px6 manual (paccar engine)

Y53-1029 2/07

Operator’s Manual

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 “General Safety Instructions” on page 5.

Keep this manual with the equipment. If the equipment 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 atthe time of printing. PACCAR Inc reserves the right to make changes at any time without obligation. If you find differencesbetween your engine and the information in this manual, contact your local PACCAR Authorized Repair Location or write toPACCAR 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 areneeded, we recommend using only genuine parts from PACCAR.

NOTE: Warranty information including the EPA and California Emission Warranty is located in the section entitled“WARRANTY,” beginning on page 69. Make sure you are familiar with the warranty or warranties applicable to yourengine.

PACCAR Y53-1029 2/07

Foreword

Y53-1029 2/07 PACCAR

Important Reference Numbers

IMPORTANT REFERENCE NUMBERS

Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or main-tenance is required.

Part Name Number Number

Engine Model

Engine Serial Number (ESN)

Control Parts List (CPL)

Fuel Pump Part Number

Electronic Control Module (ECM)

Electronic Control Module Serial Numbers (ECM)

Filter Part Numbers:

• Air Cleaner Element

• Lubricating Oil

• Fuel

• Fuel-Water Separator

• Coolant

PACCAR Y53-1029 2/07


• Crankcase Ventilation

• Particulate Filter

Governor Control Module (GCM) (if applicable)

Belt Part Numbers:

•

•

•

Clutch

• Model

• Serial Number

• Part Number

• Oil Type

- Model

- Part Number

Part Name Number Number

Y53-1029 2/07 PACCAR

PACCAR PX-6 Contents

Foreword


Introduction

Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4General Safety Instructions . . . . . . . . . . . . . . . . . . . . . 5Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . 8

Engine Identification

Engine Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PACCAR Engine Nomenclature . . . . . . . . . . . . . . . . . . 12Fuel Pump Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . 13ECM Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Variable Geometry Turbocharger . . . . . . . . . . . . . . . . . 15Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operating Instructions

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Starting Procedure . . . . . . . . . . . . . . . . . . . . . Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . Starting Procedure After Extended Shutdown or

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Unique Operating Characteristics of an Engine with

Aftertreatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . Engine Operating Range . . . . . . . . . . . . . . . . . . . . . . . Engine Braking System . . . . . . . . . . . . . . . . . . . . . . . . Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Interference (EMI) . . . . . . . . . . . . . . .

Maintenance Guidelines

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Record Form . . . . . . . . . . . . . . . . . . . . .

Service Literature

Additional Service Literature . . . . . . . . . . . . . . . . . . . .

171922

2223

26273438394142

434350

51

Operator’s Manual – 1 –

Contents PACCAR PX-6

Maintenance Specifications

General Engine Specifications . . . . . . . . . . . . . . . . . . . 53Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . 54Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Fuel Recommendations and Specifications . . . . . . . . . 58Lubricating Oil Recommendations and

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Coolant Recommendations and Specifications . . . . . . 64

WARRANTY

PACCAR PX-6 Engine United States andCanada Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . 69

United States and Canada Fire ApparatusTruck Applications Coverage . . . . . . . . . . . . . . . . . . 71

Emission Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74California Emission Control System Warranty,

On-Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75California Emissions Components Statements for

PX-6 Engine (2007) Emissions EnginesCoverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

– 2 – Operator’s Manual

INTRODUCTION

Safety Signals

A number of alerting messages are in this manual. Pleaseread and follow them. They are there for your protection andinformation. These messages can help you avoid injury toyourself, your passengers, and help prevent costly damageto the vehicle.

Key symbols and “signal words” are used to indicate whatkind of message is going to follow. Pay special attention toinstructions prefaced by symbols and signal words“WARNING”, “CAUTION”, or “NOTE”. Please do not ignoreany of these alerts.

WARNING

When you see this symbol & word, the message thatfollows is especially vital. This signals somethingthat can cause injury or even death. This messagewill tell you what the hazard is, what can happen ifyou don’t heed the warning, and how to avoid it.

Example:

WARNING! Do not carry additional fuel contain-ers in your vehicle. Fuel containers, either full orempty, may leak, explode, and cause or feed afire. Do not carry extra fuel containers, evenempty ones are dangerous.

CAUTION

This symbol and word signals something that coulddamage your vehicle.

Example:

CAUTION: Continuing to operate your vehiclewith insufficient oil pressure will cause seriousengine damage.

PACCAR Y53-1029 2/07 – 3 –

Introduction

NOTE

Gives you information we feel you would like to have. It could have to do with care of your vehicle or with driving more efficiently.

Example:

NOTE: Pumping the accelerator will not assist instarting the engine.

Illustrations

General Information

Some of the illustrations throughout this manual are genericand will not look exactly like the engine or parts used in yourapplication. The illustrations can contain symbols to indicatean action required and an acceptable or not acceptable con-dition.

The illustrations are intended to show repair or replacementprocedures. The procedure will be the same for all applica-tions, although the illustration can differ.

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.

– 4 – Y53-1029 2/07 PACCAR

Introduction

General Safety Instructions

Important Safety Notice

WARNING! Improper practices, carelessness, orignoring the warnings can cause burns, cuts,mutilation, asphyxiation or other personal injuryor 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 providepersonal safety. Special safety precautions are included inthe procedures when they apply.

• Work in an area surrounding the product that is dry, welllit, ventilated, free from clutter, loose tools, parts, ignitionsources and hazardous substances. Be aware of haz-ardous conditions that can exist.

• Always wear protective glasses and protective shoeswhen working.

• Rotating parts can cause cuts, mutilation or strangula-tion.

• Do not wear loose-fitting or torn clothing. Remove alljewelry when working.

• Disconnect the battery (negative [-] cable first) and dis-charge any capacitors before beginning any repair work.

• Disconnect the air starting motor if equipped to preventaccidental engine starting. Put a "Do Not Operate" tag inthe operator's compartment or on the controls.

• Use ONLY the proper engine barring techniques formanually rotating the engine. Do not attempt to rotatethe 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 fillercap 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 onanything that is supported ONLY by lifting jacks or ahoist.

• Relieve all pressure in the air, oil, fuel, and cooling sys-tems before any lines, fittings, or related items areremoved or disconnected. Be alert for possible pressurewhen disconnecting any device from a system that uti-lizes pressure. Do not check for pressure leaks with yourhand. High pressure oil or fuel can cause personal injury.

PACCAR Y53-1029 2/07 – 5 –

Introduction

• To reduce the possibility of suffocation and frostbite,wear protective clothing and ONLY disconnect liquidrefrigerant (Freon) lines in a well ventilated area. To pro-tect the environment, liquid refrigerant systems must beproperly emptied and filled using equipment that pre-vents the release of refrigerant gas (fluorocarbons) intothe atmosphere. Federal law requires capturing andrecycling refrigerant.

• To reduce the possibility of personal injury, use a hoist orget assistance when lifting components that weigh 23 kg[50 lb] or more. Make sure all lifting devices such aschains, hooks, or slings are in good condition and are ofthe correct capacity. Make sure hooks are positionedcorrectly. Always use a spreader bar when necessary.The lifting hooks must not be side-loaded.

• Corrosion inhibitor, a component of SCA and lubricatingoil, contains alkali. Do not get the substance in eyes.Avoid prolonged or repeated contact with skin. Do notswallow internally. In case of contact, immediately washskin with soap and water. In case of contact, immediatelyflood eyes with large amounts of water for a minimum of15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEPOUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammablematerials and must be used with caution. Follow themanufacturer's instructions to provide complete safetywhen using these materials. KEEP OUT OF REACH OFCHILDREN.

• To reduce the possibility of burns, be alert for hot partson products that have just been turned off, exhaust gasflow, and hot fluids in lines, tubes, and compartments.

• Always use tools that are in good condition. Make sureyou understand how to use the tools before performingany service work. Use ONLY genuine replacement partsfrom PACCAR.

• Always use the same fastener part number (or equiva-lent) when replacing fasteners. Do not use a fastener oflesser 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 ofAmerica have determined that used engine oil can becarcinogenic and can cause reproductive toxicity. Avoidinhalation of vapors, ingestion, and prolonged contactwith used engine oil.

• Liquefied petroleum gas is heavier than air and canaccumulate near the floor, in sumps, and low-lying areas.

– 6 – Y53-1029 2/07 PACCAR

Introduction

• Natural gas is lighter than air and can accumulate underhood and awnings.

• To reduce the possibility of suffocation and frostbite,wear protective clothing and ONLY disconnect naturalgas and liquefied petroleum gas lines in a well ventilatedarea.

• Coolant is toxic. If not reused, dispose of in accordancewith local environmental regulations.

• The catalyst reagent contains urea. Do not get the sub-stance in your eyes. In Case of contact, immediatelyflood eyes with large amounts of water for a minimum of15 minutes. Avoid prolonged contact with skin. In case ofcontact, immediately wash skin with soap and water. Donot swallow internally. In the event the catalyst reagent isingested, contact a physician immediately.

• The catalyst substrate contains Vanadium Pentoxide.Vanadium Pentoxide has been determined by the Stateof California to cause cancer. Always wear protectivegloves and eye protection when handling the catalystassembly. Do not get the catalyst material in your eyes.In Case of contact, immediately flood eyes with largeamounts of water for a minimum of 15 minutes. Avoidprolonged 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 Stateof California to cause cancer. In the event the catalyst isbeing replaced, dispose of in accordance with local reg-ulations.

• California Proposition 65 Warning - Diesel engineexhaust and some of its constituents are known to theState of California to cause cancer, birth defects, andother reproductive harm.

CAUTION: Corrosive chemicals can damage theengine. Do not expose the engine to corrosivechemicals.

PACCAR Y53-1029 2/07 – 7 –

Introduction

Acronyms and Abbreviations

General Information

The following list contains some of the acronyms and abbre-viations used in this manual.

API American Petroleum Institute

ASTM American Society of Testing and Materials

ATS After-Treatment System

°C Celsius

CARB California Air Resources Board

C.I.D. Cubic Inch Displacement

CNG Compressed Natural Gas

CPL Control Parts List

cSt Centistokes

DPF Diesel Particulate Filter

ECM Electronic Control Module

EGR Exhaust Gas Recirculation

ELC Extended Life Coolant

EMI Electromagnetic Interference

EPA Environmental Protection Agency

ESN Engine Serial Number

°F Fahrenheit

FMI Failure Mode Indentifier

GVW Gross Vehicle Weight

HEST High Exhaust System Temperature

LPG Liquified Petroleum Gas

Hg Mercury

hp Horsepower

H2O Water

ICM Ignition Control Module

km/l Kilometers per Liter

kPa Kilopascal

LNG Liquid Natural Gas

LTA Low Temperature Aftercooling

MPa Megapascal

mph Miles Per Hour

mpq Miles Per Quart

– 8 – Y53-1029 2/07 PACCAR

Introduction

N•m Newton-meter

NG Natural Gas

OEM Original Equipment Manufacturer

PID Parameter Identification Descriptions

ppm Parts Per Million

psi Pounds Per Square Inch

PTO Power Takeoff

rpm Revolutions Per Minute

SAE Society of Automotive Engineers

SCA Supplemental Coolant Additive

STC Step Timing Control

SID Subsystem Identification Descriptions

VGT Variable Geometry Turbocharger

VS Variable Speed

VSS Vehicle Speed Sensor

PACCAR Y53-1029 2/07 – 9 –

Introduction

– 10 – Y53-1029 2/07 PACCAR

ENGINE IDENTIFICATION

Engine Dataplate

The engine dataplate provides important facts about theengine. The engine serial number (ESN) and control parts list(CPL) provide information for service and ordering parts. Theengine dataplate must not be changed unless approved byPACCAR Inc.

