELLING DEALER EXPRESSLY DISCLAIM ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OF INCOME OR LOST PROFITS ENGINE OR VEHICLE DOWNTIME THIRD PARTY DAMAGE INCLUDING DAM AGE OR LOSS TO OTHER ENGINES VEHICLES OR PROPERTY ATTACHMENTS TRAILERS AND CARGO LOSS OR DAMAGE TO PERSONAL CONTENTS COM MUNICATION EXPENSES LODGING AND OR MEAL EXPENSES FINES APPLICABLE TAXES OR BUSINESS COSTS OR LOSSES ATTORNEYS FEES AND ANY LIA BILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY PACCAR WARRANTY This warranty gives you specific legal rights and you may also have other rights which vary from state to state Emission Warranty Products Warranted This emission warranty applies to new PACCAR Engines marketed by PACCAR that are used in the United States in vehicles designed for transporting persons or property on a street or highway Coverage PACCAR warrants to the first purchaser and each subse quent purchaser that the Engine is designed built and equipped so as to conform at the time of sale by PACCAR with all U S Federal emission regulations applicable at the time of manufacture and that it is free from defects
21. 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 de rate If any of the lamps remain on or begin to flash refer to Engine Indicator Lamps on page 25 WAIT 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 09 PACCAR Operating Instructions NOTE The length of time the Wait to Start lamp di remains illuminated depends on the ambient tem A perature 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 PACCAR Y53 1030A 12 09 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 regis ter 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 a
22. P 5 JP 8 Jet B JP 4 CITE Diesel Diesel Kerosene OK OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK 48 34 40 24 50 35 51 37 51 37 48 36 51 37 57 45 57 45 57 45 a Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable b Winter blend fuels such as found at commercial fuel dispensing outlets are combinations of number 1D and number 2D diesel fuel and are acceptable c BTU Content Degree API Gravity Low API gravity fuels have a higher thermal energy content BTU As a general rule there is a 3 to 5 per cent decrease in BTU content for every 10 degree increase in API gravity there is also a 0 7 degree API gravity increase with an increase in fuel temperature This decrease in energy content equates roughly to the same percentage of power loss Use of fuels with higher API gravity will cause higher than normal fuel consumption NOTE PACCAR recommends that the cetane num ber of diesel fuel be a minimum of 45 for engines that are expected to operate at temperatures below 0 C 32 F and a minimum of 42 for engines that are operated at temperatures above 0 C 32 F NOTE Using diesel fuel with a lower than recom mended cetane number can cause hard starting instability and excessive white smoke To maintain satisfactory operation at low ambient temperatures it is important to specify diesel fuel of the correct cet ane number il PACCAR Y53
23. R AND THE SELLING DEALER EXCEPT FOR THE ABOVE LIMITED WAR RANTY PACCAR AND THE SELLING DEALER MAKE NO OTHER WARRANTIES EXPRESS OR IMPLIED PACCAR AND THE SELLING DEALER EXPRESSLY DIS 85 CLAIM ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PUR POSE PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OF INCOME OR LOST PROFITS ENGINE OR VEHICLE DOWNTIME THIRD PARTY DAMAGE INCLUDING DAM AGE OR LOSS TO OTHER ENGINES VEHICLES OR PROPERTY ATTACHMENTS TRAILERS AND CARGO LOSS OR DAMAGE TO PERSONAL CONTENTS COM MUNICATION EXPENSES LODGING AND OR MEAL EXPENSES FINES APPLICABLE TAXES OR BUSINESS COSTS OR LOSSES ATTORNEYS FEES AND ANY LIA BILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY 86 Y53 1030A 12 09 WARRANTY PACCAR PACCAR Medium Duty Engines P O Box 1518 Bellevue WA 98009 Y53 1030A
24. THE SELLING DEALER MAKE NO OTHER WARRANTIES EXPRESS OR IMPLIED PACCAR AND THE SELLING DEALER EXPRESSLY DISCLAIM ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OF INCOME OR LOST PROFITS ENGINE OR VEHICLE DOWNTIME THIRD PARTY DAMAGE INCLUDING DAM AGE OR LOSS TO OTHER ENGINES VEHICLES OR PROPERTY ATTACHMENTS TRAILERS AND CARGO LOSS OR DAMAGE TO PERSONAL CONTENTS COM MUNICATION EXPENSES LODGING AND OR MEAL EXPENSES FINES APPLICABLE TAXES OR BUSINESS 75 COSTS OR LOSSES ATTORNEYS FEES AND ANY LIA BILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY This warranty gives you specific legal rights and you may also have other rights which vary from state to state United States and Canada Fire Apparatus Truck Applications Coverage Products Warranted This warranty applies to new PACCAR PX 8 Engines sold and used in the United States or Canada and operated in fire apparatus truck applications Base Engine Warranty The Base Engine Warranty covers any failures of the Engine which result under normal use and service from a defect in material or factory workmanship Warrantable Failure This coverage begins on the date of delivery to the first purchaser and ends five years or 100 000 miles 160 935 kilometers whichever occurs first 1 U
25. accident and lead to per sonal injury The exhaust brake only helps the service brakes by using pressure to slow the drive train You must use the service brakes for quick or emergency stops WARNING Do not use the exhaust brake when operating on surface with poor traction such as wet icy or snow covered roads Retarders can cause the wheels to skid on a slippery surface You could lose control of the vehicle and jack nife if the wheels begin to skid resulting in an accident WARNING Do not use an exhaust brake when driving bobtail or with an unloaded trailer There may not be enough weight on the rear axle to provide traction This could cause a lose of con trol and jackknife resulting in an injury accident Make sure the exhaust brake is switched OFF when bobtailing or with an unloaded trailer When the engine VGT exhaust brake switch is in the ON position the engine s electronic control module ECM monitors inputs such as accelerator pedal position and engine speed From these inputs the ECM determines when to enable the engine VGT exhaust brake feature when the proper braking conditions are present Other features switches like cruise control can also affect when the engine VGT exhaust brake activates For more information on how the engine VGT exhaust brake functions refer to vehicle operation manual or contact a PACCAR Authorized Repair Location A WARNING To reduce the possibility of personal injury o
26. aintenance Schedule General Information Perform maintenance at whichever interval occurs first At each scheduled maintenance interval perform all previous maintenance checks that are due for scheduled mainte nance Daily or Refueling Maintenance Check Engine Lubrication Oil Level Check Correct To check engine oil level park vehicle on level ground and wait 5 minutes after shutting engine OFF Remove dipstick and wipe it off with a clean lint free rag Acne dipstick all the way in and pull it out again to check oil level Correct oil level is between the low L and high H marks on dipstick Fuel Water Separator Drain Crankcase Breather Tube Check Aftertreatment Diesel Exhaust Fluid Level Check Air Intake Piping Inspect 45 Hose Pipe condition Leaks Hose clamps for tightness Clearance to other components Aftertreatment Exhaust Piping Inspect Cracks Clearance to other components i e electrical har nesses etc Hose pipe condition cracks chaffing exhaust leaks Cooling Fan Inspect Cracks Clearance to other components Air Tank and Reservoirs if equipped Inspect Engine Coolant Level Check Correct With the engine off and temperature cool Check coolant level It should be visible within the sight glass glass level indicator on the surge tank Add coolant as necessary by removing the pressure cap on the neck of the surge ta
27. anufacturer 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 equiva lent when replacing fasteners Do not use a fastener of lesser quality if replacements are necessary Do not perform any repair when fatigued or after con suming 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 PACCAR PACCAR 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 mainte nance and repairs and when storing the vehicle inside C
28. at every oil change Replace the secondary or pressure side fuel filter at every other oil change Oil Drain Intervals See the following flowchart to determine the maximum rec ommended oil change and filter change intervals in kilome ters miles hours or months whichever comes first If yours is a refuse or Mixer dumper use table 2 For other applications use table 1 If No If the vehicle has not been listed select the correct oil drain interval from Table 1 Table 1 Maximum Oil Drain Intervals A Severe Duty If the Vehicle Meets Any of These Conditions Average fuel economy is less than 2 98 km liter 7 0 mpg or idle time is 40 percent or greater or vehicle operates in dusty areas or gross vehicle weight is greater than 27 215 kg 60 000 Ibs Average fuel economy is greater than 2 98 km liter 7 0 mpg and gross vehicle weight is less than 27 215 kg 60 000 Ibs B Normal Duty If the Vehicle Meets Both of These Conditions Vehicle uses the severe duty oil drain interval A Vehicle uses the normal duty oil drain interval B PACCAR Y53 1030A 12 09 49 Maintenance Guidelines Table 1 Maximum Oil Drain Intervals A Severe Duty B Normal Duty If the Vehicle Meets Any of These Conditions If the Vehicle Meets Both of These Conditions 14 500 km 9000 mi 500 hours 6 months or 7571 liters 2000 US 24 000 km 15 000 mi 500 hours 6 months o
