Exhaust Emission Components

Service Manual SM043-001

(02/ 19)

Aftertreatment System
 Contents

Contents

Chapter 1: Safety ...................................................................................... 7

General Safety Instructions .............................................................................................................................. 8
Aftertreatment Specific Precautions ................................................................................................................. 8

Chapter 2: Applies To ............................................................................. 11

Vehicles this book applies to ........................................................................................................................... 12
Build Information for Models with VECU ......................................................................................................... 12

Chapter 3: Exploded View ..................................................................... 13

Aftertreatment Control Module ........................................................................................................................ 14
DEF Tank ........................................................................................................................................................ 15
Exhaust Pipe Turbo to DPF Inlet .................................................................................................................... 16

Chapter 4: What's New .......................................................................... 17

What's New for 2017 Emissions ..................................................................................................................... 18

Chapter 5: General Information ............................................................ 19

Aftertreatment System for 2017 ...................................................................................................................... 20
Features of the 2017 Aftertreatment Unit ....................................................................................................... 21

Chapter 6: Specifications ...................................................................... 25

Diesel Exhaust Fluid Recommendations and Specifications .......................................................................... 26
Constant Power Requirements ....................................................................................................................... 27
Freezing Conditions ........................................................................................................................................ 27
DEF Handling ................................................................................................................................................. 28
DEF Storage ................................................................................................................................................... 28
Contamination / Incorrect Fluid ....................................................................................................................... 29
Exhaust System Torque Specifications ........................................................................................................... 30
Engine Aftertreatment System Power Requirements ..................................................................................... 30
DEF Volume Derate Specifications ................................................................................................................. 30

Chapter 7: How it Works ........................................................................ 33

Aftertreatment System (ATS) .......................................................................................................................... 34
Diesel Particulate Filter (DPF) System ........................................................................................................... 34
Extended Idling ............................................................................................................................................... 34
Selective Catalytic Reduction (SCR) System ................................................................................................. 35
The 2017 Aftertreatment System General Schematic .................................................................................... 36
How to Enable an Automatic Regeneration of the DPF .................................................................................. 36
DEF Gauge ..................................................................................................................................................... 37

Chapter 8: Maintenance ......................................................................... 39

Aftertreatment System Maintenance Schedule .............................................................................................. 40
Diesel Exhaust Fluid (DEF) Filter ................................................................................................................... 40
Clean DPF/SCR Canister ............................................................................................................................... 40
Diesel Exhaust Fluid (DEF) Tank Straps ........................................................................................................ 40
Diesel Exhaust Fluid (DEF) Lamp .................................................................................................................. 41
Emissions System Lamp ................................................................................................................................ 41

Chapter 9: Disassembly and Assembly ............................................... 43

DEF Tank ........................................................................................................................................................ 44
Contents

How to Remove DEF Pump Unit .................................................................................................................... 45

Special Considerations for DEF Supply Line .................................................................................................. 46
Hose Routing RH Under Cab Canister with RH DEF Tank ............................................................................. 46
Remove and Replace DEF Tank Coolant Loop .............................................................................................. 47

Chapter 10: Troubleshooting ................................................................ 49

Aftertreatment Harness Detailed Schematic for 2017 .................................................................................... 50
Emissions DEF Tank Harness Schematic for 2017 ........................................................................................ 52
Warning Symbols Quick Reference ................................................................................................................ 53
Notification of High Exhaust System Temperature ......................................................................................... 54
Notification Regeneration is Required ............................................................................................................ 54
How to Start a Parked Regeneration .............................................................................................................. 55
DEF Level Warning – Non-Emergency Vehicles ............................................................................................ 57
DEF Quality Warning – Non-Emergency Vehicles .......................................................................................... 57
SCR Component Failure Warning – Non-Emergency Vehicles ...................................................................... 58
DEF Level Warning – Emergency Vehicles .................................................................................................... 58
DEF Quality Warning – Emergency Vehicles .................................................................................................. 59
SCR Component Failure Warning – Emergency Vehicles .............................................................................. 59
Final Verification Test of OBD System ............................................................................................................ 60
DEF Tank Level Programming Guide ............................................................................................................. 61