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).• Engine model information.• Control parts list (CPL).• Valve lash (overhead) setting.• Horsepower and rpm rating.

PACCAR Y53-1029 2/07 – 11 –


If the engine dataplate (1) is not readable, the ESN (2) can befound on the engine block on top of the lubricating oil coolerhousing. Additional engine information is on the electroniccontrol module (ECM) dataplate.

PACCAR Engine Nomenclature

The PACCAR engine nomenclature provides the enginemodel and horsepower rating.

– 12 – Y53-1029 2/07 PACCAR


Fuel Pump Dataplate

The Bosch® fuel injection pump dataplate is located on thefuel pump. The dataplate contains the following informationwhich will assist in servicing or replacement:

• Pump serial number.• Part number.• Factory code.

• Bosch® part number.• Date code.

ECM Dataplate

Rear gear train engines covered by this manual are equippedwith a CM2150 Electronic Control Module (ECM). A CM2150ECM has two 60-pin connectors and an additional 4-pin con-nector. One 60-pin connector is for inputs and outputs only,while the other 60-pin connector is for aftertreatment andvehicle inputs and outputs. The 4-pin connector providesdedicated power to the ECM.

PACCAR Y53-1029 2/07 – 13 –


The electronic control module (ECM) dataplate shows infor-mation about the ECM and how the ECM was programmed.The dataplate is located on the ECM.

The following information is available on the ECM dataplatewhich will assist in servicing or replacement:

• ECM part number (PN).• ECM serial number (SN).• ECM date code (DC).• Engine serial number (ESN).• ECM code: Identifies the software in the ECM.

Air Compressor

If your engine has an air compressor, it will have a dataplatelocated on the rear side of the air compressor.

The dataplate contains the following information that assistsin servicing or replacement:

• Part number.• Date code.• Serial number.

NOTE: Not all engines are equipped with an aircompressor.

– 14 – Y53-1029 2/07 PACCAR


Variable Geometry Turbocharger

The variable geometry turbocharger (VGT) dataplate islocated on the turbocharger inlet compressor housing. Thedataplate contains the following information that will assist inservicing or replacement:

• Assembly part number.• Serial number.• Customer number.• Model number.

NOTE: The electronic actuator on the VGT is a ser-viceable component and has a separate dataplatethat assists in servicing or replacement.

Exhaust System

The aftertreatment assembly has information stamped intothe canister showing important information for servicing andreplacement. There are three important stamping locationson the aftertreatment assembly:

1. Aftertreatment diesel oxidation catalyst part number andserial number; located on the catalyst section.

2. Aftertreatment diesel particulate filter part number andserial number; located on the filter section.

3. Aftertreatment assembly part number; located on theoutlet of the aftertreatment system.

PACCAR Y53-1029 2/07 – 15 –


A typical aftertreatment information stamping can providethe:

1. Section name.2. Part number.3. Date code.4. Assembly number (only located on the outlet section).5. Serial number.

– 16 – Y53-1029 2/07 PACCAR

OPERATING INSTRUCTIONS

General Information

Correct care of your engine will result in longer life, betterperformance, and more economical operation.

Follow the daily maintenance checks listed in“MaintenanceSchedule” on page 43.

The new PACCAR engine associated with this manual doesnot require a ”break-in” procedure. This section of the manualprovides all of the necessary information required for properengine operation.

Check the oil pressure indicators, temperature indicators,warning lights, and other gauges daily to make sure they areoperational.

PACCAR Y53-1029 2/07 – 17 –


WARNING! Combustible vapors near the airintake system could be ingested into the engine,causing the engine to suddenly accelerate andoverspeed or explode. This condition couldresult in an unexpected increase in engine rpmand/or fire, resulting in personal injury or prop-erty damage. Do not operate your vehicle in areawhere combustible chemicals or vapors may bepresent.

IT IS THE RESPONSIBILITY OF THE OWNERAND OPERATOR TO OPERATE THE VEHICLE INA SAFE ENVIRONMENT.

NOTE: Numerous safety devices (ie engine shutoffdevices) are available to minimize the risk of engineoverspeeding caused by combustible vapors beingingested into the air intake system. PACCAR has noway of knowing what environment your vehicle willbe operated in.

– 18 – Y53-1029 2/07 PACCAR


Normal Starting Procedure

Starting

Ensure the parking brake is set and the transmission is inneutral.

With the accelerator pedal in the idle position, turn the keyswitch to the ON position.

With the key in the ON position, the engine indicator lampswill come on momentarily and then go out. The engine indi-cator lamps include:

1. Check engine lamp; yellow in color.2. STOP engine lamp; red in color.3. Diesel Particulate Filter (DPF) status indicator; yellow in

color.4. High Exhaust System Temperature (HEST); amber in

color.

PACCAR Y53-1029 2/07 – 19 –


Under cold conditions, the Wait-to-Start lamp (generally ayellow lamp using a symbol similar to the graphic, or thewords WAIT TO START) will also illuminate at key on, and willstay on for a period of up to 30 seconds.

NOTE: The length of time the Wait-to-Start lampremains illuminated depends on the ambient tem-perature. The lower the ambient temperature, thelonger the lamp will be illuminated.

Once the Wait-to-Start lamp turns off, turn the key to thestarting position to start the engine.

CAUTION: Engaging the starter motor for morethan 30 seconds may cause it to overheat andcan damage the starter motor. Never engage thestarter motor for more than 30 seconds and wait2 minutes between each attempt to start theengine to allow the starter motor to cool. Thiscaution does not apply to air starters.

CAUTION: The engine must have adequate oilpressure within 15 seconds after starting theengine. If the oil pressure gauge does not regis-ter the minimum pressure, or drops below theminimum pressure, a red warning light in thegauge will come on, a warning buzzer willsound, and the Stop Engine Lamp will come on.This should be considered an emergency. Oper-ating the engine is this condition may causesevere engine damage. You should stop thevehicle as safely as possible. The vehicle mustbe serviced and the problem corrected beforedriving again.

– 20 – Y53-1029 2/07 PACCAR


After starting a cold engine, increase the engine speed (rpm)slowly to provide adequate lubrication to the bearings and toallow the oil pressure to stabilize.

Some engines are equipped with a Fast Idle Warm Up fea-ture. When enabled, this feature elevates the idle speed ofthe engine in cold ambient conditions, in order to shorten thetime necessary to warm up the engine. When the idle speedis elevated, the engine noise may change, this is normal. Tobring the engine back to low idle speed:

• For vehicles equipped with a manual transmission andclutch switch: Depress the clutch pedal.

• For vehicles equipped with a brake switch: Depress theservice brake pedal.

• Depress the accelerator pedal.

For more information on the Fast Idle Warm Up feature, con-tact a PACCAR authorized repair location.

CAUTION: Do not operate the engine at low idlefor long periods with engine coolant tempera-ture below the minimum specification as indi-cated in “Cooling System” on page 56. This canresult in the following:

• Fuel dilution of the lubricating oil.• Carbon build up in the cylinder.• Cylinder head valve sticking.• Reduced performance.

If an engine must idle for an extended period oftime, it should be done at fast idle (1,000 rpm orgreater) until the coolant temperature meets thespecification.

PACCAR Y53-1029 2/07 – 21 –


Cold Weather Starting

General Information

Follow the Normal Starting Procedure in this section. Ifequipped with an intake air heater, the Wait-To-Start lamp willstay on longer.

Refer to the vehicle operator's manual instructions for anyadditional cold weather starting procedures.

Using Starting Aids

This engine is equipped with an intake grid heater to helpstart the engine in cold weather conditions. Contact yourauthorized PACCAR repair location for other cold weatherstarting aid options.

WARNING! Using starting fluid to help start theengine could cause a fire or explosion, resultingin personal injury, property damage and severeengine damage. Do not use starting fluid to startthis engine.

This engine is equipped with an intake air heater. Coldweather starting aids are available for your engine. Contact alocal PACCAR Authorized Repair Location for more informa-tion.

Starting Procedure After Extended Shutdown or Oil Change

General Information

Follow the Normal Starting Procedure in this section. Theengine will run at idle only until the minimum oil pressure isdetected by the ECM.

– 22 – Y53-1029 2/07 PACCAR


Operating the Engine

Normal

Monitor the oil pressure and coolant temperature gauges fre-quently. Refer to “Lubricating Oil System,” page 54 and“Cooling System,” page 56 for recommended operating pres-sures and temperatures. Shut off the engine if any pressureor temperature does not meet the specifications.

Continuous operation with engine coolant temperature aboveor below the engine coolant temperature specifications listedin “Cooling System,” page 56 can damage the engine.

Engine Overheating

CAUTION: The cooling system may overheat ifthe engine coolant is the minimum level. A sud-den loss of coolant, caused by a split hose orbroken hose clamp could also lead to an over-heat condition. Always inspect to ensure hosesand clamps are not cracked, worn or loose.

NOTE: The system may also temporarily overheatduring severe operations conditions such as:

• Climbing a hill on a hot day.

• Stopping after high–speed driving.

PACCAR Y53-1029 2/07 – 23 –


NOTE: If the “Engine Coolant Temperature” warninglight comes on and the audible alarm sounds show-ing an overheat condition, or if you have any otherreason to suspect the engine may be overheating,DON'T TURN OFF THE ENGINE unless a low waterwarning device indicates a loss of coolant. Followthese 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 forinstructions on transmission shifting and parkingbrake information.

• Check to ensure that the oil pressure gauge readsnormal.

• Increase the engine speed to about one–half offull operating speed, or 1,100 to 1,200 rpm, maxi-mum.

• Return the engine speed to normal idle after twoor three minutes.

• Monitor the engine temperature. After the temper-ature returns to normal, allow the engine to idle 3to 5 minutes before shutting it off. This allows theengine to cool gradually and uniformly.

• If the overheating came from severe operatingconditions, the temperature should have cooled bythis time.

• Check the sight gauge (glass level indicator) onthe side of the coolant expansion tank.

CAUTION: Never leave the engine idling whenthe vehicle is unattended. If the engine shouldoverheat, immediate action is required to correctthe condition. Failure to take immediate actionmay result in serious engine damage. If youmust leave your vehicle unattended, shut downthe engine.

– 24 – Y53-1029 2/07 PACCAR


WARNING! Removing the radiator fill cap whilethe engine is hot can be dangerous. Neverremove the caps of the expansion tank while theengine is still hot; you could be badly burned.

• Scalding steam and fluid under pressure mayescape and cause serious personal injuries.