29. ation is on the electronic control module ECM dataplate PACCAR MANUFACTURED BY Cuero TH Horsepower Rating Engine Model 17d00047 00d00008 PACCAR Engine Nomenclature The PACCAR engine nomenclature provides the engine model and horsepower rating 12 Y53 1030A 12 09 PACCAR OPERATING INSTRUCTIONS General Information Correct care of your engine will result in longer life better performance and more economical operation We Follow the daily maintenance checks listed in Maintenance Schedule on page 45 VOLTAGE The new PACCAR engine associated with this manual does TN D not require a break in procedure This section of the manual x NC bor x provides all of the necessary information required for proper amp 3 amp 3 engine operation g p x PS TX y TX eg8gasj Check the oil pressure indicators temperature indicators warning lights and other gauges daily to make sure they are operational PACCAR Y53 1030A 12 09 13 14 Y53 1030A 12 09 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 prop erty damage Do not operate your vehi
30. bligations The California Air Resources Board and PACCAR Inc are pleased to explain the emission control system warranty on your 2009 and subsequent model year diesel engine In Cal ifornia new motor vehicle engines must be designed built and equipped to meet the State s stringent anti smog stan dards PACCAR must warrant the emission control system on your diesel engine for the periods of time listed below pro vided there has been no abuse neglect or improper mainte nance of your diesel engine Your emission control system may include parts such as the fuel injection system and engine electronic control module Also included may be hoses connectors and other emission related assemblies PACCAR Y53 1030A 12 09 If an emission related part on your engine is found to have a defect in material or factory the part will be repaired or replaced by PACCAR This is your emission control system defects warranty Manufacturer s Warranty Coverage This warranty coverage is provided for five years or 100 000 miles 160 935 km or 3 000 hours of engine operation whichever first occurs from the date of delivery of the engine to the first purchaser Where a Warrantable Condition exists PACCAR will repair your engine at no cost to you including diagnosis parts and labor Owner s Warranty Responsibilities As the engine owner you are responsible for the perfor mance of the required maintenance listed in your PACCAR Operator s Manual Y
31. chemicals can damage the Y53 1030A 12 09 f Acronyms and Abbreviations General Information The following list contains some of the acronyms and abbre viations used in this manual API ASTM ATS BTU C CARB C I D CPL cSt DEF DPF ECM EGR ELC 8 American Petroleum Institute American Society of Testing and Materials After Treatment System British Thermal Unit Celsius California Air Resources Board Cubic Inch Displacement Control Parts List Centistokes Diesel Exhaust Fluid Diesel Particulate Filter Electronic Control Module Exhaust Gas Recirculation Extended Life Coolant EMI EPA ESN F FMI GVW HEST LPG Hg hp ICM km l kPa LTA MPa mph mpq Y53 1030A 12 09 Introduction Electromagnetic Interference Environmental Protection Agency Engine Serial Number Fahrenheit Failure Mode Indentifier Gross Vehicle Weight High Exhaust System Temperature Liquified Petroleum Gas Mercury Horsepower Water Ignition Control Module Kilometers per Liter Kilopascal Low Temperature Aftercooling Megapascal Miles Per Hour Miles Per Quart PACCAR Introduction Nem NG OEM PID ppm psi PTO RGT rpm SAE SCA SCR STC SID VGT VS VSS PACCAR Newton meter Natural Gas Original Equipment Manufacturer Parameter Identification Descriptions Parts Per Million Pounds Per Square Inch Power Takeoff Rear Gear Train Revolutions Per Minute Society of Automotive Engineers Sup
32. cle in area where combustible chemicals or vapors may be present IT IS THE RESPONSIBILITY OF THE OWNER AND OPERATOR TO OPERATE THE VEHICLE IN A SAFE ENVIRONMENT NOTE Numerous safety devices ie engine shutoff devices are available to minimize the risk of engine overspeeding caused by combustible vapors being ingested into the air intake system PACCAR Operating Instructions 8 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 PACCAR Y53 1030A 12 09 15 E 17d00100a 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 2 3 16 Check engine lamp amber in color STOP engine lamp red in color Diesel Particulate Filter DPF status indicator amber in color 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
33. coolant must be treated by adding 0 24 liter 8oz of liquid silicate fluid for every 45 liters 12 gal of total coolant system volume It is critical to not over treat the coolant with silicate fluid If over treatment is suspected drain the cooling system and discard the filter Clean the cooling system immediately Symptoms of silicate over treatment can be thickened coolant in the lower radiator tank water pump seal leakage soon after sili cate addition reduced heater output and or elevated engine temperatures To obtain order forms or ask questions relative to ordering the silicate fluid contact Silicate Fluid Order Program P O Box 27388 Houston TX 77277 7388 Phone 800 346 9041 Fax 800 876 5317 67 If the replacement coolant is Chevron Texaco Shell Rotella or their private label counterparts the coolant must be replaced with new coolant whenever the engine is over hauled or repairs involve the replacement of the following components Rocker lever housing gasket Lubricating oil cooler housing gasket e Cylinder head gasket Thermostat housing gasket For further details of engine coolant for PACCAR PX 8 engines refer to Cummins Coolant Requirements and Main tenance Bulletin 3666132 Checking Coolant Condition To ensure the Extended Life Coolant ELC in your vehicle always provides maximum freeze protection perform the fol lowing tests 1 Check the coolant color at every maintenance int
34. eave your vehicle unattended shut down the engine PACCAR Operating Instructions A 23 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 e 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 e Carefully and slowly turn cap one turn to allow excess pressure to escape then push down and turn for final removal See the Truck Oper ator s Manual for instructions on checking and filling the coolant expansion tank Performance Sound Service A Engine a oi800k01 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 Y53 1030A 12 09 PACCAR Loss of power An
35. ents that may affect engine emission controls The use of non genuine engine or vehicle replacement parts that are not equivalent to the PACCAR engine or OEM vehicle manufacturer s original part may impair the engine and vehicle emissions control system from working or functioning effectively and may jeop ardize your emissions warranty coverage The owner may elect to have maintenance replacement or repair of the emission control parts performed by a facility other than a PACCAR authorized dealer or an authorized Cummins Distributor and may elect to use parts other than 84 Y53 1030A 12 09 WARRANTY new genuine approved rebuilt parts and assemblies for such maintenance replacement or repair however the cost of Such service or parts and subsequent failures resulting from Such service or parts will not be covered under this emission control system warranty except for Emergency Repairs as described below PACCAR Responsibilities The warranty coverage begins when the engine is delivered to the first purchaser Repairs and service will be performed by any authorized PACCAR Engine dealer or an authorized Cummins Distributor using new or genuine approved rebuilt parts and assemblies PACCAR will repair any of the emis sion control parts found by PACCAR to be defective without charge for parts or labor including diagnosis which results in determination that there has been a failure of a warranted emission control part Eme
36. er val It should be a bright red with no signs of debris or any oil 2 Test the freeze point at least two times a year A refractometer or test strips can be used to measure the protection level 3 Keep the cooling system at full levels by topping up using ELC pre diluted 50 50 68 Y53 1030A 12 09 Maintenance Specifications ra8toda A refractometer must be used to measure the freezing point of the coolant accurately Use Fleetguard refractometer Part Number C2800 PACCAR Maintenance Specifications Recommended Extended Life Coolant Suppliers Brand Name Supplier LE za PACCAR Authorized PACCAR engine dealer oi804vw CAUTION Do not use a floating ball hydrometer A The use of floating ball hydrometers can give an incorrect reading Using a floating ball hydrome ter for testing the freezing point of the coolant is an inaccurate test and will cause a false reading of the coolant freezing point Use a refractome ter to obtain an accurate test of the coolant freezing point Y53 1030A 12 09 69 Cooling System Sealing Additives A 70 CAUTION The use of sealing additives in the cooling system will cause damage to the engine Sealing additives will plug various areas of the radiators and oil cooler The plugging of the cooling system will hamper heat transfer thus causing internal engine damage Do not use sealing additives in the cooling system The u