Chapter 11: Frequently Asked Questions ............................................ 63

Chapter 12: Appendix ............................................................................ 65

Glossary .......................................................................................................................................................... 67
 Contents

© 2016 PACCAR Inc. - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or
optional on this vehicle. This manual may also include a description of features and equipment which are no
longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating
to features or equipment which are not on this vehicle. PACCAR reserves the right to discontinue, change
specifications, or change the design of its vehicles at any time without notice and without incurring any
obligation. The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in
part, by any means is strictly prohibited without prior written authorization from PACCAR Inc.
Contents
Chapter 1 | SAFETY
General Safety Instructions ............................................................................................................... 8
Aftertreatment Specific Precautions .................................................................................................. 8

SM043-001 (02/19) 7
CHAPTER 1: SAFETY - General Safety Instructions

General Safety Instructions

A number of alerting messages are in this manual. Please read and follow them. They are there for
your protection and information. These messages can help you avoid injury to yourself or others
and help prevent costly damage to the vehicle.

Aftertreatment Specific Precautions

WARNING

If you operate in environments that contain explosive vapors or flammable materials, look to see if your vehicle’s DPF Switch is
equipped with a DISABLE function. The DISABLE function must be activated prior to entering the above environment(s) to prevent
automatic engine regeneration from occurring, which could cause an explosion or fire. Failing to activate the DISABLE function be-
fore entering a combustible environment may cause an explosion or fire that could lead to death, personal injury, equipment or prop-
erty damage.

WARNING

Temperature of the tail pipe, exhaust pipe, the diesel particular filter (DPF)/selective catalytic reduction (SCR) device and surround-
ing components including enclosures and steps, will be elevated during and shortly after a regeneration event or normal vehicle op-
eration when engine is under high or heavy loading.

WARNING

Parking the vehicle too close to any combustible materials or vapors may start a fire, ignite an explosion or burn someone standing
close by. Before pushing the DPF Switch on the dash, walk around your vehicle and ensure you have at least 5 ft. (1.5 m) clearance
from the sides and top of your vehicle to any combustibles. Ensure no one is in the immediate vicinity of the tail pipe. Failure to
comply could ignite a fire or cause an explosion, resulting in death, personal injury, equipment or property damage.

WARNING

Never initiate a regeneration in a closed building or enclosure. Always park your vehicle outside and ensure no one is in the immedi-
ate vicinity. Failure to comply could ignite a fire or cause an explosion, resulting in death, personal injury, equipment or property dam-
age.

CAUTION

It is unlawful to tamper with, modify, or remove any component of the SCR system. Failure to comply may result in equipment or
property damage.

WARNING

Diesel Exhaust Fluid (DEF) contains urea. DO NOT get the substance in your eyes. In case of contact, immediately flush eyes with
large amounts of water for a minimum of 15 minutes. DO NOT swallow internally. In the event the diesel exhaust fluid is ingested,
contact a physician immediately. Reference the Materials Safety Data Sheet (MSDS) for additional information. Failure to comply
may result in personal injury.

CAUTION

Never attempt to create Diesel Exhaust Fluid (DEF) by mixing agricultural grade urea with water. Agricultural grade urea does not
meet the necessary specifications required and the engine aftertreatment system may be damaged. Failure to comply may result in
equipment damage.

8 SM043-001 (02/19)
 Aftertreatment Specific Precautions - CHAPTER 1: SAFETY

CAUTION

PACCAR Inc requires the use of DEF meeting ISO 22241-1 (DIN 70070) specifications. There is
NO acceptable substitute. Failure to use the correct DEF may cause engine damage and/or void
the warranty.
• Some locations may reference the DIN 70070 standard. DEF specification limits of this
standard are identical to ISO 22241-1.

CAUTION

Do not submerge or allow water to enter the DPF assembly. Components of the assembly can be damaged and affect the perform-
ance of the engine aftertreatment system. Failure to comply may result in equipment or property damage.

CAUTION

If Diesel Exhaust Fluid (DEF) is spilled on metal surfaces (for example the steps, fuel tanks or grab handles) rinse and clean immedi-
ately with water. Failure to do so may leave permanent corrosive stains on the metal surfaces which can not be removed.