• Wait until the coolant temperature is below122°F (50°C).

• Protect your face, hands, and arms by coveringthe cap with a large, thick rag to protect againstescaping fluid and steam.

• Carefully and slowly turn cap one turn to allowexcess pressure to escape, then push downand turn for final removal. See the Truck Opera-tor’s Manual for instructions on checking andfilling the coolant expansion tank.

Take the time to learn what normal operating conditions arefor your engine so that when an abnormal condition arises,you will be able to recognize it as such and take the appropri-ate action.

Most failures give an early warning. Look and listen forchanges in performance, sound, or engine appearance thatcan indicate service or engine repair is needed. Somechanges to look for are:

• Engine misfires.• Vibration.• Unusual engine noises.• Sudden changes in engine operating temperatures or

pressures.• Excessive smoke.

PACCAR Y53-1029 2/07 – 25 –


• Loss of power.• An increase in oil consumption.• An increase in fuel consumption.• Fuel, oil, or coolant leaks.

CAUTION: Do not allow your engine to idle, atlow rpm's (400-600 rpm), longer than five min-utes. Long periods of idling after the engine hasreached operating temperatures can decreaseengine temperature and cause gummed pistonrings, clogged injectors, and possible enginedamage from lack of lubrication. The normal tor-sional vibrations generated by the engine canalso cause transmission wear. If an engine mustidle for an extended period of time, it should bedone at fast idle (1,000 rpm or greater).

NOTE: An idle shutdown feature, available on PACCAREngines, can be programmed to shut the engine downafter a period of low idle speed operation with no driveractivity. A flashing warning lamp will inform the driver ofan impending shutdown.

NOTE: The power take off (PTO) feature, available onPACCAR engines, can be programmed to adjustengine idle speed with the use of switches to pre-pro-grammed set points.

Unique Operating Characteristics of an Engine with Aftertreatment

General Information

The aftertreatment system is designed to decrease theexhaust particulate emissions from the vehicle tailpipe. It iscomposed of six main components:

1. Aftertreatment inlet.2. Aftertreatment particulate filter differential pressure sen-

sor.3. Aftertreatment diesel oxidation catalyst.

– 26 – Y53-1029 2/07 PACCAR


4. Aftertreatment diesel particulate filter.5. Aftertreament outlet.6. Aftertreatment gas temperature sensors.

CAUTION: Ultra-low-sulfur diesel fuel is requiredfor an engine equipped with an aftertreatmentdiesel particulate filter. If ultra-low-sulfur fuel isnot used, the engine might not meet emissionsregulations, and aftertreatment diesel particu-late filter or aftertreatment diesel oxidation cata-lyst can be damaged.

Emissions

Aftertreatment System Description

In order to meet 2007 EPA engine emission requirements,vehicles will have an exhaust After-Treatment System (ATS)which includes a Diesel Particulate Filter (DPF), Regenera-tion Switch and warning lights. The DPF will trap soot fromthe engine exhaust gases. The ATS will periodically clean theDPF.

The Regeneration Switch is mounted on the dash and canoverride the ATS. Various situations may require the operatorto use the functions of this switch. Refer to “Parked Regener-ation” on page 32 and “Stop an Automatic or Parked Regen-eration” on page 34 for more information. ATS specificwarning lights and indictor symbols are located on the dashpanel.

PACCAR Y53-1029 2/07 – 27 –


Functionality / Notification Information

The ATS will clean the DPF by using hot exhaust gases nor-mally generated by the engine. This typically occurs duringhighway operation. This is referred to as a "Passive" Regen-eration and is transparent to the operation of the vehicle.

Occasionally, the exhaust gases are too cool for passiveregeneration. When this occurs, the ATS will clean the DPFby increasing the exhaust temperature. This is referred to asan "Automatic" Regeneration and is also transparent to theoperation of vehicle. An Automatic Regeneration event typi-cally lasts 30 minutes. During and shortly after the event, theexhaust gases from the DPF may reach temperatures inexcess of 650°C (1200°F). See the information in the follow-ing table on probable causes and recommended actionsrelated to the warning lights and indicator symbols of theATS.

The ATS may not be able to clean the DPF when the vehicleis driven at extended low speeds or with frequent start andstops. In such cases, warning lights and indicator symbolswill alert the operator to take action. The operator should beaware of whether the lights are on alone or in combinationwith others. The following table will describe each warninglight(s) and what actions are needed from the operator.

– 28 – Y53-1029 2/07 PACCAR


Notification of High Exhaust System Temperature

Indicator Information What to Do

On steady The High Exhaust Temperature (HEST) warn-ing lamp will illuminate, regardless of ATS sta-tus, as your vehicle slows below 5 mph / 8 kph to warn the driver when the vehicle's exhaust outlet temperature is extremely hot (at least 450°C / 842°F). This will typically occur when:

An Automatic or Parked Regeneration is in pro-cess

or

During normal vehicle operation when engine is under high or heavy loading

Follow all warnings listed below. Use the STOP function of the Regeneration Switch if the situation requires. Follow the instructions described “Stop an Automatic or Parked Regener-ation” on page 34.

WARNING! Temperatures of the exhaust pipes and at theoutlets of the exhaust system during and shortly after aregeneration event will be extremely hot. If the HighExhaust System Temperature (HEST) warning lamp ison:

• Do not park in an area of combustible vapors or mate-rials. You must keep combustibles at least five (5) feetaway from the exhaust (outlet) stream (as it exits thetail pipe) while the HEST light is illuminated. Alwayspark your vehicle outside. Failure to do so could ignitean explosion or harm bystanders which could result inserious injury.

• Do not park in an area where people are close by. Youmust keep bystanders at least five (5) feet away fromthe exhaust outlet while the HEST light is illuminated.Failure to do so could result in serious injury.

• The exhaust piping, diesel particular filter (DPF) or tailpipe become extremely hot during engine operation orany regeneration event and can cause serious burnsto the skin. Allow adequate cooling time before work-ing on or near any part of the exhaust system.

PACCAR Y53-1029 2/07 – 29 –


On steady The DPF status indicator symbol will illuminate when the soot level in the DPF is above the desired level and it needs cleaning.

The DPF needs cleaning soon. Follow the instructions described “Cleaning the DPF” on page 32.

NOTE: If you ignore the warning lamp and do not initiateregeneration at the soonest, safest possible time, the DPFwill become increasingly clogged with soot and can lead toengine shutdown.

Blink once every second

The DPF status indicator symbol will blink when the soot level in the DPF continues to stay above the desired level and it needs cleaning.

Clean the DPF as soon as safely possible. Follow the instruc-tions described “Cleaning the DPF” on page 32.

CAUTION: If you do not initiate regeneration after theDPF Indicator lamp is blinking, you only have a shorttime before the check engine light will illuminate and theengine will go into protection mode and de-rate power.

Blinking

On steady

The DPF status indicator symbol will blink when the soot level in the DPF continues to stay above the desired level and it MUST be cleaned.

The engine will de-rate power.

Clean the DPF immediately. Follow the instructions described “Cleaning the DPF” on page 32.

CAUTION: If you do not initiate regeneration after theDPF Indicator lamp is blinking and the check enginelight is illuminated, you only have a short time beforethe stop engine light will illuminate and the engine willautomatically begin to shutdown.


– 30 – Y53-1029 2/07 PACCAR


On steady The Stop Engine light is illuminated when the soot level in the DPF continues to stay above the desired level.

The soot level in the DPF is now at full capacity.

The engine will begin to shutdown.

At this point, you CANNOT clean the DPF and the engine's ECU will shutdown the engine.

WARNING! If the Stop Engine warning lamp illuminates,it means you have a serious engine system problem.This should be considered an emergency. You shouldstop the vehicle as safely as possible and turn OFF theignition. The vehicle must be serviced and the problemcorrected before driving again. Failure to do so maycause severe engine, DPF damage or personal injury.

NOTE: The engine shutdown system is engine specific;therefore to learn how this system works on your vehicle,refer to the Engine Manufacturer's Operation and Mainte-nance Manual supplied with your vehicle.


PACCAR Y53-1029 2/07 – 31 –


Cleaning the DPF

Carefully read the following instructions to clean the DPF. Ifyou have any problems or difficulties contact your nearestauthorized PACCAR Engine dealer for assistance.

The ATS needs conditions typically found in highway drivingto clean the DPF. If your DPF Indicator lamp is illuminated,the easiest option is to help the ATS by proceeding to thenearest highway.7. Select a highway that has a posted legal speed of more

than 35 mph.8. Drive your vehicle until the DPF light goes off. This may

take 30–45 minutes of speeds greater than 20 mph (32kph).

If your operation or planned route in the immediate future lim-its your ability to reach highway speeds, proceed to the nextsection titled Parked Regeneration.

Parked Regeneration

In very limited applications or operations the DPF must becleaned by initiating a Parked Regeneration. Follow theseseven steps to initiate a Parked Regeneration:

1. Pull the vehicle over to a safe location.2. Ensure no one is in the immediate vicinity to the tailpipe.3. Maintain a minimum of 5 feet of clearance to any com-

bustible materials from the edge and top of the vehicle.

WARNING! Parking the vehicle too close to anycombustible materials or vapors may start a fire,ignite an explosion or burn someone standingclose by. Before pushing the Regenerationswitch on the dash, walk around your vehicleand ensure you have at least five (5) feet clear-ance from the sides and top of your vehicle toany combustibles. Ensure no one is in the imme-diate vicinity to the tailpipe. Failure to do socould cause a fire or lead to serious injury to youand/or bystanders.

WARNING! Never initiate a regeneration in aclosed building or enclosure. Always park yourvehicle outside and ensure no one is in theimmediate vicinity. Failure to do so could ignitean explosion or harm bystanders which couldresult in serious injury.

– 32 – Y53-1029 2/07 PACCAR


NOTE: Typical operation areas or materials that cancontain explosive vapors, flammable materials orpeople in close proximity of the vehicle are:• Fuel depots.• Grain elevators.• Dry grass, leaves or trees.• Transfer refuse stations/dumps.• Parking lots.• Load/unload terminals.

NOTE: While the list above may appear comprehen-sive, it is your responsibility to take the necessaryprecautions and be aware of your surroundings andensure that no combustibles (materials or vapors) orbystanders are close by before initiating a regenera-tion.

4. Verify that the following conditions are met before pro-ceeding. A Parked Regeneration will not initiate if any ofthese conditions are not met.

• Parking brake is applied / set• Engine is at low idle• No throttle, brake or clutch applied• PTO is disengaged• Transmission is in neutral

5. Get out and walk all around vehicle to ensure that thevehicle is at least 5 feet away from all combustible mate-rials and no one is in the immediate vicinity.

6. Climb back into the vehicle.7. Push the Regeneration (START) Switch located on the

dash for at least 4 seconds to initiate a Parked Regener-ation.

NOTE: Acknowledgment that a Parked Regenera-tion has initiated will vary by engine. The most pre-dominant acknowledgement to you will be anincrease in engine RPM and overall engine noise.

NOTE: A Parked Regeneration may take 30 or moreseconds to initiate as the ATS system conducts vari-ous self-checks to verify all the system requirementshave been met.