37. eration below 30 C 86 F could cause severe damage to the engine Idle the engine 3 to 5 min utes at approximately 1000 rpm to warm the engine before activating the engine brakes A CAUTION Do not operate the engine brake until 34 53 1030 12 09 PACCAR Operating Instructions RESUME ACCEL Engine Brakes eb800be 00800004 ON position Once activated the operation of the engine clutchless gear shifting will cause the engine to brake is fully automatic stall or lead to engine damage Engine brakes used in clutchless shifting causes additional To activate the engine brakes switch the on off switch to the CAUTION Using the engine brakes to aid in NOTE See the Tips for Operation steps in this strain on the engine valve train and causes LE section for specific information about engine brake severe internal engine damage Do not use operation under certain road conditions engine brakes to assist in gear shifting the vehicle s service brakes when slowing the vehi is below 850 rpm or when an electronic fault code is active NOTE The engine brakes are designed to assist The ECM will disable the engine brakes when engine speed cle to a stop Remember service brakes will be required to bring the vehicle to a stop PACCAR Y53 1030A 12 09 35 brake that will not deactivate will cause severe engine damage Inoperable engine brakes can cause an additional strain on the engine val
38. fore the expiration of the applicable warranty Owner must notify a PACCAR authorized dealer or an authorized Cum mins Distributor of any Warrantable Failure and make the engine available for repair by such facility The Warrantable Failure must be brought to the attention of a PACCAR autho rized engine dealer within 30 days of discovery Except for Engines disabled by a Warrantable Failure Owner must also deliver the Engine to the repair facility Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a Warrant able Failure Owner is responsible for non Engine repairs and for down time expenses cargo damage fines all applicable taxes all business costs and other losses resulting from a Warrantable Failure Owner is responsible for a 100 U S Dollars deductible per each service visit under this plan in the 3rd 4th and 5th years of base engine warranty The deductible will not be charged during the first two years of the base engine war ranty PACCAR Y53 1030A 12 09 Limitations Your sole and exclusive remedy against PACCAR and the Selling Dealer arising from your purchase and use of this Engine is limited to the repair or replacement of warrantable failures a
39. hen the intake air heater grid heater needs to warm the intake air prior to starting the engine The WAIT TO START lamp on time will vary depending on the ambient air temperature See Normal Starting Procedure on page 15 _ 25 For vehicles equipped with an engine starting motor protec tion feature another function of the WAIT TO START lamp is to flash for two minutes if the starting motor is engaged for 30 seconds or more The WAIT TO START lamp can look like The words WAIT TO START spelled out A symbol similar to the graphic illustrated The color of the symbol or words can vary based on the manufacturer of the vehicle but will typically be red or amber Check Engine Lamp The CHECK ENGINE lamp illuminates when the engine needs service at the first available opportunity The CHECK ENGINE lamp is located on the face of the tachometer and illuminates amber when a problem exists but the vehicle can still be safely driven Vehicle should be 26 53 1030 12 09 Operating Instructions serviced to correct the problem but the situation should not be considered an emergency The Check Engine lamp will activate for several reasons These include but are not limited to Water in Fuel and Diesel Particulate Filter DPF generation required Stop Engine Lamp The STOP ENGINE lamp indicates when illuminated the need to stop the engine as soon as it can be safely done The engine must remain sh
40. his section of the operator s manual _ 59 Maintenance Specifications CAUTION Using diesel fuels blended with lubri At operating temperatures below 0 C 32 F acceptable per A cating may cause damage to your exhaust after formance can be obtained by using blends of number 2D and treatment system Service intervals for number 1D aftertreatment systems will be reduced Do not use diesel fuel blended with lubricating oil in engines equipped with an aftertreatment sys tem CAUTION Do not use high sulfur diesel fuel as it will damage the exhaust aftertreatment system Also the engine will not meet emission regula tions Use only Ultra Low Sulfur Diesel ULSD fuel an aftertreatment system together with ULSD fuel to meet the 2010 U S Environmental Protection Agency EPA regulations li NOTE The engine has been optimized for use with Ultra low sulfur diesel fuel is defined as diesel fuel not exceeding 0 0015 15 ppm mass percent sulfur content ultra low diesel fuel is also defined by ASTM 5 15 There are no acceptable substitutes PACCAR recommends the use of ASTM number 2D fuel The use of number 2 diesel fuel will result in optimum engine performance 60 53 1030 12 09 PACCAR Maintenance Specifications The following chart lists acceptable types of fuels for this engine Acceptable Types of Fuels Number 1D Number 2D par Pe MASSEN Jet A1 J
41. iciently Example NOTE Pumping the accelerator will not assist in LE starting the engine Please take the time to read these messages when you see them and remember WARNING Something that could cause an injury or even death CAUTION Something that could cause damage to your vehicle NOTE Useful information Y53 1030A 12 09 Introduction 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 con dition The illustrations are intended to show repair or replacement procedures The procedure will be the same for all applica tions although the illustration can differ PACCAR Introduction General Safety Instructions Important Safety Notice ignoring the warnings can cause burns cuts WARNING Improper practices carelessness mutilation asphyxiation or other personal injury or death Read and understand all of the safety precautions and warn ings before performing any repair This list contains the gen eral safety precautions that must be followed to provide personal safety Special safety precautions are included in the procedures when they apply PACCAR Work in an area surrounding the product that is dry well lit ventilated free from clutter
42. il Drain Intervals table in this procedure 2 Service interval is every oil change or 24 000 km 15 000 mi 500 hours or 6 months whichever occurs first A heavy duty year round antifreeze that meets the chemical composition of GM6038M must be used The change interval is 2 years or 385 000 km 240 000 mi whichever occurs first Anti freeze is essential for freeze overheat and corrosion protection SCA is essential for liner pitting and scaling protection 3 Service interval is 2 years or 385 000 km 240 000 mi whichever occurs first 4 Follow the manufacturers recommended maintenance procedures for the starter alter nator batteries electrical components PACCAR Maintenance Guidelines engine brake exhaust brake charge air cooler radiator air compressor air cleaner refrigerant compressor and fan clutch 5 Reset valve lash if needed to nominal speci fications Refer to General Engine Specifica tions on page 55 The aftertreatment diesel particulate filter clean replace interval is based on the use of lubricating oils that meet the Cummins Engineering Standard C E S 20081 oil specification If a non low ash lubricating oil meeting the American Petroleum Institute API performance classification Cl 4 SL and or C E S 20078 is used the service intervals for the aftertreatment systems will be reduced to 241 000 150 000 mi or 5000 hours Replace the primary or suction side fuel filter
43. in material or factory workmanship which would cause it not to meet these regulations within the longer of the following periods A Five years or 100 000 miles 160 935 kilometers of oper 1 United States includes American Samoa the Common wealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands PACCAR Y53 1030A 12 09 ation whichever occurs first as measured from the date of delivery of the Engine to the first purchaser or B The Base Engine Warranty If the vehicle in which the Engine is installed is registered in the state of California a separate California Emission War ranty also applies Replacement Parts PACCAR recommends that any service parts used for main tenance repair or replacement of emission control systems be new or genuine approved rebuilt parts and assemblies and that the engine be serviced by an authorized PACCAR Engine dealer or an authorized Cummins Distributor Your vehicle contains air fuel and electrical components that may affect engine emission controls The use of non genuine engine or vehicle replacement parts that are not equivalent to the PACCAR engine or OEM vehicle manufacturer s original part may impair the engine and vehicle emissions control system from working or functioning effectively and may jeop ardize your emissions warranty coverage Limitations Your sole and exclusive remedy against PACCAR and the Selling Dealer arising from your purchase a