• Make sure to only use approved containers to transport and store DEF. Containers made of
polyethylene and polypropylene are recommended.
• If DEF is spilled, rinse and clean immediately with water.
• Avoid prolonged contact with skin. In case of contact, wash immediately with soap and wa-
ter. If not washed immediately, a white film will be left when the DEF dries.

NOTE

Ultra low sulfur diesel (ULSD) fuel is required for engines equipped with an aftertreatment diesel particulate filter. If ULSD is not
used, the engine may not meet emissions regulations, and the DPF or aftertreatment Diesel Oxidation Catalyst (DOC) can be dam-
aged.

NOTE

Spilled DEF, if left to dry or wiped away with a cloth only, will leave a white residue. Failure to clean the spilled DEF may result in an
incorrectly diagnosed leak of the DEF dosing system.

NOTE

Do not use tap water to rinse components that will be used to deliver diesel exhaust fluid. Tap water will contaminate the DEF. If
distilled water is not available, rinse with tap water and then rinse with DEF.

SM043-001 (02/19) 9
CHAPTER 1: SAFETY - Aftertreatment Specific Precautions

10 SM043-001 (02/19)
Chapter 2 | APPLIES TO
Vehicles this book applies to ........................................................................................................... 12
Build Information for Models with VECU ......................................................................................... 12

SM043-001 (02/19) 11
CHAPTER 2: APPLIES TO - Vehicles this book applies to

Vehicles this book applies to

This document applies to all vehicles manufactured with 2017 emissions compliant engines.
This document applies to all vehicle models powered by PACCAR MX13 and MX11 or Cummins
ISX12 and ISX15 engines.
• T680, T880, 579, 567 with CECU
• W900 ,T800, T660, C500, 389, 386, 384, 367, 365 with VECU (see Build Information for
Models with VECU on page 12 to identify these chassis)
• W900, T800, T660, and C500 with CECU

Build Information for Models with VECU

The CECU VECU Multiplex (CVMux) architecture includes both a Cab Electronic Control Unit
(CECU) and the new Vehicle Electronic Control Unit (VECU) to control various systems on the
truck.
Full VECU system installation began October 08, 2018 (although some trucks were built and
released before this date) on PACCAR Heavy Duty vehicles with 2.1m cabs and either EPA17
Diesel or EPA18 Natural Gas engines. The tables below may help identify trucks equipped with the
VECU system.

12 SM043-001 (02/19)
Chapter 3 | EXPLODED VIEW
Aftertreatment Control Module ........................................................................................................ 14
DEF Tank ......................................................................................................................................... 15
Exhaust Pipe Turbo to DPF Inlet ..................................................................................................... 16

SM043-001 (02/19) 13
CHAPTER 3: EXPLODED VIEW - Aftertreatment Control Module

Aftertreatment Control Module

Aftertreatment control modules are installed on vehicles powered by PACCAR MX engines. These
units are not included on vehicles with Cummins engines or PACCAR PX series engines.
2.3 meter cabs will have the ACM located under the cab floor directly under the driver seat.
Figure 1: 2.3 meter Cab Platform Powered by PACCAR MX Engines

2.1 meter cab platform vehicles will have the ACM located in the battery box.
Figure 2: 2.1 meter Cab Platform (Inside Battery Box)

All other vehicle platforms with PACCAR MX engines will have the ACM mounted inside the frame
rails, passenger side, forward of the back of cab crossmember.
Figure 3: Inside Rail Location (All Other Vehicle Platforms)

14 SM043-001 (02/19)
 DEF Tank - CHAPTER 3: EXPLODED VIEW

DEF Tank
If the DEF tank has a metal cover, it can be removed to access the DEF tank retaining straps.

Once the retaining straps are accessible, they can be removed via nut and bolt on top and bottom
of each strap. These straps hold the tank onto the structure.