PACCAR Y53-1029 2/07 – 33 –


NOTE: A Parked Regeneration will initiate only if theDPF status light is illuminated or blinking.

If you are unable to initiate a Parked regeneration and theDPF status light is illuminated, contact your nearest autho-rized PACCAR Engine dealer for assistance.

Stop an Automatic or Parked Regeneration

If an Automatic or Parked Regeneration is in process and youwant the regeneration to stop, OR you want to prevent aregeneration from occurring, your vehicle is equipped with aswitch that can STOP an Automatic or Parked Regeneration.Since Automatic Regenerations can occur at any time withthis engine, you must depress the STOP portion of theRegeneration Switch ANYTIME you plan to drive your vehicleinto a building, enclosure or area where the activation of aregeneration is not allowed. If the regeneration does not stop,turn the vehicle ignition OFF.

WARNING! Never allow an Automatic regenera-tion to automatically start while inside a buildingsuch as a service bay, shop or building of anykind. Any time you are parking your vehicleinside a building or enclosure, ALWAYS pressthe Regeneration (STOP) switch prior to enteringthe building. Failure to do so could ignite anexplosion which could result in serious injury toyou and/or bystanders.

WARNING! Never initiate a Parked Regenerationin a closed building or enclosure. Always parkyour vehicle outside. Failure to do so couldignite an explosion which could result in seriousinjury to you and/or bystanders.

Engine Indicator Lamps

General Information

The following engine indicator lamps cover only the lampscontrolled by the engine's ECM. The vehicle manufacturercan provide additional indicator lamps. Please refer to thevehicle's operator's manual for additional lamp information.

Wait to Start Lamp

The WAIT TO START lamp illuminates when the intake airheater needs to warm the intake air prior to starting theengine.

– 34 – Y53-1029 2/07 PACCAR


The WAIT TO START lamp on time will vary depending onthe ambient air temperature. See “Normal Starting Proce-dure” on page 19.

Check Engine Lamp

The CHECK ENGINE lamp illuminates when the engineneeds service at the first available opportunity.

The CHECK ENGINE lamp is amber, and can look like:• The words WARNING or CHECK ENGINE spelled out.• A symbol of an engine, similar to the graphic.• DPF regeneration is required.

Another function of the CHECK ENGINE lamp is to flash for30 seconds at key-on when one of the following occurs. Thisflashing function is referred to as the MAINTENANCE lamp.The STOP ENGINE lamp will also illuminate when the sootlevel in the DPF continues to stay above the desired level.

shutdown. The MAINTENANCE lamp could flash for any ofthe following reasons:

• Maintenance required (if the Maintenance Monitor isenabled).

• Water-in-fuel is detected.• Low engine lubricating oil level (if equipped with an

engine lubricating oil level sensor).• Coolant level is low.

Stop Engine Lamp

The STOP ENGINE lamp indicates, when illuminated, theneed to stop the engine as soon as it can be safely done. Theengine must remain shut down until the engine can berepaired.

When the DPF is at full capacity, the engine will begin to

PACCAR Y53-1029 2/07 – 35 –


For engines with the Engine Protection Shutdown featureenabled, if the STOP ENGINE lamp begins to flash, theengine will automatically shut down after 30 seconds. Theflashing STOP engine lamp aler ts the operator to theimpending shutdown.

The STOP ENGINE lamp is red in color, and can look like:• The words STOP or STOP ENGINE spelled out• A symbol of an engine with an exclamation point in the

center, similar to the graphic.

Aftertreatment Diesel Particulate Filter Lamp

The DPF status indicator lamp will illuminate when the sootlevel in the DPF is above the desired level and it needs clean-ing.

An illuminated AFTERTREATMENT DIESEL PARTICULATEFILTER lamp indicates that the aftertreatment diesel particu-late filter needs to be regenerated at the next possible oppor-tunity. This can be accomplished by:

1. Changing to a more challenging duty cycle, such ashighway driving, for at least 20 minutes.

2. Performing a stationary regeneration. Follow the instruc-tions in “Unique Operating Characteristics of an Enginewith Aftertreatment” on page 26.

The DPF status indicator lamp will flash once every secondwhen the soot level in the DPF continues to stay above thedesired level and it needs cleaning.

When this lamp is flashing, the operator should:

1. Change to a more challenging duty cycle, such as high-way driving, for at least 20 minutes.

2. Performing a stationary regeneration. Follow the instruc-tions in “Unique Operating Characteristics of an Enginewith Aftertreatment” on page 26.

– 36 – Y53-1029 2/07 PACCAR


The DPF status indicator will flash once every second andthe Check Engine lamp will illuminate when the soot level inthe DPF continues to stay above the desired level and itMUST be cleaned.

The High Exhaust Temperature (HEST warning lamp will illu-minate whenever the vehicle slows below 5mph/8kph to warnthe driver when the vehicle's exhaust outlet temperature isextremely hot (at least 842F / 450C). The warning lamp willalso illuminate when the exhaust outlet temperature isextremely hot during normal engine operation or during a sta-tionary regeneration.

High Exhaust System Temperature Lamp

The HIGH EXHAUST SYSTEM TEMPERATURE lamp indi-cates, when illuminated, that exhaust temperatures are highdue to regeneration of the aftertreatment diesel particulatefilter. The lamp could illuminate during normal engine opera-tion or during stationary regeneration.

When this lamp is illuminated, ensure that the exhaust pipeoutlet is not directed at any surface or material that will melt,burn, or explode.

PACCAR Y53-1029 2/07 – 37 –


WARNING! When this lamp is illuminated, theexhaust gas temperature could reach 800°C(1500°F), which is hot enough to ignite or meltcommon materials, and to burn people.

• Keep the exhaust outlet away from people andanything that can burn, melt, or explode.

• Nothing within 0.6 m [2 ft] of the exhaustoutlet.

• Nothing that can burn, melt, or explodewithin 1.5 m (5 ft) (such as gasoline, wood,paper, plastics, fabric, compressed gascontainers, hydraulic lines).

• In an emergency, turn off the engine to stop theflow of exhaust.

NOTE: The HIGH EXHAUST SYSTEM TEMPERA-TURE lamp does not signify the need for any kind ofvehicle or engine service; it merely alerts the vehicleoperator to high exhaust temperatures. It will becommon for the HIGH EXHAUST SYSTEM TEM-PERATURE lamp to illuminate on and off during nor-mal vehicle operation as the engine completesregeneration.

Engine Operating Range

General Information

CAUTION: Operating the engine at full throttlebelow peak torque will shorten engine life tooverhaul, can cause serious engine damage,and is considered engine abuse. Do not operatethe engine at full throttle operation below peaktorque rpm (refer to engine dataplate for peaktorque rpm) for more than 30 seconds.

PACCAR engines are designed to operate successfully at fullthrottle under transient conditions down to peak torqueengine speed. This is consistent with recommended operat-ing practices.

CAUTION: Operating the engine beyond themaximum engine speed can cause severeengine damage. Do not operate the enginebeyond the maximum engine speed. Use properoperating techniques for the vehicle to preventengine overspeed. The maximum engine speedspecification is listed in “General Engine Speci-fications” on page 53.

– 38 – Y53-1029 2/07 PACCAR


Engine Braking System

Variable Geometry Turbo (VGT) Brake System General Information

This engine is equipped with a variable geometry turbo-charger (VGT) with an exhaust brake feature. This featureallows the variable geometry turocharger to act as anexhaust brake by retarding the speed of the engine to provideadditional vehicle braking power and extend the life of thevehicle service brakes. The on/off function is controlled by aswitch located on the dash of the vehicle. The engine (VGT)

exhaust brake works by retarding engine speed by creatinghigh exhaust back pressure. This back pressure is obtainedby restricting airflow through the turbine housing of the turbo-charger. This restriction through the turbine housing of theturbocharger is created through positioning of the slidingnozzle (1) located internally to the variable geometry turbo-charger (VGT). the position of the sliding nozzle is controlledby the engine electronic control module (ECM).

WARNING! The exhaust brake is not intended asthe primary brake for the vehicle, nor is it anemergency brake. The service brakes must beused in an emergency. Relying solely on theexhaust brake to stop the vehicle in an emer-gency could cause an accident and lead to per-sonal injury. The exhaust brake only helps theservice brakes by using pressure to slow thedrive train. You must use the service brakes forquick or emergency stops.

WARNING! Do not use the exhaust brake whenoperating on surface with poor traction (such aswet, icy, or snow covered roads gravel). Retard-ers can cause the wheels to skid on a slipperysurface. You could lose control of the vehicleand jacknife if the wheels begin to skid, resultingin an accident.

PACCAR Y53-1029 2/07 – 39 –


WARNING! Do not use an exhaust brake whendriving bobtail or with an unloaded trailer. Theremay not be enough weight on the rear axle toprovide traction. This could cause a lose of con-trol and jackknife resulting in an injury accident.Make sure the exhaust brake is switched OFFwhen bobtailing or with an unloaded trailer.

When the engine (VGT) exhaust brake switch is in the Onposition, the engine's electronic control module (ECM) moni-tors inputs (such as accelerator pedal position and enginespeed). From these inputs, the ECM determines when toenable the engine (VGT) exhaust brake feature when theproper braking conditions are present.

Other features/switches like cruise control, can also affectwhen the engine (VGT) exhaust brake activates. For moreinformation on how the engine (VGT) exhaust brake func-tions, refer to vehicle operation manual or contact a PACCARAuthorized Repair Location.

WARNING! To reduce the possibility of personalinjury or property damage, always be preparedto use the vehicle service brakes for emergencystopping. The safe control speed of a vehicle willvary with the size of the load, the type of load,the grade, and the road conditions.

NOTE: The exhaust brake can only be activatedwhen 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 designedto assist the vehicle's service brakes when slowingthe vehicle to a stop.

Vehicle service brakes must always be used. The enginebrake is not intended to be used as the primary brake of thevehicle, nor is it an emergency brake. The engine retarderonly helps the service brakes by using pressure to slow thedivetrain. Use the service brakes for quick stops.

– 40 – Y53-1029 2/07 PACCAR


CAUTION: Exceeding governed engine speedcan cause engine damage. Operating the enginebeyond the maximum engine speed may causeserious engine damage and considered engineabuse. Use the engine and vehicle braking sys-tems to control engine speed.

The optimum braking power of the engine (VGT) exhaustbrake is reached at rated engine speed. Correct gear selec-tion, therefore, is critical.

Typically, on vehicles equipped with automatic transmissions,the engine electronic control module (ECM) and the trans-mission will determine the correct gear selection.

Engine Shutdown

General Information

NOTE: Allow the engine to idle 3 to 5 minutes beforeshutting it off after a full-load operation. This allowsadequate cool down of pistons, cylinders, bearings,and turbocharger components.

PACCAR Y53-1029 2/07 – 41 –


Electromagnetic Interference (EMI)

General Information

Some engine applications utilize accessories (CB radios,mobile transmitters, etc.) that generate and use radio fre-quency energy that, if not installed and used properly, cancause electromagnetic interference (EMI) conditions to existbetween the accessory and PACCAR electronic controlledfuel system. PACCAR is not liable for any performance prob-lems with either the fuel system or the accessory due to EMI.EMI is not considered by PACCAR to be an engine failureand therefore is not warrantable.