44. increase in oil consumption An increase in fuel consumption Fuel oil or coolant leaks N CAUTION Do not allow your engine to idle at low rpm s 400 600 rpm longer than five min utes Long periods of idling after the engine has reached operating temperatures can decrease engine temperature and cause gummed piston rings clogged injectors and possible engine damage from lack of lubrication The normal tor sional vibrations generated by the engine can also cause transmission wear If an engine must idle for an extended period of time it should be done at fast idle 1 000 rpm or greater NOTE An idle shutdown feature available on PACCAR Engines can be programmed to shut the engine down after a period of low idle speed operation with no driver activity A flashing warning lamp will inform the driver of an impending shutdown NOTE The power take off PTO feature available on PACCAR engines can be programmed to adjust engine idle speed with the use of switches to pre pro grammed set points Y53 1030A 12 09 Operating Instructions Cold Weather It is possible to operate engines in extremely cold environments if they are properly prepared and maintained Satisfactory performance of an engine in low ambient temperature conditions requires modification of the engine surrounding equipment operating practices and maintenance procedures The correct engine coolant lubricating oil and fuels must be used for the c
45. ion Check Radiator Pressure Cap Check Batteries Check Battery Cables and Connections Check e Battery condition electrolyte level cracks signs of leaking overcharging Harness cables for loose connections chafing broken retention clips Battery hold downs for tightness Battery box mounting bolt torque corrosion Every 64 000 km 40 000 mi 1000 Hours or 1 Year Maintenance Check Fuel Filter Spin On Type Change Drive Belt Cooling Fan Change Belt Tensioner Automatic Water Pump Check Cooling System Check Radiator Pressure Cap Check Supplemental additive conditioner level Coolant level Coolant protection Replace coolant filter PACCAR Y53 1030A 12 09 Every 128 000 km 80 000 mi 2000 Hours or 2 Years Maintenance Check Cooling System Drain Flush Fill Engine Steam Cleaning Clean Air Compressor Discharge Lines Clean e Radiator Hoses Check Hose condition deterioration signs of leaking Hose clamp torque Vibration Damper Check Damper for cracks nicks gouges Condition of damper rubber isolator Damper fastener torque Crankcase Ventilation Filter Replace Every 241 000 km 150 000 mi 5000 Hours or 4 Years Maintenance Check Overhead Set Adjust Exhaust System Change Replace exhaust flex pipe s Every 321 500 km 200 000 mi 6500 Hours Mainte nance Check e Aftertreatment Diesel Particulate Filter Clean
46. itions to exist between the accessory and PACCAR electronic controlled fuel system PACCAR is not liable for any performance problems with either the fuel system or the accessory due to EMI EMI is not considered by PACCAR to be an engine failure and therefore is not warrantable System EMI Susceptibility PACCAR S electrical system design will protect your engine from most if not all electromagnetic energy emitting devices that meet the Federal Communications Commission legal requirements System EMI Radiation Levels Your PACCAR product has been designed to emit minimum electromagnetic energy Electronic components are required to pass various PACCAR EMI specifications Testing has shown that when the engine is properly maintained it will not PACCAR Operating Instructions interfere with onboard communication equipment or with the vehicle s ability to meet any applicable EMI standards and regulated specifications If an interference condition is observed follow the suggestions below to reduce the amount of interference 1 Locate the receiving antenna as far away from the engine and as high as possible 2 Locate the receiving antenna as far away as possible from all metal obstructions e g exhaust stacks 3 Consult a representative of the accessory supplier in your area to e Calibrate accurately the device for proper frequency power output and sensitivity both base and remote site devices must be properly calibra
47. ivery of the Engine to the first purchaser whichever of the three occurs first Before a claim for excessive oil consumption will be con sidered Owner must submit adequate documentation to show that consumption exceeds PACCAR published stan dards Failures of belts and hoses supplied by PACCAR are cov ered for the first year from the date of delivery of the Engine to the first purchaser PACCAR does not warrant antifreeze lubricants filters filter elements or any other part which is considered a mainte nance item Parts used to repair a Warrantable Failure may be new parts approved rebuilt parts or repaired parts PACCAR is not responsible for failures resulting from the use of parts not approved by PACCAR A new approved rebuilt part used to repair a Warrantable Failure assumes the identity of the part it replaced and is entitled to the remaining coverage hereun der PACCAR is not responsible for damage or loss resulting from Engine horsepower torque upgrades PACCAR Y53 1030A 12 09 PACCAR Inc reserves the right to interrogate Electronic Con trol Module ECM data for purposes of failure analysis PACCAR DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS THIS WARRANTY AND THE EMISSION WARRANTY SET FORTH HEREINAFTER ARE THE SOLE WARRANTIES MADE BY PACCAR IN REGARD TO THESE ENGINES THIS LIMITED WARRANTY IS THE SOLE WARRANTY MADE BY PACCAR AND THE SELLING DEALER EXCEPT FOR THE ABOVE LIMITED WARRANTY PACCAR AND
48. loose tools parts ignition sources and hazardous substances Be aware of haz ardous conditions that can exist Always wear protective glasses and protective shoes when working Rotating parts can cause cuts mutilation or strangula tion Do not wear loose fitting or torn clothing Remove all jewelry when working Disconnect the battery negative cable first and dis charge any capacitors before beginning any repair work Y53 1030A 12 09 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 prac tice can cause serious personal injury property damage or damage to the fan blade s causing premature fan fail ure 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 prod uct 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 sys tems before any lines fittings or related items are removed or disconnected Be alert for possible pressure when disconnecting any device from a system that u
49. ls begin to skid or if there is a fishtailing motion do not activate the engine brakes f traction is maintained using the retarding power of the engine alone and more braking power is required switch the two position selector switch to the LOW position and activate the engine brakes by switching the on off switch to the ON position PACCAR If the vehicle s drive wheels begin to skid or there is a fishtailing motion switch the on off switch to the OFF position If traction is maintained when the engine brakes are activated and more braking power is required move the two position selector switch to the HI position Again if the vehicle has lost traction or if there is a fishtailing motion switch the on off switch to the OFF position Do not attempt to use the engine brakes in the HI position Y53 1030A 12 09 41 ON START 3 TO 5 MINUTES oi800v05 Engine Shutdown General Information shutting it off after a full load operation This allows adequate cool down of pistons cylinders bearings and turbocharger components NOTE Allow the engine to idle 3 to 5 minutes before 42 Y53 1030A 12 09 Operating Instructions Electromagnetic Interference EMI General Information Some engine applications utilize accessories CB radios mobile transmitters etc that generate and use radio frequency energy that if not installed and used properly can cause electromagnetic interference EMI cond
50. n emergency Oper ating 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 ny Operating Instructions eg8gask 07900017 Idle the engine 3 to 5 minutes before operating with a load After starting a cold engine increase the engine speed rpm 18 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 3 to 5 minutes 9l800v02 service brake pedal Depress the accelerator pedal Y53 1030A 12 09 PACCAR Operating Instructions For more information on the Fast Idle Warm Up feature contact a PACCAR authorized repair location oi800be CAUTION Do not operate the engine at low idle A for long periods with engine coolant tempera ture below the minimum specification in Cool ing System on page 57 This can result in the following Fuel dil
51. n running on the Date of Delivery to the First Purchaser The accrued time mileage or hours is cal culated when the engine is brought into an Authorized Dealer for correction of warrantable failures PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect including but not limited to damage due to accident opera tion without adequate coolants or lubricants overfueling overspeeding lack of maintenance of cooling lubricating or PACCAR Y53 1030A 12 09 intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications to the engine PACCAR is also not responsible for failures caused by incorrect oil fuel or diesel exhaust fluid or by water dirt or other contaminants in the fuel oil or diesel exhaust fluid Failure of replacement parts used in repairs due to the above non warrantable conditions is not warrantable PACCAR is not responsible for failures resulting from improper repair or the use of parts which are not genuine approved parts PACCAR is not responsible for the material and labor costs of emission control parts and assemblies replaced during Scheduled Maintenance of the engine as specified in PACCAR Operator s Manuals THIS WARRANTY TOGETHER WITH THE EXPRESS COMMERCIAL WARRANTIES ARE THE SOLE WARRAN TIES MADE BY PACCAR IN REGARD TO THESE ENGINES THIS LIMITED EMISSIONS WARRANTY IS THE SOLE WARRANTY MADE BY PACCA