The DEF pump, its filter, tank vent, electronics and hoses are usually mounted to the rear of the
tank. Typically the first item to remove is the pump cover plate. The DEF pump itself is mounted to a
separate plate which has to be removed to separate the pump for replacement. The graphic below
is an example of a rectangular DEF tank; most tank assemblies have similar arrangements.
Figure 4: Rectangular DEF Tank

SM043-001 (02/19) 15
CHAPTER 3: EXPLODED VIEW - Exhaust Pipe Turbo to DPF Inlet

Exhaust Pipe Turbo to DPF Inlet

Please refer to these illustrations if the exhaust piping between the DPF and the Turbo require
removing. The illustrations are a typical representation to most applications. Some 1.9 and 2.3
meter cab platforms may vary. The clamps and gaskets remain the same.

Figure 5: High Route Exhaust 2.1 meter Cab Platform

1 5" Clamp to DPF inlet

2 Gasket
3 4" Clamp Turbo Outlet to Flex Pipe
4 and 5 Gasket

16 SM043-001 (02/19)
Chapter 4 | WHAT'S NEW
What's New for 2017 Emissions ...................................................................................................... 18

SM043-001 (02/19) 17
CHAPTER 4: WHAT'S NEW - What's New for 2017 Emissions

What's New for 2017 Emissions

For 2017 Emissions, the DPF unit and the SCR unit (including the DEF doser and mixing chamber)
are combined into a single unit. Guidelines regarding DEF doser orientation are removed. Sensors
for temperature in the system have been reduced.
PACCAR has implemented a new DEF hose design and therefore, related hose routing guidelines
are no longer specified.
The system is programmed to circulate DEF fluid for 10 minutes after engine shutdown. This helps
reduce freezing issues and crystallization concerns. It changes requirements for when working on
electrical systems because the system needs battery power for 10 minutes after engine shutdown.
On the DEF tank itself, the level and temperature sensors are combined into one single Urea
Quality Sensor. This single sensor provides Urea quality, tank level and temperature data to the
system control units.

18 SM043-001 (02/19)
Chapter 5 | GENERAL INFORMATION
Aftertreatment System for 2017 ....................................................................................................... 20
Features of the 2017 Aftertreatment Unit ........................................................................................ 21

SM043-001 (02/19) 19
CHAPTER 5: GENERAL INFORMATION - Aftertreatment System for 2017

Aftertreatment System for 2017

Exhaust systems on heavy and medium duty trucks and tractors have become more complex in
response to regulations mandated by the Environmental Protection Agency (EPA). Each iteration of
the regulation, the vehicle emissions have been reduced for particulate matter, hydrocarbon and
nitrous oxide.

1 Hydrocarbon Doser and Inlet to the DPF/SCR Unit

2 2017 DPF/SCR Unit
3 Exhaust Outlet
4 Diesel Exhaust Fluid Tank and Pump

Kenworth and Peterbilt vehicles have an emissions strategy that utilizes a Diesel Particulate Filter
and a Selective Catalytic Reduction device to manage particulate matter, hydrocarbon, carbon
monoxide and nitrous oxide emissions from the vehicle. In addition to this equipment, controls are
installed to operate, maintain and alert the driver so that vehicle emissions adhere to the regulations
mandated by the EPA. Depending on the severity of the system faults, some of these lights may
start flashing and the check engine light and/or stop engine light may come on. In response to
emissions related dash warning lamps, the operator has these items to manage in order to
eliminate the warning lamp before the fault derates or stops the engine.
• Diesel Exhaust Fluid tank
• Diesel Exhaust Fluid level gauge
• DPF manual regeneration switch
• Maintenance intervals for the engine and emissions system
This manual is intended to provide service information on these pieces of equipment. Equipment
such as the Exhaust Gas Recirculation (EGR) and the Hydrocarbon Doser (where applicable) are
explained in the engine manufacturer’s literature.

Malfunction Indicator Lamp

Illuminates when an engine emissions failure has occurred. The vehicle can be safely driven but
should be serviced to correct the problem. The situation should not be considered an emergency. In

20 SM043-001 (02/19)
 Features of the 2017 Aftertreatment Unit - CHAPTER 5: GENERAL INFORMATION

some cases, the Malfunction Indicator Lamp (MIL) will activate in conjunction with the High Exhaust
System Temperature (HEST), Diesel Particulate Filter (DPF) and Diesel Exhaust Fluid (DEF)
warning lamps.