System EMI Susceptibility

Your PACCAR product has been designed and tested forminimum sensitivity to incoming electromagnetic energy.Testing has shown that there is no engine performance deg-radation at relatively high energy levels; however, if very highenergy levels are encountered, then some noncritical diag-nostic fault code logging can occur. The fuel system EMI sus-ceptibility level will protect your engine from most, if not all,electromagnetic energy-emitting devices that meet the Fed-eral Communications Commission legal requirements.

System EMI Radiation Levels

Your PACCAR product has been designed to emit minimumelectromagnetic energy. Electronic components are requiredto pass various PACCAR industry EMI specifications. Testinghas shown that when the engine is properly installed, it willnot interfere with onboard communication equipment or withthe vehicle's ability to meet any applicable EMI standardsand regulated specifications.

If an interference condition is observed, follow the sugges-tions below to reduce the amount of interference:

1. Locate the receiving antenna as far away from theengine and as high as possible.

2. Locate the receiving antenna as far away as possiblefrom all metal obstructions (e.g., exhaust stacks).

3. Consult a representative of the accessory supplier inyour area to:

• Calibrate accurately the device for proper frequency,power output, and sensitivity (both base and remotesite devices must be properly calibrated)

• Obtain antenna reflective energy data measure-ments to determine the optimum antenna location

• Obtain optimum antenna type and mountingarrangement for your application

• Make sure your accessory equipment model is builtfor maximum filtering to reject incoming electromag-netic noise.

– 42 – Y53-1029 2/07 PACCAR

MAINTENANCE GUIDELINES

Overview

General Information

PACCAR recommends that the engine be maintainedaccording to the Maintenance Schedule in this section.

If the engine is operating in ambient temperatures below18°C [0°F] or above 38°C [100°F], perform maintenance atshorter intervals. Shorter maintenance intervals are alsorequired if the engine is operated in a dusty environment or iffrequent stops are made. Contact your local PACCAR Autho-rized Repair Location for recommended maintenance inter-vals.

Some of these maintenance procedures require special toolsor must be completed by qualified personnel. Contact yourlocal PACCAR Authorized Repair Location for detailed infor-mation.

If your engine is equipped with a component or accessory notmanufactured by PACCAR, refer to the component manufac-turer's maintenance recommendations.

Use the chart provided in this section as a convenient way torecord maintenance performed.

Maintenance Schedule

General Information

Perform maintenance at whichever interval occurs first.

At each scheduled maintenance interval, perform all previousmaintenance 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 groundand wait 5 minutes after shutting engine OFF.

• Remove dipstick and wipe it off with a clean, lint freerag.

• Reinsert dipstick all the way in and pull it out again tocheck oil level.

• Correct oil level is between the low (L) and high (H)marks on dipstick.

• Fuel – Water Separator – Drain• Air Intake Piping – Inspect

• Hose/Pipe condition – Chaffing, Deterioration,Leaks

PACCAR Y53-1029 2/07 – 43 –


• 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 tank.• 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 concentrationbased on freeze protection prior to adding it to the

cooling system. Adding or using 100% antifreeze ina cooling system may result in cooling system plug-ging and overheating problems.

Every 12,000 km (7500mi), 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• Cracked tubes or header• Clogged fins/tubes• Hose/pipe condition - deterioration/signs of leaking• Hose clamp torque• Air fuel, etc.

Every 24,000 km (15,000mi), 500 Hours, or 6 months – Maintenance Check

• Fuel Filter, Spin on type replace• Lubricating Oil – Change• Lubricating Oil filters – Replace

– 44 – Y53-1029 2/07 PACCAR


• Cooling System Antifreeze Check• Supplemental additive/conditioner level• Coolant level• Coolant protection

• Batteries – Check• Battery Cables and Connections – Check• Battery condition - electrolyte level, cracks, signs of leak-

ing, overcharging• Harness/cables for loose connections, corrosion, chaf-

ing, broken retention clips• Battery hold-downs for tightness• Battery box mounting bolt torque

Every 48,000 km [30,000 mi], 1000 Hours, or 1 Year - Maintenance Check

• Drive Belts - Check/Correct• Belt condition - signs of wear/deterioration• Belt alignment

• Fan Belt Tensioner - Check/Correct• Mounting bolt torque• Tensioner maintains proper belt tension

• Air Compressor Carbon Build-up - Check/Correct

Every 96,000 km [75,000 mi], 2500 Hours, or 2 Years - Maintenance Check

• Cooling System - Drain/Flush/Fill

• 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

Every 321,500 km [200,000 mi], 6500 Hours - Mainte-nance Check

• Aftertreatment Diesel Particulate Filter – Clean• Complete Cleaning of filter using a DPF cleaning

machine• Replace filter if necessary

PACCAR Y53-1029 2/07 – 45 –


NOTE: 1. If the oil drain interval being used is greater

than 24,000 km [15,000 mi], as determinedby the Oil Drain Intervals section below, thefuel filter change can be extended until the oildrain interval.

2. The oil drain intervals are based on an engineequipped with a 14.2 liter [15 qt] capacitylubricating oil pan and a normal duty cycle.For detailed information on oil drain intervalsfor a specific application/duty cycle, refer tothe Oil Drain Intervals section of this proce-dure.

3. Extended coolant drain/flush/fill intervals maybe followed when certain requirements aremet. For information on these requirements,refer to the Coolant Requirements and Main-tenance Bulletin 3666132.

4. The aftertreatment diesel particulate filterclean/replace interval is based on the use oflubricating oils that meet the Cummins Engi-neering Standard (C.E.S.) 20081 oil specifi-cation. If a non-low ash lubricating oil meetingthe American Petroleum Institute (API) perfor-mance classification CI-4/SL and/or C.E.S.

20078 is used, the service intervals for theaftertreatment systems will be reduced to241,000 km [150,000 mi] or 5000 Hours.

5. Follow the manufacturer's recommendedmaintenance procedures for the starter, alter-nator, generator, batteries, electrical compo-nents, exhaust brake, charge air cooler,radiator, air compressor, air cleaner, freoncompressor, and fan clutch.

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.

Is the vehicle one of those listed below?• Delivery truck.• Fire truck/emergency vehicle.

If Yes -

Select the correct oil drain interval from Table 1.

If No -

Is the vehicle one of those listed below?• Refuse truck.• Mixer/dumper.

– 46 – Y53-1029 2/07 PACCAR


If Yes -

Select the correct oil drain interval from Table 2.

If No -

If vehicle has not been listed, select the correct oil drain inter-val from Table 3.

Table 1—Maximum Oil Drain Intervals

(A) Severe Duty(If the Vehicle Meets Any of These Conditions)

(B) Normal Duty(If the Vehicle Meets Both Conditions)

Average fuel economy is less than 2.98 km/liter [7 mpg], or idle time is 40 percent or greater, or vehicle operates in dusty conditions, or gross vehicle weight is greater than 20,865 kg [46,000 lb].

Average fuel economy is greater than 2.98 km/liter [7 mpg] and gross vehicle weight is less than 20,865 kg [46,000 lb].

Vehicle uses the severe-duty oil drain interval (A). Vehicle uses the normal-duty oil drain interval (B).

If equipped with a 14.2 liter [15 qt] oil pana: 14,500 km [9000 mi], 500 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 14.2 liter [15 qt] oil pan1: 24,000 km [15,000 mi], 500 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 17 liter [18 qt] oil pan1: 19,000 km [12,000 mi], 550 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

If equipped with a 18 liter [19 qt] oil pan1: 32,000 km [20,000 mi], 550 hours, 6 months, or 7571 liters [2000 gallons] of fuel, which ever comes first.

a. If the type/oil capacity of the oil pan is not known (1) contact a PACCAR Dealer, (2) determine the capacity of the oil pan option for the engine being ser-viced using Quickserve Online and the engine serial number, or (3) for the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

PACCAR Y53-1029 2/07 – 47 –


Table 2—Oil Drain Interval

Refuse Truck, Mixer, or Dump Truck

With a 14.2 liter [15 qt] Oil Pana With a 18 liter [19 qt] Oil Pana

Kilometers Miles Hours Months Kilometers Miles Hours Months

10 to 15 mph average 9,650 6,000 500 6 12,500 8,000 550 6

15 to 20 mph average 13,700 8,500 500 6 17,750 11,000 550 6

20 to 25 mph average 14,500 9,000 500 6 19,000 12,000 550 6

Above 25 mph average 19,000 12,000 500 6 25,750 16,000 550 6

a. If the type/oil capacity of the oil pan is not known (1) contact a PACCAR Dealer, (2) determine the capacity of the oil pan option for the engine being serviced using Quickserve Online and the engine serial number, or (3) for the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

Table 3—Oil Drain Interval

Vehicle/EquipmentWith a 14.2 liter [15 qt] Oil Pana With a 18 liter [19 qt] Oil Pana

Kilometers Miles Hours Months Kilometers Miles Hours Months

Truck Crane 14,500 9,000 500 6 19,000 12,000 550 6

Yard Spotter 14,500 9,000 500 6 19,000 12,000 550 6

All Others 14,500 9,000 500 6 19,000 12,000 550 6

a. If the type/oil capacity of the oil pan is not known (1) contact a PACCAR Dealer, (2) determine the capacity of the oil pan option for the engine being serviced using Quickserve Online and the engine serial number, or (3) for the first oil drain interval, use the 14.2 liter [15 qt] oil drain interval. When filling the engine with oil, determine the oil capacity of the oil pan.

– 48 – Y53-1029 2/07 PACCAR


PACCAR bases its oil drain specifications on duty cycle andoil contamination. This contamination occurs in all engines atvarying rates regardless of design.

Maintaining the correct oil and filter change interval is a vitalfactor in preserving the integrity of an engine. Filters must bechanged when the oil is changed.

If the type/oil capacity of the oil pan is not known:• Contact a PACCAR dealer.• Determine the capacity of the oil pan option for the

engine being serviced using Quickserve Online and theengine serial number.

• For the first oil drain interval, use the 14.2 liter [15 qt] oildrain interval. When filling the engine with oil, determinethe oil capacity of the oil pan.

PACCAR Y53-1029 2/07 – 49 –


Maintenance Record Form

Engine Serial No. Engine Model:

Owner’s Name: Equipment Name/No.

Datekm (Miles), Hours,

or Time IntervalActual km (Miles)

or HoursMaintenance

Check PerformedCheck Performed

ByComments

– 50 – Y53-1029 2/07 PACCAR

SERVICE LITERATURE

Additional Service Literature

General Information

The following publications can be purchased from yourauthorized PACCAR Engine dealer.