52. nd use of this Engine is limited to the repair or replacement of warrantable failures at authorized United States and Canadian PACCAR 79 Engine Dealers or an authorized Cummins Distributor or an authorized PACCAR Engine facility where applicable sub ject to PACCAR s time mileage and hour limitations of the engine emission warranty The maximum time mileage and hour limitations of the engine emission warranty begin run ning on the Date of Delivery to the First Purchaser The accrued time mileage or hours is calculated when the engine is brought into an Authorized Dealer for correction of warrantable failures Failures other than those resulting from defects in material or factory workmanship are not covered by this Warranty PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect including but not limited to damage due to accident opera tion without adequate coolants or lubricants overfueling overspeeding lack of maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications of the Engine PACCAR is also not responsible for failures caused by incorrect oil fuel or diesel exhaust fluid or by water dirt or other contaminants in the fuel oil or diesel exhaust fluid Fail ure of replacement parts used in repairs due to the above non warrantable conditions is not warrantable P
53. ne brakes Make max imum use of your engine brakes by gearing down and letting the engine brakes do the work Y53 1030A 12 09 39 eb800vi If frequent use of the vehicle service brakes is required it is recommended that a slower control speed be used by selecting a lower transmission gear Tips for Operation on Slick Roads The operation of any vehicle is difficult to predict on slick roads The first 10 to 15 minutes of rainfall are the most dangerous as road dirt and oil mixed with rain create a very slippery surface 40 Y53 1030A 12 09 Operating Instructions eb800bc when driving operating your vehicle bobtail or with a loaded or unloaded trailer on road sur faces with poor traction wet icy or snow cov ered roads or in heavy traffic Braking caused by the normal operation of the engine brake could cause you to lose control of the vehicle resulting in an injury accident WARNING Do not operate the engine brake When driving on slick roads start with the on off switch in the OFF position and the two position selector switch in the LOW position PACCAR Operating Instructions eb800vf If your tractor is equipped with a twin screw rear axle position the power divider switch in the unlocked position Remove your foot from the accelerator pedal to make sure the vehicle will maintain traction with the retarding power of the engine alone If the vehicle drive whee
54. ngine 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 WARRANTY beginning on page 73 Make sure you are familiar with the warranty or warranties applicable to your H NOTE Warranty information including the EPA and California Emission Warranty is located in the section entitled engine PACCAR Y53 1030A 12 09 Foreword PACCAR PX 8 Foreword Introduction Safety Signals oer b DARE bs uyu dee bs Ill stratioris p ee et LEO General Safety Instructions Acronyms and Abbreviations Engine Identification Engine Dataplate PACCAR Engine Nomenclature Operating Instructions General Information Normal Starting Procedure Cold Weather Starting Starting Procedure After Extended Shutdown or Oil Change u REY Operating the Engine Cold Weather reser MUERE IBERIA Coolant Recommentations and Specifications Lubricating Recommentations and Specifications Diesel Fuel Recommendations Engine Indicator Lamps Operator s Manual Contents Engine Operating Range 27 Engine Braking System
55. nited States includes American Samoa the Common wealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands 76 Y53 1030A 12 09 WARRANTY Engine aftertreatment components included in the PACCAR Critical Parts List CPL and marked with a PACCAR part number are covered under Base Engine Warranty Addi tional coverage is outlined in the Emission Warranty section PACCAR Responsibilities PACCAR will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure PACCAR will pay for the lubricating oil antifreeze filter ele ments belts hoses and other maintenance items that are not reusable due to the Warrantable Failure PACCAR will pay for reasonable labor costs for Engine removal and reinstalla tion when necessary to repair a Warrantable Failure PACCAR will pay reasonable costs for towing a vehicle dis abled by a Warrantable Failure to the nearest authorized repair location In lieu of the towing expense and at its sole discretion PACCAR will pay reasonable costs for a mechanic to travel to and from the location of the vehicle when its engine repair is performed at the site of the failure Owner Responsibilities Owner is responsible for the operation and maintenance of the Engine as specified in PACCAR Operator s Manual Owner is also responsible for providing proof that all recom mended maintenance has been performed PACCAR WARRANTY Be
56. nk Replacement or top up coolant should have the same antifreeze concentration and corrosion inhibi tor content as the original coolant in the cooling sys tem Never add 100 antifreeze to the cooling system Always dilute antifreeze to the correct concentration based on freeze protection prior to adding it to the Chaffing Deterioration 46 Y53 1030A 12 09 Maintenance Guidelines cooling system Adding or using 100 antifreeze in a cooling system may result in cooling system plug ging and overheating problems Every 16 000 km 10 000mi 250 Hours or 3 months Maintenance Check Air Cleaner Restriction Check Correct Service filter element when Air Cleaner Restriction Gauge option locks in the extreme High position Hose pipe condition deterioration signs of leaking Hose clamp torque Charge Air Piping check Correct Hose pipe condition chaffing deterioration leaks Hose clamps for tightness Clearance to other components Charge Air Cooler Check Correct e Cracked tubes or header Clogged fins tubes Hose pipe condition deterioration signs of leaking Hose clamp torque Exhaust system Check Correct check for leaks and proper support Every 32 000 km 20 000 mi 500 Hours or 6 months Maintenance Check Fuel Filter Spin on type replace Lubricating Oil Change PACCAR Maintenance Guidelines Lubricating Oil filters Replace Antifreeze Concentrat
57. o prolong the life of internal moving components Follow the oil and filter change intervals as rec ommended in this section of the manual The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals is a critical factor in maintaining engine performance and durability Extending the oil and filter change interval beyond the recom mendations will decrease engine life due to factors such as corrosion deposits and wear Refer to Oil Drain Intervals on page 49 to determine which oil drain interval to use for an application ommendations are ignored warranty could be NOTE The responsibility is with the owner If rec affected API American Petroleum Institute PACCAR Maintenance Specifications CES Cummins Engineering Standard PACCAR allows for midrange applications the use of lubri cating oils that meet or exceed CES 20078 or CES 20081 with no change in oil drain interval But if a non low ash lubri cating oil meeting the Cummins Engineering Standard CES classification CES 20078 is used the service interval s for the aftertreatment system will be reduced CES 20081 PACCAR Y53 1030A 12 09 07d00259 63 To determine if the lubricating oil meets CES 20078 or CES 20081 review the label on the back of the lubricating oil bot tle for the CES 20078 or CES 20081 reference If acquiring the lubricating oil in bulk contact the supplier for the lubricat
58. old weather range in which the engine is being operated Below are the recommendations for these critical engine fluids Coolant Recommentations and Specifications The cooling system in your vehicle was factory filled with Extended Life Coolant ELC that meets or exceeds all ASTM D 6210 requirements PACCAR recommends only using a 50 50 mixture of distilled water and ELC when cooling system service is required A 50 50 mixture of ELC and distilled water will provide freeze protection down to 34 F 36 7 C which is adequate for most locations in North America For extremely cold operating conditions a 60 40 mixture coolant water ratio can be used to provide freeze protection down to 62 F 52 2 C PACCAR Operating Instructions Lubricating Recommentations and Specifications Refer to Lubricating Oil Recommendations and Specifications on page 62 for the correct specifications Diesel Fuel Recommendations The Diesel fuel must have maximum cloud and pour points 6 C 10 F lower than the ambient temperature in which the engine operates PACCAR Y53 1030A 12 09 Engine Indicator Lamps General Information The following engine indicator lamps cover only the lamps controlled by the engine s ECM The vehicle manufacturer can provide additional indicator lamps Please refer to the vehicle s operator s manual for additional lamp information WAIT Wait to Start Lamp The WAIT TO START lamp illuminates w
59. oolant 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 Introduction 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 immedi ately 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 reg ulations 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 engine Do not expose the engine to corrosive chemicals A CAUTION Corrosive