NOTE

The malfunction indicator lamp (MIL) will illuminate if the on-board diagnostics (OBD) system detects a possible emissions system
failure. The vehicle should be brought in for service at the next opportunity to ensure the condition is corrected.

High Exhaust System Temperature (HEST) Warning Lamp

Engine aftertreatment system includes a high exhaust system temperature (HEST) warning lamp.

Keep vehicle a safe distance from combustible items.

WARNING

Temperature of the tail pipe, exhaust pipe, the diesel particular filter (DPF)/selective catalytic reduction (SCR) device and surround-
ing components including enclosures and steps, will be elevated during and shortly after a regeneration event or normal vehicle op-
eration when engine is under high or heavy loading.

If the High Exhaust System Temperature (HEST) warning lamp is on:

• Do not park in an area of combustible vapors or materials. You must keep combustibles at
least 5 ft. (1.5 m) away from the exhaust (outlet) stream (as it exits the tail pipe) while the
HEST lamp is illuminated. Always park your vehicle outside. Failure to do so could ignite an
explosion or harm bystanders which could result in serious injury.
• Do not park in an area where people are close by. You must keep combustibles at least 5 ft.
(1.5 m) away from the exhaust outlet while the HEST lamp is illuminated. Failure to do so
could result in serious injury.
• Do not approach the exhaust system or surrounding areas without allowing adequate time for
the system to cool down. Failure to do so could result in serious burns to the skin.

Diesel Particulate Filter (DPF) Warning Lamp

This warning symbol will appear when the DPF needs to be regenerated and then also during the
regeneration cycle. This icon may also appear if the system is attempting to automatically
regenerate while the vehicle is in Power Take Off operation mode.

Engine aftertreatment system includes a diesel particulate filter and DPF warning lamp.

Features of the 2017 Aftertreatment Unit

The aftertreatment canister now contains the DPF, DEF Doser and the SCR units. The input
remains Marmon style connections and the outlet is still Torca connections.

SM043-001 (02/19) 21
CHAPTER 5: GENERAL INFORMATION - Features of the 2017 Aftertreatment Unit

Combining the two units into a single canister results in all sensors to be located in one place. Most
importantly, the overall count of temperature sensors reduced to 4 for the system.

All system modules for the DPF and the SCR reside on the canister.

22 SM043-001 (02/19)
 Features of the 2017 Aftertreatment Unit - CHAPTER 5: GENERAL INFORMATION

SM043-001 (02/19) 23
CHAPTER 5: GENERAL INFORMATION - Features of the 2017 Aftertreatment Unit

24 SM043-001 (02/19)
Chapter 6 | SPECIFICATIONS
Diesel Exhaust Fluid Recommendations and Specifications ........................................................... 26
Constant Power Requirements ........................................................................................................ 27
Freezing Conditions ......................................................................................................................... 27
DEF Handling .................................................................................................................................. 28
DEF Storage .................................................................................................................................... 28
Contamination / Incorrect Fluid ........................................................................................................ 29
Exhaust System Torque Specifications ........................................................................................... 30
Engine Aftertreatment System Power Requirements ...................................................................... 30
DEF Volume Derate Specifications ................................................................................................. 30

SM043-001 (02/19) 25
CHAPTER 6: SPECIFICATIONS - Diesel Exhaust Fluid Recommendations and Specifications

Diesel Exhaust Fluid Recommendations and Specifications

CAUTION

It is unlawful use Diesel Exhaust Fluid (DEF) that does not meet the specifications provided or to operate the vehicle/equipment with-
out DEF. Failure to comply may result in equipment or property damage.

WARNING

Diesel Exhaust Fluid (DEF) contains urea. DO NOT get the substance in your eyes. In case of contact, immediately flush eyes with
large amounts of water for a minimum of 15 minutes. DO NOT swallow internally. In the event the diesel exhaust fluid is ingested,
contact a physician immediately. Reference the Materials Safety Data Sheet (MSDS) for additional information. Failure to comply
may result in personal injury.

CAUTION

Never attempt to create Diesel Exhaust Fluid (DEF) by mixing agricultural grade urea with water. Agricultural grade urea does not
meet the necessary specifications required and the engine aftertreatment system may be damaged. Failure to comply may result in
equipment damage.