Bulletin Number Title of Publication

4021578 Engine Service Manual

4021570 Electronic Control System Troubleshooting and Repair Manual

4021572 Engine Wiring Diagram

4021602 Operation and Maintenance Manual

3379000 Air for Your Engine

3379001 Fuel for Diesel Engines

3379009 Operation of Diesel Engines in Cold Climates

3810340 Engine Oil Recommendations

3666132 Coolant Requirements and Maintenance

3666255 Warranty Failcode Manual (Midrange Engines)

PACCAR Y53-1029 2/07 – 51 –

Service Literature

– 52 – Y53-1029 2/07 PACCAR

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 6.7 liters (409 C.I.D.)

Bore and Stroke 107 mm (4.21 in.) × 124 mm (4.88 in.)

Approximate Dry Weight (with standard accesories) 519 kg (1,144 lb)

Valve ClearanceIntake 0.254 mm (0.010 in.)

Exhaust 0.660 mm (0.026 in.)

Maximum Overspeed Capability (15 seconds maximum) 4,200 rpm

Minimum Ambient Temperature for Unaided Cold Start -12.2°C (-10°F)

Maximum Engine Cranking Speed 150 rpm

Engine Idle Speed Minimum 600 rpm to maximum 1,000 rpm

Altitude Limit 3658 m (12,000 ft)

PACCAR Y53-1029 2/07 – 53 –


i)

Lubricating Oil System

Oil PressureAt Low Idle (minimum allowable) 69 kPa (10 psi)

At Rated Speed (minimum allowable) 207 kPa (30 psi)

Oil Regulating Valve Opening Pressure Range 448 kPa (65 psi) to 517 kPa (75 ps

Oil Filter Differential Pressure to Open Bypass 345 kPa (50 psi)

Lubricating Oil Filter Capacity 0.950 liters (1 qt)

Lubricating Oil Capacity of Standard Engine

Standard Oil Pan

Pan Only 14.2 liters (15 qt)

Total System 16.7 liters (17.6 qt)

High to Low (on dipstick) 1.9 liters (2 qt)

High-Capacity Oil Pan

Pan Only 18 liters (19 qt)

Total System 20.3 liters (21.4 qt)

High to Low (on dipstick) 1.9 liters (2 qt)

Maximum Oil Temperature 138°C (280°F)

– 54 – Y53-1029 2/07 PACCAR


NOTE: if the type/oil capacity of the oil pan is notknown:

• Contact a PACCAR dealer.• Determine the capacity of the oil pan option

for the engine being serviced using Quick-serve Online and the engine serial number.

• For the first oil drain interval, use the 14.2 liter[15 qt] oil drain interval. When filling theengine with oil, determine the oil capacity ofthe oil pan.

PACCAR Y53-1029 2/07 – 55 –


Cooling System

Coolant Capacity (engine only) 11 liters (2.9 gal)

Standard Modulating Thermostat Range 86 to 97°C (186 to 207°F)

Minimum Recommended Pressure Cap 103 kPa (15 psi)

Maxiumum Allowed Operating Temperature 107°C (225°F)

Minimum Recommended Operating Temperature 71°C (160°F)

– 56 – Y53-1029 2/07 PACCAR


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'sdesign life. If other brands are substituted, the purchasershould ensure the filter specification meet or exceed theFleetguard specifications.

PACCAR can not be responsible for problems caused bynon-genuine filters that do not meet PACCAR performance ordurability requirements.

Filter Part Numbers

Lubricating Oil FilterFleetguard Part Number

LF3970

Fuel Filter (primary)Fleetguard Part Number

FF5632

Fuel Filter(prefilter with water-in-fuel sensor)Fleetguard Part Number

FS1065

Crankcase Ventilation Filter(rocker lever cover mounted)Fleetguard Part Number

CV5200000

Crankcase Ventilation Filter(rear engine mounted)Fleetguard Part Number

CV5060100

PACCAR Y53-1029 2/07 – 57 –


Fuel Recommendations and Specifications

Fuel Recommendations

WARNING! Mixing other fuels with diesel cancause an explosion. Do not mix gasoline, alco-hol, or gasohol with diesel fuel. Make sure youknow your fuel source and use the recom-mended diesel fuel as indicated in this sectionof the Operator's manual.

CAUTION: Dirt or water in the fuel system cancause severe damage to both the fuel pump andthe fuel injectors. Due to the precise tolerancesof diesel injection systems, it is extremelyimportant that the fuel be kept clean and free ofdirt or water. Know your fuel source and makesure all steps are taken for dispensing or usingclean fuel in your vehicle.

CAUTION: Lighter fuel can reduce economy orpossibly damage fuel system components.Lighter fuels typically do not have enoughlubricity elements in the fuel to properly lubri-cate the fuel injection system. Be sure you fol-low the fuel recommendations as indicated inthis section of the operator's manual.

CAUTION: Using diesel fuels blended with lubri-cating may cause damage to your exhaust after-treatment system. Service intervals foraftertreatment systems will be reduced. Do notuse diesel fuel blended with lubricating oil inengines equipped with an aftertreatment sys-tem.

CAUTION: Do not use high sulfur diesel fuel as itwill damage the exhaust aftertreatment system.Also, the engine will not meet emission regula-tions. Use only Ultra Low Sulfur Diesel (ULSD)fuel.

NOTE: The engine has been optimized for use withan aftertreatment system together with ULSD fuel tomeet the 2007 U.S. Environmental ProtectionAgency (EPA) regulations.

PACCAR recommends the use of ASTM number 2D fuel.The use of number 2 diesel fuel will result in optimum engineperformance.

At operating temperatures below 0°C [32°F], acceptable per-formance can be obtained by using blends of number 2D andnumber 1D.

– 58 – Y53-1029 2/07 PACCAR


The following chart lists acceptable types of fuels for thisengine.

NOTE: PACCAR recommends that the cetane num-ber of diesel fuel be a minimum of 45 for enginesthat are expected to operate at temperatures below0°C (32°F) and a minimum of 42 for engines that areoperated 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 maintainsatisfactory operation at low ambient temperatures,it is important to specify diesel fuel of the correct cet-ane number.

Acceptable Types of Fuels

Number 1D

DieselabNumber 2D

DieselbNumber 1K Kerosene

Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE

OK OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK

48-34c 40-24c 50-35c 51-37c 51-37c 48-36c 51-37c 57-45c 57-45c 57-45c

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 percent

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 tem-perature. 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.

PACCAR Y53-1029 2/07 – 59 –


NOTE: PACCAR requires all permissible fuels tohave adequate fuel lubricity. This means the BOCLEnumber is 3100 or greater as measured by ASTMspecification D6078, Scuffing Load Ball On CylinderEvaluator (SLBOCLE). Lubricity can also be mea-sured by ASTM, specification D6079, ISO 12156,High Frequency Reciprocating Rig (HFRR) in whichthe fuel must have a wear scar diameter of 0.45 mm[0.02 in] or less.

NOTE: For information on alternative fuels, such asbiodiesel, and additional information for fuel recom-mendations and specifications, please refer to theFuel for PACCAR Engines, Bulletin 3379001.

Warranty and the Use of Biodiesel Fuel

PACCAR neither approves nor disapproves of the use ofbiodiesel fuel blends. There is a major difference betweenoperating on pure (100% concentration) biodiesel fuels andbiodiesel or petrodiesel fuel blends. Currently, there are nofirm industry standards on the content and properties for bio-fuels. The consistency and predictability of bio-diesel opera-tion is not well documented nor its variations to the long-termeffects on performance, durability or emissions compliance ofthe PACCAR engine. The use of biodiesel fuel does not affectPACCAR materials and workmanship warranty. Failures

caused by the use of biodiesel fuels or other fuel additivesare not defects of PACCAR parts or workmanship and there-fore will not be covered by PACCAR warranty.

– 60 – Y53-1029 2/07 PACCAR


Lubricating Oil Recommendations and Specifications

General Information

CAUTION: Extending the oil and filter changeinterval beyond the recommendations willdecrease the engine life due to factors such ascorrosion, deposits, and wear. Engine oil filterscapture dirt and remove deposits from the oil toprolong 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 withappropriate oil drain and filter change intervals, is a criticalfactor 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 ascorrosion, deposits, and wear. Refer to “Oil Drain Intervals”on page 46 to determine which oil drain interval to use for anapplication.

NOTE: The responsibility is with the owner. If recom-mendations are ignored, warranty could be affected.

API: American Petroleum Institute

CES: Cummins Engineering Standard

PACCAR allows, for midrange applications, the use of lubri-cating oils that meet or exceed CES 20078 or CES 20081with 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) forthe aftertreatment system will be reduced.

To determine if the lubricating oil meets CES 20078 or CES20081, review the label on the back of the lubricating oil bot-tle for the CES 20078 or CES 20081 reference. If acquiringthe lubricating oil in bulk, contact the supplier for the lubricat-ing oil specifications and confirm that the oil meets CES20078 or CES 20081.

PACCAR Y53-1029 2/07 – 61 –


Also located on the lubricating oil bottle is the API servicesymbol which is shown in the illustration. The upper half ofthe symbol displays the appropriate oil categories. The cen-ter section identifies the SAE oil viscosity grade. The table

below shows how the Cummins Engineering Standard (CES)compares to the American Petroleum Institute (API) classifi-cation.

NOTE: A lubricating oil that meets the AmericanPetroleum Institute (API) performance classificationCJ-4/SL may not meet the CES 20081 requirement.Always make sure the lubricating oil used meets theCES 20081 requirement in addition to the API per-formance classification CJ-4/SL.

PACCAR recommends the use of high-quality SAE 15W-40heavy-duty engine oil.

The primary PACCAR recommendation is for the use of 15W-40 multigrade lubricating oil for normal operation at ambienttemperatures above -15°C [5°F]. The use of multigrade oilreduces deposit formation, improves engine cranking in lowtemperature conditions and increases engine durability bymaintaining lubrication during high temperature operatingconditions. Since multigrade oils have been shown to provideapproximately 30 percent lower oil consumption comparedwith monograde oils, it is important to use multigrade oils tobe certain the engine will meet applicable emissions require-ments.

Cummins Engine Standard Classification

(CES)

American Petroleum Institute Classification

(API)Comments

CES-20071CES-20072CES-20076CES-20077

API CH-4/SJNot recommended. Lubricating oil drain interval must be reduced by 50%. Aftertreatment maintenance interval will be reduced.

CES-20078 CI-4/SL Aftertreatment maintenance interval will be reduced.

CES-20081 CJ-4/SL Maximum aftertreatment maintenance interval. No change in lubricating oil drain interval.

– 62 – Y53-1029 2/07 PACCAR


Use of "synthetic engine oils" (those made with API group 3or 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 beapplied to synthetic oils that are applied to petroleum (min-eral) based engine oils.

While the preferred viscosity grade is 15W-40, lower viscositymultigrade oils can be used in colder climates. See theaccompanying chart. Any viscosity grade lower than 15W-40must still meet CES 20081.

Synthetic engine oils, API Group III and Group IV base-stocks, are recommended for use in PACCAR engines oper-ating in ambient temperature conditions consistently below -25°C [-13°F]. Synthetic 0W-30 oils that meet the require-ments of API Group III or Group IV basestocks, can be usedin operations where the ambient temperature never exceeds0°C [32°F]. Multiviscosity oils rated 0W-30 do not offer the

same level of protection against fuel dilution as do highermultigrade oils. Higher cylinder wear can be experiencedwhen using 0W-30 oils in high-load situations.