60. ou are responsible for presenting your engine to an authorized PACCAR Dealer or an authorized Cummins Distributor as soon as a problem exists The war ranty repairs should be completed in a reasonable amount of time not to exceed 30 days PACCAR recommends that you retain all receipts covering maintenance on your engine but PACCAR cannot deny war ranty solely for the lack of receipts or for the failure to ensure the performance of all scheduled maintenance 81 As the engine owner you should also be aware that PACCAR may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper mainte nance or unapproved modifications If you have any questions regarding your warranty rights and responsibilities you should contact the vehicle OEM manu facturer at the customer center telephone number provided with your vehicle operating instructions or the California Air Resource Board at 9528 Telstar Avenue El Monte CA 91731 A warranted part which is scheduled for replacement as required maintenance is warranted up to the first scheduled replacement point Prior to the expiration of the applicable warranty Owner must give notice of any warranted emission control failure to an authorized PACCAR Engine dealer or an authorized Cum mins Distributor and deliver the engine to such facility for repair Owner is responsible for incidental costs such as communi cation expenses meals lodging incurred by
61. plemental Coolant Additive Selective Catalytic Reduction Step Timing Control Subsystem Identification Descriptions Variable Geometry Turbocharger Variable Speed Vehicle Speed Sensor Y53 1030A 12 09 10 Y53 1030A 12 09 Introduction PACCAR w ENGINE IDENTIFICATION Engine Dataplate PACCAR PX 8 Engine meno Model mund Rote of odv Se dh MANUFACTURED BY CUMMINS INC abled i em Idle Speed rpm YO Advertised HP XXX al XXX rpm Family mnnn FEL EPA CARB Firing order MO Timing 1 0 0 ELECTRONIC Catalyst b paru Valve fost cold TID Bb C L 0 0 E PE Taie of Wig O WARNING Injory may resell and warroniy is voided if fuel rote rpm or oltitedes IMPORTANT ENGINE INFORMATION This engine conforms with 0 5 EPAICARG ri ions fer model year QUU exceed published sarin values for this This engine is fer export tip end il is wol cerliied for sole is the model ond application 00d00001 The engine dataplate provides important facts about the engine The engine serial number ESN and control parts list CPL provide information for service and ordering parts The engine dataplate must not be changed unless approved by PACCAR Inc PACCAR Y53 1030A 12 09 inier Medel Ui Foel Rete ol odr H DD Nu ih eee idle Speed epa III Advertised BP IIX el KIII rpm Fonily
62. r 7571 liters 2000 US gal of fuel whichever occurs first gal of fuel whichever occurs first Vehicle uses the severe duty oil drain interval Vehicle uses the normal duty oil drain interval B Table 2 Oil Drain Intervals Refuse Truck Mixer or Dump Truck Kilometers Miles Hours Months Below 10 mph average 4 850 3 000 500 6 10 to 15 mph average 9 650 6 000 500 6 15 to 20 mph average 13 700 8 500 500 6 20 to 25 mph average 14 500 9 000 500 6 Higher than 25 mph average 19 000 12 000 500 6 PACCAR bases its oil drain specifications on duty cycle and Maintaining the correct oil and filter change interval is a vital oil contamination This contamination occurs in all engines at factor in preserving the integrity of an engine Filters must be varying rates regardless of design changed when the oil is changed 50 Y53 1030A 12 09 PACCAR Maintenance Guidelines Maintenance Record Form Engine Serial No Engine Model Owner s Name Equipment Name No Date km Miles Hours Actual Miles Maintenance Check Performed Commens or Time Interval or Hours Check Performed By PACCAR Y53 1030A 12 09 52 Y53 1030A 12 09 Maintenance Guidelines PACCAR Additional Service Literature General Information SERVICE LITERATURE The following publications can be purchased from your authorized P
63. r property damage always be prepared to use the vehicle service brakes for emergency stopping The safe control speed of a vehicle will vary with the size of the load the type of load the grade and the road conditions NOTE The exhaust brake can only be activated when the accelerator pedal is at its low idle position With the throttle at low idle position fueling com mands to the cylinders will not detract from the brak ing power of the brake system NOTE The engine VGT exhaust brake is designed to assist the vehicle s service brakes when slowing the vehicle to a stop Y53 1030A 12 09 29 Operating Instructions Typically on vehicles equipped with automatic transmissions the engine electronic control module ECM and the transmission will determine the correct gear selection E eb800be Vehicle service brakes must always be used The engine brake is not intended to be used as the primary brake of the vehicle nor is it an emergency brake The engine retarder only helps the service brakes by using pressure to slow the divetrain Use the service brakes for quick stops CAUTION Exceeding governed engine speed A can cause engine damage Operating the engine beyond the maximum engine speed may cause serious engine damage and is considered engine abuse Use the engine and vehicle brak ing systems to control engine speed The optimum braking power of the engine VGT exhaust brake is reached a
64. ration at ambient temperatures above 15 C 5 F The use of multi grade oil reduces deposit formation improves engine crank ing in low temperature conditions and increases engine PACCAR Maintenance Specifications durability by maintaining lubrication during high temperature operating conditions Since multigrade oils have been shown to provide approximately 30 percent lower oil consumption compared with monograde oils it is important to use multi grade oils to be certain the engine will meet applicable emis sions requirements Use of synthetic engine oils those made with API group 3 or group 4 base stocks is permitted subject to the same per formance and viscosity limitations of petroleum mineral based engine oils The same oil change intervals must be applied to synthetic oils that are applied to petroleum min eral based engine oils Temperature F 40 20 0 20 40 60 80 100 120 140 All Seasons EX m s All Seasons Winter Conditions Winter Conditions Arctic Conditions 40 30 20 10 0 10 20 30 40 50 60 Temperature C 07d00260 While the preferred viscosity grade is 15W 40 lower viscosity multigrade oils can be used in colder climates See the accompanying chart Any viscosity grade lower than 15W 40 must still meet CES 20081 PACCAR Y53 1030A 12 09 Synthetic engine oils API Group 11 and Group IV base stocks are recommended for use in PACCAR engines oper
65. rgency Repairs In the case of an emergency where an authorized PACCAR Engine dealer or an authorized Cummins Distributor is not available repairs may be performed by any available repair location or by any individual using any replacement parts A part not being available within 30 days or a repair not being complete within 30 days constitutes an emergency PACCAR will reimburse the Owner for expenses including diagnosis not to exceed the manufacturers suggested retail price for all PACCAR WARRANTY warranted parts replaced and labor charges based on the manufacturers recommended time allowance for the war ranty repair and the geographically appropriate hourly labor rate Replaced parts and paid invoices must be presented at an authorized PACCAR Engine dealer or authorized Cum mins Distributor as a condition of reimbursement for emer gency repairs not performed by an authorized PACCAR Engine dealer or an authorized Cummins Distributor Warranty Limitations Your sole and exclusive remedy against PACCAR and the Selling Dealer arising from your purchase and use of this Engine is limited to the repair or replacement of warrantable failures at authorized United States and Canadian PACCAR Engine Dealers or an authorized PACCAR Engine facility where applicable subject to PACCAR s time mileage and hour limitations of the engine emission warranty The maxi mum time mileage and hour limitations of the engine emis sion warranty begi
66. ry accident Make sure the engine brake is switched OFF pA NOTE Once you have determined what the safe when bobtailing Or witir an unlioaded trailer LE speed is for your vehicle operate the engine brakes Control speed is the speed at which the forces with the transmission in the lowest gear that will not pushing a vehicle down a grade are equal to the forces cause the engine speed to exceed the rated engine holding it back speed The optimum braking power of the engine brakes is reached at rated engine speed Correct gear selection therefore is critical The two position selector switch can be used to vary braking power as road conditions change W e OX eb800vf 38 53 1030 12 09 PACCAR Operating Instructions The engine brake is NOT intended as the primary brake for the vehicle nor is it an emergency brake The engine brake only helps the service brakes by using pressure to slow the drivetrain Use the service brakes for quick stops PACCAR eb800bb WARNING Do not drive with frequent or contin uous use of the service brakes This can over heat the brakes and result in excessive lining wear increased stopping distances possibly an accident and may lead to personal injury Before descending a steep grade shift to a lower gear keep the vehicle speed low and avoid continu ous application to the brakes NOTE The longer or steeper the hill the more important it is to use your engi