CAUTION

PACCAR Inc requires the use of DEF meeting ISO 22241-1 (DIN 70070) specifications. There is
NO acceptable substitute. Failure to use the correct DEF may cause engine damage and/or void
the warranty.
• Some locations may reference the DIN 70070 standard. DEF specification limits of this
standard are identical to ISO 22241-1.

PACCAR Inc is not responsible for failures or damage resulting from what PACCAR Inc determines
to be abuse or neglect, including but not limited to: operation without correctly specified DEF; lack
of maintenance of the engine aftertreatment system; improper storage, or shutdown practices;
unauthorized modifications of the engine and engine aftertreatment system. PACCAR is also not
responsible for failures caused by incorrect DEF or by water, dirt or other contaminants in the DEF.
Refer to your engine and vehicle operator's manuals for maintenance, storage, and shutdown
information.
For engines using SCR operating in the United States and Canada, it is recommended that the DEF
used be certified by the American Petroleum Institute (API).

NOTE

To ensure the correct DEF is used, PACCAR Inc recommends the use of TRP® CleanBlue Diesel Exhaust Fluid which is available in
different quantity options from small to bulk containers.

26 SM043-001 (02/19)
 Constant Power Requirements - CHAPTER 6: SPECIFICATIONS

DEF Availability
• DEF is readily available at truck stops and at all PACCAR Engine dealers. For assistance
locating DEF, contact your local PACCAR authorized repair location.
• If your vehicle is out of DEF and you are unable to locate a source to purchase DEF, please
contact the vehicle OEM customer care center at the telephone number provided in the
vehicle operator’s manual. The vehicle OEM customer care center will be able to contact the
nearest dealer location to you and arrange for an emergency shipment of DEF to your
location 24 hours a day.
The following are other common names used for Diesel Exhaust Fluid (DEF):
• AUS 32 (Aqueous Urea Solution 32)
• AdBlue
• NOx Reduction Agent
• Catalyst Solution
Regardless of what the DEF is called, the DEF must meet the ISO 22241-1 (DIN 70070)
specifications.

Constant Power Requirements

There are two power configurations for engines:
Without Battery Disconnect Power is supplied by the relevant distribution centers for each model.
Vehicles with Cummins and When disconnects are equipped, a separate bypass harness is fitted containing a
PACCAR PX Engines and Battery separate engine power fuse. The fuse is located in the battery box. The harness
Disconnect routes with the battery cables and connects to the engine harness near the starter
motor.
Vehicles with PACCAR MX Power is supplied by the relevant distribution centers for each model.
Engines and Battery Disconnect

Freezing Conditions
Precautions regarding DEF in freezing conditions.

CAUTION

The Diesel Exhaust Fluid (DEF) system recirculates fluid to the doser to prevent damage from heat after key off. If your vehicle is
equipped with battery disconnect switches do NOT disconnect battery power within TEN minutes of switching the ignition key off.
Failure to comply may result in vehicle or property damage.

CAUTION

Do NOT add any chemicals/additives to the Diesel Exhaust Fluid (DEF) in an effort to prevent freezing. If chemicals/additives are
added to the DEF, the engine aftertreatment system may be damaged.

DEF will freeze around -12°C (11°F). The DEF system on the vehicle is designed to accommodate
this and does not require any intervention.

SM043-001 (02/19) 27
CHAPTER 6: SPECIFICATIONS - DEF Handling

DEF Handling

CAUTION

If Diesel Exhaust Fluid (DEF) is spilled on metal surfaces (for example the steps, fuel tanks or grab handles) rinse and clean immedi-
ately with water. Failure to do so may leave permanent corrosive stains on the metal surfaces which can not be removed.

• Make sure to only use approved containers to transport and store DEF. Containers made of
polyethylene and polypropylene are recommended.
• If DEF is spilled, rinse and clean immediately with water.
• Avoid prolonged contact with skin. In case of contact, wash immediately with soap and wa-
ter. If not washed immediately, a white film will be left when the DEF dries.