As these oils have directionally thinner oil films than 15W-40oils, top-quality Fleetguard® filters must be used above 20°C[70°F]. Some oil suppliers might claim better fuel economyfor these oils. PACCAR can neither approve nor disapproveany product not manufactured by PACCAR. These claims arebetween the customer and oil supplier. Obtain a commitmentfrom the oil supplier that the oil will give satisfactory perfor-mance 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 samelubricating oil that will be used during normal operation.

Aftermarket Oil Additive Usage

PACCAR does not recommend the use of aftermarket oiladditives. The present high-quality fully additive engine lubri-cating oils are very sophisticated, with precise amounts ofadditives blended into the lubricating oil to meet stringentrequirements. These furnished oils meet performance char-acteristics that conform to the lubricant industry standards.Aftermarket lubricating oil additives are not necessary toenhance engine oil performance and in some cases canreduce the furnished oil's capability to protect the engine.

PACCAR Y53-1029 2/07 – 63 –


Coolant Recommendations and Specifications

Fully Formulated Coolant/Antifreeze

PACCAR recommends the use of fully formulated antifreeze/coolant meeting Cummins Engineering Standards (C.E.S.)14603.

Typica l ly, ant i f reeze/coolants meet ing ASTM4985(GM6038M specification) or ASTM D6210 criteria areacceptable antifreeze/coolants for engines covered by themanual.

Low-silicate antifreeze/coolants meeting ASTM D4985(GM6038M specification) are not adequate for extended ser-vice intervals.

PACCAR recommends using either a 50/50 mixture of good-quality water and fully formulated antifreeze, or fully formu-lated coolant when filling the cooling system.

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 chloridesand sulfates cause cooling system corrosion.

Water Quality

Calcuim Magnesium(hardness)

Maximum 170 ppm as (CaCO3 + MgCO3)

Chloride 40 ppm as (Cl)

Sulfur 100 ppm as (SO4)

– 64 – Y53-1029 2/07 PACCAR


Fully formulated antifreeze must be mixed with good qualitywater at a 50/50 ratio (40- to 60-percent working range). A50/50 mixture of antifreeze and water gives a -36°C [-33°F]freezing point and a 108°C [226°F] boiling point, which isadequate for locations in North America. The actual lowestfreezing 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 silicagel problem.

PACCAR vehicle engine-cooling systems are filled with fullyformulated extended-life coolant (ELC).

PACCAR recommends the use of fully formulated extendedlife 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 Rotellaor their private label counterparts which do not meet the elas-tomer compatibility section of CES 14603, the coolant mustbe treated by adding 0.24 liter (8oz) of liquid silicate fluid forevery 45 liters (12 gal) of total coolant system volume. It iscritical to not over treat the coolant with silicate fluid. If over-treatment is suspended, drain the cooling system and dis-card the filter. Clean the cooling system immediately.Symptoms of silicate over-treatment can be thickened cool-ant in the lower radiator tank, water pump seal leakage soonafter silicate addition, reduced heater output and/or elevatedengine temperatures.

To obtain order forms or ask questions relative to orderingthe silicate fluid, contact:

Silicate Fluid Order ProgramP.O. Box 27388Houston, TX 77277-7388

Phone: 800-346-9041Fax: 800-876-5317

If the replacement coolant is Chevron Texaco, Shell Rotellaor their private label counterparts the coolant must bereplaced with new coolant whenever the engine is over-hauled or repairs involve the replacement of the followingcomponents:

• Rocker lever housing gasket.• Lubricating oil cooler housing gasket.• Cylinder head gasket.• Thermostat housing gasket.

For further details of engine coolant for PACCAR PX-6engines, refer to Cummins Coolant Requirements and Main-tenance Bulletin 3666132.

PACCAR Y53-1029 2/07 – 65 –


A refractometer must be used to measure the freezing pointof the coolant accurately. Use Fleetguard® refractometer,Part Number C2800.

CAUTION: Do not use a floating ball hydrometer.The use of floating ball hydrometers can give anincorrect reading. Using a floating ball hydrome-ter for testing the freezing point of the coolant isan inaccurate test and will cause a false readingof the coolant freezing point. Use a refractome-ter to obtain an accurate test of the coolantfreezing point.

– 66 – Y53-1029 2/07 PACCAR


Cooling System Sealing Additives

CAUTION: The use of sealing additives in thecooling system will cause damage to the engine.Sealing additives will plug various areas of theradiaters and oil cooler. The plugging of thecooling system will hamper heat transfer thus,causing internal engine damage. Do not usesealing additives in the cooling system. The useof sealing additives will:

• Buildup in coolant low-flow areas• Plug the radiator and oil cooler• Possibly damage the water pump seal.

Cooling System Soluble Oils

CAUTION: Do not use soluble oils in the coolingsystem. The use of soluble oils in the coolingsystem will cause damage to the engine. Solubleoils in the cooling system will:

• Corrode brass and copper• Damage heat transfer surfaces• Damage seals and hoses.

PACCAR Y53-1029 2/07 – 67 –


– 68 – Y53-1029 2/07 PACCAR

WARRANTY

PACCAR PX-6 Engine United States and Canada Coverage

Products Warranted

This warranty applies to new PACCAR PX-6 Engines sold byPACCAR and delivered to the first purchaser that are used inon-highway applications in the United States1 or Canada withone exception. PACCAR provides different warranty cover-age for engines used in fire apparatus truck applications.

Base Engine Warranty

This warranty covers any failures of the Engine which result,under normal use and service, from a defect in material orfactory workmanship (Warrantable Failure). This coveragebegins on the date of delivery and ends two years after thedate of delivery of the Engine to the first purchaser. Addi-tional coverage is outlined in the Emission Warranty section.

PACCAR Responsibilities

PACCAR will pay for all parts and labor needed to repair thedamage 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 arenot reusable due to the Warrantable Failure. PACCAR willpay for reasonable labor costs for Engine removal and rein-stallation 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 authorizedrepair station for the first year from the date of delivery of theEngine to the first purchaser or the duration of the warranty,whichever occurs first. In lieu of the towing expense, PAC-CAR will pay reasonable costs for mechanics to travel to andfrom the location of the vehicle, including meals, mileage,and lodging when an engine repair is performed at the site ofthe failure.

1. United States includes American Samoa, the Common-wealth of Northern Mariana Islands, Guam, Puerto Rico, and the U.S. Virgin Islands.

PACCAR Y53-1029 2/07 – 69 –

WARRANTY

Owner Responsibilities

Owner is responsible for the operation and maintenance ofthe Engine as specified in the applicable PACCAR Operator’sManual. Owner is also responsible for providing proof that allrecommended maintenance has been performed.

Before the expiration of the applicable warranty, Owner mustnotify a PACCAR authorized dealer or an authorized Cum-mins Distributor of any Warrantable Failure and make theengine available for repair by such facility. Except for Enginesdisabled by Warrantable Failure during the first year from thedate of delivery to the first purchaser or the duration of thewarranty, whichever occurs first, Owner must also deliver theEngine to the authorized repair facility.

Owner is responsible for the cost of lubricating oil, antifreeze,filter elements and other maintenance items provided duringwarranty repairs unless such items are not reusable due tothe Warrantable Failure. Owner is responsible for communi-cation expenses, meals, lodging and similar costs incurredas a result of a Warrantable Failure.

Owner is responsible for non-Engine repairs and for "down-time" expenses, cargo damage, fines, all applicable taxes, allbusiness costs and other losses resulting from a WarrantableFailure.

Limitations

PACCAR is not responsible for failures or damage resultingfrom what PACCAR determines to be abuse or neglect,including, but not limited to: operation without adequate cool-ants or lubricants; overfueling; overspeeding; lack of mainte-nance of lubricating, cooling or intake systems; improperstorage, starting, warm-up, run-in or shutdown practices;unauthorized modifications of the Engine. PACCAR is alsonot responsible for failures caused by incorrect oil or fuel orcatalytic reagent or by water, dirt or other contaminants in thefuel, oil, or catalytic reagent.

This warranty does not apply to accessories supplied by thevehicle OEM which are covered by the OEM vehicle war-ranty.

Failures resulting in excessive oil consumption are coveredfor the duration of the coverage or 100,000 miles (160,935kilometers) or 6,250 hours from the date of delivery of theEngine to the first purchaser, whichever of the three occursfirst. Before a claim for excessive oil consumption will be con-sidered, Owner must submit adequate documentation toshow that consumption exceeds PACCAR published stan-dards.

Failures of belts and hoses supplied by PACCAR are coveredfor the first year from the date of delivery of the Engine to thefirst purchaser.

– 70 – Y53-1029 2/07 PACCAR

WARRANTY

Parts used to repair a Warrantable Failure may be new parts,approved rebuilt parts, or repaired parts. PACCAR is notresponsible for failures resulting from the use of parts notapproved by PACCAR. A new approved rebuilt part used torepair a Warrantable Failure assumes the identity of the partit replaced and is entitled to the remaining coverage hereun-der.

PACCAR reserves the right to interrogate Electronic ControlModule (ECM) data for purposes of failure analysis.

PACCAR DOES NOT COVER WEAR OR WEAROUT OFCOVERED PARTS.

THIS WARRANTY AND THE EMISSION WARRANTY SETFORTH HEREINAFTER ARE THE SOLE WARRANTIESMADE BY PACCAR IN REGARD TO THESE ENGINES.

PACCAR MAKES NO OTHER WARRANTIES, EXPRESSOR IMPLIED, OR OF MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE.

PACCAR IS NOT RESPONSIBLE FOR INCIDENTAL ORCONSEQUENTIAL DAMAGES.

This warranty gives you specific legal rights, and you mayalso 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 Engines sold byPACCAR and delivered to the first purchaser that are used infire apparatus truck applications in the United States1 orCanada.

Base Engine Warranty

The Base Engine Warranty covers any failures of the Enginewhich result, under normal use and service, from a defect inmaterial or factory workmanship (Warrantable Failure). Thiscoverage begins on the date of delivery to the first purchaserand ends five years or 100,000 miles (160,935 kilometers),whichever occurs first.

Engine aftertreatment components included in the PACCARCritical Parts List (CPL) and marked with a PACCAR partnumber are covered under Base Engine Warranty. Additionalcoverage is outlined in the Emission Warranty section.


PACCAR Y53-1029 2/07 – 71 –

WARRANTY


PACCAR will pay for all parts and labor needed to repair thedamage 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 notreusable due to the Warrantable Failure. PACCAR will pay forreasonable labor costs for Engine removal and reinstallationwhen necessary to repair a Warrantable Failure.

PACCAR will pay reasonable costs for towing a vehicle dis-abled by a Warrantable Failure to the nearest authorizedrepair location. In lieu of the towing expense, PACCAR willpay reasonable costs for mechanics to travel to and from thelocation of the vehicle, including meals, mileage, and lodgingwhen its engine repair is performed at the site of the failure.