67. ry and ends two years or 250 000 miles 402 336 kilometers or 6 250 hours whichever occurs 1 United States includes American Samoa the Common wealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands PACCAR Y53 1030A 12 09 first after the date of delivery of the Engine to the first pur chaser Additional coverage is outlined in the Emission War ranty section PACCAR Responsibilities PACCAR will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure PACCAR will pay for the lubricating oil antifreeze filter ele ments belts hoses and other maintenance items that are not reusable due to the Warrantable Failure PACCAR will pay for reasonable labor costs for Engine removal and rein stallation when necessary to repair a Warrantable Failure PACCAR will pay for the first year from the date of delivery of the Engine to the first purchaser reasonable costs for towing a vehicle disabled by a Warrantable Failure to the nearest authorized repair station In lieu of the towing expense and in its sole discretion PACCAR may pay reasonable costs for a mechanic to travel to and from the location of the vehicle when an engine repair is performed at the site of the failure 73 Owner Responsibilities Owner is responsible for the operation and maintenance of the Engine as specified in the applicable PACCAR Opera tor s Manual Owner is also respon
68. s with large amounts of water for a minimum of 15 min utes Do not swallow internally In the event the diesel exhaust fluid is ingested contact a physi cian immediately Reference the Materials Safety Data Sheets MSDS for additional information CAUTION Never attempt to create Diesel Exhaust Fluid by mixing agricultural grade urea with water Agricultural grade urea does not meet the necessary specifications required and the aftertreatment system may be damaged Fuel Recommendations and Specifications Fuel Recommendations A A A Y53 1030A 12 09 WARNING Mixing other fuels with diesel can cause an explosion Do not mix gasoline alco hol or gasohol with diesel fuel Make sure you know your fuel source and use the recom mended diesel fuel as indicated in this section of the Operator s manual CAUTION Dirt or water in the fuel system can cause severe damage to both the fuel pump and the fuel injectors Due to the precise tolerances of diesel injection systems it is extremely important that the fuel be kept clean and free of dirt or water Know your fuel source and make sure all steps are taken for dispensing or using clean fuel in your vehicle CAUTION Lighter fuel can reduce economy or possibly damage fuel system components Lighter fuels typically do not have enough lubricity elements in the fuel to properly lubri cate the fuel injection system Be sure you fol low the fuel recommendations as indicated in t
69. se of sealing additives will e Buildup in coolant low flow areas Plug the radiator and oil cooler e Possibly damage the water pump seal Failure to comply may result in equipment or property damage Maintenance Specifications Sealing Additive Y53 1030A 12 09 PACCAR Maintenance Specifications Cooling System Soluble Oils system The use of soluble oils in the cooling system will cause damage to the engine Soluble oils in the cooling system will Corrode brass and copper Damage heat transfer surfaces e Damage seals and hoses CAUTION Do not use soluble oils in the cooling Failure to comply may result in equipment or property damage PACCAR Y53 1030A 12 09 aata 72 Y53 1030A 12 09 Maintenance Specifications PACCAR Jaa ss WARRANTY PACCAR PX 8 Engine United States and Canada Coverage Products Warranted This warranty applies to new PACCAR PX 8 Engines sold and used in the United States or Canada and operated in on highway applications with one exception there is differ ent warranty coverage for engines used in the fire apparatus truck applications The PACCAR PX 8 Engine is warranted directly to the first purchaser by PACCAR Base Engine Warranty This warranty covers any failures of the Engine which result under normal use and service from a defect in material or factory workmanship Warrantable Failure This coverage begins on the date of delive
70. sible for providing proof that all recommended maintenance has been performed Before the expiration of the applicable warranty Owner must notify a PACCAR authorized dealer or an authorized Cum mins Distributor of any Warrantable Failure and make the engine available for repair by such facility The Warrantable Failure must be brought to the attention of a PACCAR autho rized engine dealer within 30 days of discovery Owner must also deliver the Engine to the authorized engine repair facility during the warranty period unless deliver is impossible because the Engine has been disabled by a Warrantable fail ure Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items provided during warranty repairs unless such items are not reusable due to the Warrantable Failure Owner is responsible for communi cation expenses meals lodging and similar costs incurred as a result of a Warrantable Failure Owner is responsible for non Engine repairs and for down time expenses cargo damage fines all applicable taxes all business costs and other losses resulting from a Warrantable Failure 74 Y53 1030A 12 09 WARRANTY Limitations Your sole and exclusive remedy against PACCAR and the Selling Dealer arising from your purchase and use of this Engine is limited to the repair or replacement of warrantable failures at authorized United States and Canadian PACCAR Engine Dealers or an
71. t authorized United States and Canadian PACCAR Engine Dealers or an authorized Cummins Distributor or an authorized PACCAR Engine facility where applicable sub ject to PACCAR s time mileage and hour limitations of the engine warranty The maximum time mileage and hour limi tations of the engine warranty begin running on the Date of Delivery to the First Purchaser The accrued time mileage or hours is calculated when the engine is brought into an Authorized Dealer for correction of warrantable failures PACCAR is not responsible for failures or damage resulting from what PACCAR determines to be abuse or neglect including but not limited to damage due to accident opera tion without adequate coolants or lubricants overfueling overspeeding lack of maintenance of lubricating cooling or intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications of the Engine PACCAR is also not responsible for failures caused by incorrect oil fuel or diesel exhaust fluid or by water dirt or other contaminants in the fuel oil or diesel exhaust fluid Failure of replacement parts used in repairs due to the above non warrantable conditions is not warrantable This warranty does not apply to accessories supplied by PACCAR which are covered by the OEM vehicle warranty Failures resulting in excessive oil consumption are not cov ered beyond the duration of the coverage or 100 000 miles 160 935
72. t or exceed the Fleetguard specifications PACCAR can not be responsible for problems caused by non genuine filters that do not meet PACCAR performance or durability requirements 58 Filter Part Numbers Lubricating Oil Filter Fleetguard Part Number Fuel Filter primary pressure side Fleetguard Part Number Fie Fuel Filter secondary suction side with water in fuel sensor FS1065 Fleetguard Part Number Crankcase Breather Element Fleetguard Part Number S VS060900 Aftertreatment DEF Dosing Unit Filter 2980298 il NOTE An LF9009 lubricating oil filter must be used A venturi type lubricating oil filter must be used in order to benefit from the bypass filtration section of the lubricating oil filter Do not use an LF3000 lubri cating oil filter Engine durability will be reduced by using the wrong lubricating oil filter Y53 1030A 12 09 PACCAR Maintenance Specifications Diesel Exhaust Fluid Recommendations and Specifications General Information N A A PACCAR WARNING It is unlawful to tamper with or remove any component of the aftertreatment system It is also unlawful to use a Diesel Exhaust Fluid DEF that does not meet the specifications provided or to operate the vehi cle equipment with no Diesel Exhaust Fluid DEF WARNING Diesel Exhaust Fluid DEF contains urea do not get the substance in your eyes In case of contact immediately flush eye
73. t rated engine speed Correct gear selection therefore is critical 30 Y53 1030A 12 09 PACCAR Operating Instructions eb100va Compression Brake System The amount of braking power available in a given engine series varies Braking power depends on turbocharger boost pressure engine speed compression ratio injector timing and when the engine brakes open the exhaust valves PACCAR 20100103a Engine brake controls with the fuel system consists of the following A two position selector switch standard three position selector optional An on off switch Aclutch switch e A throttle sensor With the ON OFF switch in the ON position the brake automatically creates its braking effect when you remove your foot from the accelerator pedal Y53 1030A 12 09 31 es8bdga Other switches for cruise control that affect engine brake operations are Service brake air pressure switch if service brake actua tor feature is selected Clutch switch Throttle sensor The ECM allows the engine brakes to operate while the cruise control is turned on The two position selector switch standard or three position optional is located next to the on off switch in the cab and allows you to select the retarding power of one or two brakes 32 Y53 1030A 12 09 Operating Instructions Switches On Off Clutch Throttle CC PTO Service Brake 17c00013