NOTE

Spilled DEF, if left to dry or wiped away with a cloth only, will leave a white residue. Failure to clean the spilled DEF may result in an
incorrectly diagnosed leak of the DEF dosing system.

Before using containers, funnels, etc. that will be used to dispense, handle or store DEF, make sure
to wash thoroughly to remove any contaminants and then rinse with distilled water.

NOTE

Do not use tap water to rinse components that will be used to deliver diesel exhaust fluid. Tap water will contaminate the DEF. If
distilled water is not available, rinse with tap water and then rinse with DEF.

DEF Disposal
If disposing Diesel Exhaust Fluid (DEF), always check with the local authority regulations on proper
disposal process and requirements.

DEF Storage

NOTE

The following information is for reference and is to be used as a guideline only. There are many factors that determine Diesel Ex-
haust Fluid (DEF) shelf life, with temperature and duration being two of the major determining contributors. If in doubt, replace the
fluid with known quality DEF. DEF has a limited shelf life, both in the vehicle's diesel exhaust fluid tank and in storage/bulk/transpor-
tation containers.

The following conditions are ideal for maintaining DEF quality and shelf life during prolonged
transportation and storage:
• Storage temperature between -5°C and 25°C (23°F and 77°F)
• Storage in sealed containers to avoid contamination
• Avoidance of direct sunlight
In these conditions, Diesel Exhaust Fluid (DEF) has a minimum expected shelf life of 18 months. If
stored at higher temperatures for extended periods of time, the shelf life will be reduced by
approximately 6 months for every 5°C (9°F) above the highest storage temperature listed above.
Long term storage in a vehicle (in excess of 6 months) is not recommended.

28 SM043-001 (02/19)
 Contamination / Incorrect Fluid - CHAPTER 6: SPECIFICATIONS

NOTE

To assist in preventing DEF from deteriorating when stored in the vehicle's DEF tank, locate and plug the tank's venting to seal the
tank exposure to the atmosphere.

Figure 6: DEF Tank

1. DEF tank vent

Contamination / Incorrect Fluid

The following guidelines are available if DEF gets contaminated or the level of DEF the tank is
significantly different than what the gauge reads.

CAUTION

Never add water or any other fluid besides what is specified to the DEF tank. The engine aftertreatment system may be damaged.

The system monitors the DEF fluid quality under normal operating temperatures and when the
vehicle is moving 8 kph (5 mph). In some situations, the system may not check DEF quality
because of reduced operating temperatures. A service tool may be required to temporarily allow the
system to check the DEF quality at operating temperatures regardless of vehicle speed. In the
event that the incorrect fluid is added to the Diesel Exhaust Fluid tank, such as, but not limited to:
• Water
• Diesel Fuel
• Hydraulic Fluid
• Coolant
• Windshield Washer Fluid
Contact a local PACCAR Authorized Repair location to determine the appropriate repair direction. If
only water has been added to the DEF tank, drain the DEF tank, flush with distilled water and refill
with new and/or known good DEF.

SM043-001 (02/19) 29
CHAPTER 6: SPECIFICATIONS - Exhaust System Torque Specifications

Exhaust System Torque Specifications

Typical Installation 1.9 m Cab Platform

1 Gasket
2 Clamp

Component Torque

M12 holding the T Band to the Frame Bracket 75 ± 10 ft-lbs (102 ± 13 Nm)

T Band 5/16" Locknut 110 ± 10 in-lb

5" and 4" V-Band and Spherical Marmon Clamp 100-110 in-lbs

Engine Aftertreatment System Power Requirements

The engine aftertreatment system uses battery power for up to 10 minutes after the ignition is
turned off. After the ignition turns off, the engine aftertreatment system circulates DEF to help cool
down the fluid and prevent overheating. For situations where the battery will be disconnected (i.e.
for service or maintenance of the vehicle), please wait 10 minutes before disconnecting battery
power.

CAUTION

Wait at least 10 minutes after the key switch is turned OFF before disconnecting battery power. The system uses battery power to
circulate DEF and prevent overheating of the DEF system. Failure to comply may result in equipment or property damage.

DEF Volume Derate Specifications

Non-Emergency Vehicle Applications
The EPA requires that DEF levels be maintained above a minimum level. This level is a percentage
of total volume capacity of the tank. These values are in affect for both Cummins powered,
PACCAR PX and MX powered vehicles.