Owner Responsibilities

Owner is responsible for the operation and maintenance ofthe Engine as specified in PACCAR Operator’s Manual.Owner is also responsible for providing proof that all recom-mended maintenance has been performed.

Before the expiration of the applicable warranty, Owner mustnotify a PACCAR authorized dealer or an authorized Cum-mins Distributor of any Warrantable Failure and make theengine available for repair by such facility. Except for

Engines disabled by a Warrantable Failure, Owner must alsodeliver the Engine to the repair facility.

Owner is responsible for the cost of lubricating oil, antifreeze,filter elements and other maintenance items provided duringwarranty repairs unless such items are not reusable due tothe 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, allbusiness costs and other losses resulting from a WarrantableFailure.

Owner is responsible for a $100 (U.S. Dollars) deductible pereach service visit under this plan in the 3rd, 4th, and 5thyears of base engine warranty. The deductible will not becharged during the first 2 years of the base engine warranty.

Limitations

PACCAR is not responsible for failures or damage resultingfrom what PACCAR determines to be abuse or neglect,including but not limited to: operation without adequate cool-ants or lubricants; overfueling; overspeeding; lack of mainte-nance of lubricating, cooling or intake systems; improperstorage, starting, warm-up, run-in or shutdown practices;unauthorized modifications of the Engine. PACCAR is also

– 72 – Y53-1029 2/07 PACCAR

WARRANTY

not responsible for failures caused by incorrect oil, fuel or cat-alytic reagent or by water, dirt or other contaminants in thefuel, oil or catalytic reagent.

This warranty does not apply to accessories supplied byPACCAR 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 kilometers) or 6,250 hours from the date of deliveryof the Engine to the first purchaser, whichever of the threeoccurs first. Before a claim for excessive oil consumption willbe considered, Owner must submit adequate documentationto show that consumption exceeds PACCAR published stan-dards.

Failures of belts and hoses supplied by PACCAR are not cov-ered beyond the first year from the date of delivery of theEngine to the first purchaser.

Parts used to repair a Warrantable Failure may be new parts,approved rebuilt parts, or repaired parts. PACCAR is notresponsible for failures resulting from the use of parts notapproved by PACCAR. A new approved rebuilt part used torepair a Warrantable Failure assumes the identity of the partit replaced and is entitled to the remaining coverage hereun-der.

PACCAR reserves the right to interrogate Electronic ControlModule (ECM) data for purposes of failure analysis.

PACCAR DOES NOT COVER WEAR OR WEAROUT OFCOVERED PARTS.

THIS WARRANTY AND THE EMISSION WARRANTY SETFORTH HEREINAFTER ARE THE SOLE WARRANTIESMADE BY PACCAR IN REGARD TO THESE ENGINES.



This warranty gives you specific legal rights, and you mayalso have other rights which vary from state to state.

PACCAR Y53-1029 2/07 – 73 –

WARRANTY

Emission Warranty

Products Warranted

This emission warranty applies to new PACCAR Enginesmarketed by PACCAR that are used in the United States1 invehicles designed for transporting persons or property on astreet or highway.

Coverage

PACCAR warrants to the first purchaser and each subse-quent purchaser that the Engine is designed, built andequipped so as to conform at the time of sale by PACCARwith all U.S. Federal emission regulations applicable at thetime of manufacture and that it is free from defects in materialor factory workmanship which would cause it not to meetthese regulations within the longer of the following periods:(A) Five years or 100,000 miles (160,935 kilometers) of oper-ation, whichever occurs first, as measured from the date ofdelivery of the Engine to the first purchaser or (B) The BaseEngine Warranty.

If the vehicle in which the Engine is installed is registered inthe state of California, a separate California Emission War-ranty also applies.

Limitations

Failures, other than those resulting from defects in material orfactory workmanship, are not covered by this Warranty. PAC-CAR is not responsible for failures or damage resulting fromwhat PACCAR determines to be abuse or neglect, including,but not limited to: operation without adequate coolants orlubricants; overfueling; overspeeding; lack of maintenance oflubricating, cooling or intake systems; improper storage,starting, warm-up, run-in or shutdown practices; unautho-rized modifications of the Engine. PACCAR is also notresponsible for failures caused by incorrect oil, fuel or cata-lytic reagent or by water, dirt or other contaminants in thefuel, oil or catalytic reagent.

PACCAR is not responsible for non-Engine repairs, downtimeexpenses, cargo damage, fines, all applicable taxes, all busi-ness costs or other losses resulting from a Warrantable Fail-ure.



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California Emission Control System Warranty, On-Highway

Products Warranted

This Emission Control System Warranty applies to dieselengines (hereafter, engines) certified with the California AirResources Board beginning with the year 2007, marketed byPACCAR, and registered in California for use in on-highwayapplications.

Your Warranty Rights and Obligations

The California Air Resources Board and PACCAR arepleased to explain the emission control system warranty onyour 2007 and subsequent model year diesel engine. In Cal-ifornia, new motor vehicle engines must be designed, builtand equipped to meet the States stringent anti-smog stan-dards. PACCAR must warrant the emission control system onyour 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 thefuel injection system and engine electronic control module.Also included may be hoses, connectors and other emissionrelated assemblies.

If an emission-related part on your engine is found to have adefect in material or factory workmanship that produces ameasurable increase in emissions (Warrantable Condition),the part will be repaired or replaced by PACCAR. This is youremission control system defects warranty.

Manufacturer's Warranty Coverage

This warranty coverage is provided for five years or 100,000miles (160,935) km or 3,000 hours of engine operation,whichever first occurs from the date of delivery of the engineto the first purchaser. Where a Warrantable Condition exists,PACCAR will repair your engine at no cost to you includingdiagnosis, 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 PACCAROperator’s Manual. You are responsible for presenting yourengine to an authorized PACCAR Dealer or an authorizedCummins Distributor as soon as a problem exists. The war-ranty repairs should be completed in a reasonable amount oftime, not to exceed 30 days.

As the engine owner, you should also be aware that PACCARmay deny you warranty coverage if your engine or a part hasfailed due to abuse, neglect, improper maintenance or unap-proved modifications.

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If you have any questions regarding your warranty rights andresponsibilities, you should contact PACCAR Medium DutyEngine Department or the California Air Resources Board at9528 Telstar Avenue, El Monte, CA 91731.

A warranted part which is scheduled for replacement asrequired maintenance is warranted up to the first scheduledreplacement point.

Prior to the expiration of the applicable warranty, Owner mustgive notice of any warranted emission control failure to anauthorized PACCAR Engine dealer or an authorized Cum-mins Distributor and deliver the engine to such facility forrepair.

Owner is responsible for incidental costs such as: communi-cation expenses, meals, lodging incurred by Owner oremployees of Owner as a result of a Warrantable Condition.

Owner is responsible for downtime expenses, cargo damage,fines, all applicable taxes, all business costs, and otherlosses resulting from a Warrantable Condition.

California Emissions Components Statements for PX-6 Engine (2007) Emissions Engines Coverage

The emission control system warranty applies to the followingemission control parts which are subject to the failure qualifi-cations as communicated in Cummins Warranty Alert 0141,titled "Emissions Warranty Qualification."

Intake System• Intake connection• Charge Air Cooler• Turbocharger

Exhaust Gas Recirculation System• Exhaust Gas Recirculation Valve• Exhaust Gas Recirculation Cooler (and associated

plumbing)

Exhaust Manifold

Fueling System• Injector• Fuel Pump Actuator

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Electronic Control System• Engine Control Module• Barometric Air Pressure Sensor• Coolant Temperature Sensor• Rail fuel Pressure Sensor• Intake manifold pressure and temperature sensor• Compressor Inlet Temperature Sensor• Exhaust Gas Temperature Sensor• Exhaust Gas Recirculation Differential Pressure Sensor• Ambient air temperature/Barometric Air Pressure Sensor

Aftertreatment System• Aftertreatment diesel particulate filter• Aftertreatment diesel oxidation catalyst• Aftertreatment exhaust gas temperature sensors• Aftertreatment diesel particulate filter differential pres-

sure sensor (and related plumbing)

Replacement Parts

PACCAR recommends that any service parts used for main-tenance, repair or replacement of emission control systemsbe new, genuine approved rebuilt parts and assemblies, andthat the engine be serviced by an authorized PACCAREngine dealer or an authorized Cummins Distributor. Theowner may elect to

have maintenance, replacement or repair of the emissioncontrol parts performed by a facility other than a PACCARauthorized dealer or an authorized Cummins Distributor andmay elect to use parts other than new genuine approvedrebuilt parts and assemblies for such maintenance, replace-ment or repair; however, the cost of such service or parts andsubsequent failures resulting from such service or parts willnot be covered under this emission control system warranty,except for Emergency Repairs as described below.


The warranty coverage begins when the engine is deliveredto the first purchaser. Repairs and service will be performedby any authorized PACCAR Engine, dealer or an authorizedCummins Distributor using new, genuine approved rebuiltparts and assemblies. PACCAR will repair any of the emis-sion control parts found by PACCAR to be defective withoutcharge for parts or labor (including diagnosis which results indetermination that there has been a failure of a warrantedemission control part).

Emergency Repairs

In the case of an emergency where an authorized PACCAREngine dealer or an authorized Cummins Distributor is notavailable, repairs may be performed by any available repairlocation or by any individual using any replacement parts. Apart not being available within 30 days or a repair not being

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complete within 30 days constitutes an emergency. PACCARwill reimburse the Owner for expenses (including diagnosis),not to exceed the manufacturers suggested retail price for allwarranted parts replaced and labor charges based on themanufacturers recommended time allowance for the war-ranty repair and the geographically appropriate hourly laborrate. Replaced parts and paid invoices must be presented atan authorized PACCAR Engine dealer or authorized Cum-mins Distributor as a condition of reimbursement for emer-gency repairs not performed by an authorized PACCAREngine dealer or an authorized Cummins Distributor.

Warranty Limitations

PACCAR is not responsible for failures or damage resultingfrom what PACCAR determines to be abuse or neglect,including, but not limited to: operation without adequate cool-ants or lubricants; overfueling; overspeeding; lack of mainte-nance of cooling, lubricating or intake systems; improperstorage, starting, warm-up, run-in or shutdown practices;unauthorized modifications to the engine. PACCAR is alsonot responsible for failures caused by incorrect oil or fuel orby water, dirt or other contaminants in the fuel or oil.

PACCAR is not responsible for failures resulting fromimproper repair or the use of parts which are not genuineapproved parts.

PACCAR is not responsible for the material and labor costs ofemission control parts and assemblies replaced duringScheduled Maintenance of the engine as specified in PAC-CAR Operator’s Manuals.

THIS WARRANTY, TOGETHER WITH THE EXPRESSCOMMERCIAL WARRANTIES ARE THE SOLE WARRAN-TIES MADE BY PACCAR IN REGARD TO THESEENGINES.


PACCAR is not responsible for other incidental or conse-quential damages. Incidental or consequential damagesinclude but are not limited to fines, theft, vandalism orcollisions.

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px6 manual (paccar engine)

Documents

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number y53

warranty information

serious engine damage

engine united states

contents paccar px

fuel recommendations

clutch model serial