74. ted Obtain antenna reflective energy data measure ments to determine the optimum antenna location Obtain optimum antenna type and mounting arrangement for your application Make sure your accessory equipment model is built for maximum filtering to reject incoming electromag netic noise PACCAR Y53 1030A 12 09 43 44 Y53 1030A 12 09 Operating Instructions PACCAR p vew s l MAINTENANCE GUIDELINES Overview General Information PACCAR recommends that the engine be maintained according to the Maintenance Schedule in this section If the engine is operating in ambient temperatures below 18 C 0 F or above 38 C 100 F perform maintenance at shorter intervals Shorter maintenance intervals are also required if the engine is operated in a dusty environment or if frequent stops are made Contact your local PACCAR Autho rized Repair Location for recommended maintenance inter vals Some of these maintenance procedures require special tools or must be completed by qualified personnel Contact your local PACCAR Authorized Repair Location for detailed infor mation If your engine is equipped with a component or accessory not manufactured by PACCAR Inc refer to the component manu facturer s maintenance recommendations Use the chart provided in this section as a convenient way to record maintenance performed PACCAR Y53 1030A 12 09 M
75. ti lizes pressure Do not check for pressure leaks with your hand High pressure oil or fuel can cause personal injury To reduce the possibility of suffocation and frostbite wear protective clothing and ONLY disconnect liquid refrigerant Freon lines in a well ventilated area To pro tect the environment liquid refrigerant systems must be properly emptied and filled using equipment that pre vents 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 Ib 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 Y53 1030A 12 09 Introduction Naptha and Methyl Ethyl Ketone MEK are flammable materials and must be used with caution Follow the m
76. ts DEF Dosing Valve and Associated Plumbing Exhaust Gas Recirculation Flow Delta Pressure Sensor DEF Lines and Heating Elements and Associated Plumbing Line Heater Control Relay Exhaust Gas Recirculation Flow Venturi Turbocharger Speed Sensor Electronic Control System Engine Control Module and Wiring Harness Exhaust System Coolant Temperature Sensor Exhaust Manifold Compressor Inlet Temperature Sensor Aftertreatment Temperature Sensors Fuel Pressure Sensor Aftertreatment Delta Pressure Sensor Charge Temperature Pressure Sensor Fueling System Engine Position Sensor njectors Exhaust Pressure Sensor Fuel Pump and Associated Plumbing Parts Ambient Air Temperature Sensor Wire harness circuits connected at both ends to emis sions warrantable components Exhaust Gas Recirculation System Compressor in Temperature Pressure Sensor PACCAR Y53 1030A 12 09 88 Intake System Intake Manifold Charge Air Cooler and Associated Plumbing Parts Turbocharger and Associated Plumbing Parts Turbocharger Actuator Grid Heater Intake NOx Sensor Outlet NOx Sensor Replacement Parts PACCAR recommends that any service parts used for main tenance repair or replacement of emission control systems be new or genuine approved rebuilt parts and assemblies and that the engine be serviced by an authorized PACCAR Engine dealer or an authorized Cummins Distributor Your vehicle contains air fuel and electrical compon
77. ut down until the engine can be repaired For engines with the Engine Protection Shutdown feature enabled if the STOP ENGINE lamp begins to flash the engine will automatically shut down after 30 seconds The flashing STOP engine lamp alerts the operator to the impending shutdown The STOP ENGINE lamp is red in color and can look like The words STOP or STOP ENGINE spelled out PACCAR Operating Instructions Refer to PACCAR Engine Aftertreatment Systems Engine Operating Range Operator s Manual for additional information A symbol of an engine with an exclamation point in the center similar to the graphic General Information Torque Peak Full Throttle oi204vf CAUTION Operating the engine at full throttle A below peak torque will shorten engine life to overhaul can cause serious engine damage and is considered engine abuse Do not operate the engine at full throttle operation below peak torque rpm refer to engine dataplate for peak torque rpm for more than 30 seconds PACCAR Y53 1030A 12 09 Ll0g PACCAR engines are designed to operate successfully at full throttle under transient conditions down to peak torque engine speed This is consistent with recommended operating practices CAUTION Operating the engine beyond the maximum engine speed can cause severe engine damage Do not operate the engine beyond the maximum engine speed Use proper operating techniques for the vehicle to prevent engine o
78. ution 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 PACCAR Y53 1030A 12 09 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 19 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 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 j WARNING Using starting fluid to help start the 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 20 Y53 1030A 12 09 Operating Instructions Operating the Engine Normal
79. ve train causing severe internal engine damage Do not operate the engine if the engine brake will not deactivate A CAUTION Operating the engine with an engine If the engine brakes will not shut off shut off the engine immediately and contact a PACCAR Authorized Repair Location Y53 1030A 12 09 Operating Instructions Tips for Operation on Level and Dry Pavement operating on road surfaces with poor traction such as wet icy or snow covered roads or gravel Retarders can cause the wheels to skid on a slippery surface You could lose control of the vehicle and or jackknife if the wheels begin to skid resulting in an accident I WARNING Do not use the engine brake when WARNING Do not use an engine brake when AN driving bobtail or with an unloaded trailer There may not be enough weight on the rear axle to provide traction This could cause a lose of con trol and jackknife resulting in an injury accident Make sure the engine brake is switched OFF when bobtailing or with an unloaded trailer PACCAR Operating Instructions v eb8swvna To reduce vehicle speed put the engine brake on off switch in the ON position Remove your foot from the accelerator pedal and clutch pedal The engine brakes will immediately begin to operate slowing the vehicle For operation on dry pavement when maximum retarding power is required put the two position selector switch in the HI position For operation on dry and relati
80. vely flat surfaces when greater retarding power is not required put the two position selector switch in the LOW position PACCAR Tips for Operation on Grades with Dry Pavement A A WARNING The engine brake is not intended as the primary brake for the vehicle nor is it an emergency brake The service brakes must be used in an emergency Relying solely on the engine brake to stop the vehicle in an emer gency could cause an accident and lead to per sonal injury The engine brake only helps the service brakes by using pressure to slow the drive train You must use the service brakes for quick or emergency stops WARNING Do not use the engine brake when operating on surface with poor traction such as wet icy or snow covered roads Retarders can cause the wheels to skid on a slippery surface You could lose control of the vehicle and jack nife if the wheels begin to skid resulting in an accident Y53 1030A 12 09 37 Operating Instructions CAUTION Never exceed governed engine speed A because engine damage can occur Operating engine beyond the governed speed causes addi tional strain on valve train and internal engine components Operate the engine within gov erned engine speed WARNING Do not use an engine brake when N driving bobtail or with an unloaded trailer There may not be enough weight on the rear axle to provide traction This could cause a lose of con trol and jackknife resulting in an inju
81. verspeed The maximum engine speed specification is listed in the General Engine Specifications on page 55 10d00376 28 Y53 1030A 12 09 Operating Instructions Engine Braking System Variable Geometry Turbo VGT Brake System Gen eral Information This engine is equipped with a variable geometry turbocharger VGT with an exhaust brake feature This feature allows the variable geometry turbocharger to act as an exhaust brake by retarding the speed of the engine to provide additional vehicle braking power and extend the life of the vehicle service brakes The on off function is controlled by a switch located on the dash of the vehicle The engine VGT exhaust brake works by retarding engine speed by creating high exhaust back pressure This back pressure is obtained by restricting airflow through the turbine housing of the turbocharger This restriction through the turbine housing of the turbocharger is created through positioning of the sliding nozzle 1 located internally to the variable geometry turbocharger VGT the position of the sliding nozzle is controlled by the engine electronic control module ECM PACCAR Operating Instructions A A A PACCAR WARNING The exhaust brake is not intended as the primary brake for the vehicle nor is it an emergency brake The service brakes must be used in an emergency Relying solely on the exhaust brake to stop the vehicle in an emer gency could cause an

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