30 SM043-001 (02/19)
 DEF Volume Derate Specifications - CHAPTER 6: SPECIFICATIONS

Derate Level DEF Tank Volume

1 10%

2 5%

3 1%

SM043-001 (02/19) 31
CHAPTER 6: SPECIFICATIONS - DEF Volume Derate Specifications

32 SM043-001 (02/19)
Chapter 7 | HOW IT WORKS
Aftertreatment System (ATS) ........................................................................................................... 34
Diesel Particulate Filter (DPF) System ............................................................................................ 34
Extended Idling ................................................................................................................................ 34
Selective Catalytic Reduction (SCR) System .................................................................................. 35
The 2017 Aftertreatment System General Schematic ..................................................................... 36
How to Enable an Automatic Regeneration of the DPF .................................................................. 36
DEF Gauge ...................................................................................................................................... 37

SM043-001 (02/19) 33
CHAPTER 7: HOW IT WORKS - Aftertreatment System (ATS)

Aftertreatment System (ATS)

The aftertreatment system is comprised of several components to reduce the emissions from the
vehicle.
Figure 7: Engine Aftertreatment System Detail

3
2
1

1. Hydrocarbon doser from turbo

2. Aftertreatment unit (DPF, DEF doser and SCR)
3. Filtered/treated exhaust
4. Diesel exhaust fluid (DEF) tank

Diesel Particulate Filter (DPF) System

The DPF system consists of a Hydrocarbon (HC) Doser (may not apply to all engines), a Diesel
Oxidation Catalyst (DOC), and a DPF. During normal operation the DPF filters soot out of the
exhaust and constantly monitors inlet and outlet pressure. When the DPF is full, the system will
activate (via automatic or a parked regeneration) the HC Doser which sprays a small amount of
diesel fuel (the HC) into the exhaust stream which then reacts with the DOC to generate heat. This
heat will turn the trapped soot into ash until the filter is completely cleaned (regenerated). Over
time, both soot and ash accumulate in the DPF unit. While the soot is cleaned by the system, the
resulting ash must be removed by servicing the vehicle at an authorized PACCAR dealer. A vehicle
with a DPF has up to two additional indicator lamps on the dashboard. The two additional lamps,
along with the check engine lamp, alert the operator of the status of the DPF.

Extended Idling

CAUTION

Prolonged periods of idling can result in lower than optimal engine/transmission operating temperatures which could cause increased
rates of wear. An idle shutdown feature (available on PACCAR engines) can be programmed to shut the engine down after a period
of low idle operation with no driver activity. A flashing warning lamp will inform the driver of an impending shutdown. Failure to com-
ply may result in equipment or property damage.

34 SM043-001 (02/19)
 Selective Catalytic Reduction (SCR) System - CHAPTER 7: HOW IT WORKS

CAUTION

If the truck is equipped with power take-off (PTO) equipment, the engine shutdown system can be deactivated when the PTO is op-
erational; however, engine idle periods should not exceed five minutes whenever possible. Failure to comply may result in equipment
or property damage.

Long periods of idle-time (3 hours or more) may accelerate the build up of soot in the diesel
particulate filter (DPF), especially in cold weather. The system will illuminate the DPF warning light
on the instrument cluster and a message on the Driver Information Display to indicate that the DPF

requires regeneration.
This is not a problem with the vehicle; however, it indicates that the driver needs to start a parked
DPF regeneration to prevent equipment damage caused by soot build up. If the DPF lamp turns ON
and the driver is prompted to through driver notifications, perform a parked DPF Regeneration.

CAUTION

If you ignore the warning lamp and do not initiate regeneration at the soonest, safest possible time, the DPF will become increasingly
clogged with soot and can lead to severe engine derate. Failure to comply may result in equipment or property damage.

Extended engine idling may also increase hydrocarbon deposits and moisture in the DPF. The
engine will increase rpm automatically, regardless if the DPF lamp is on or off, to remove these
hydrocarbon deposits and moisture. The engine speed will remain elevated for 20-60 minutes. If
necessary, the rpms may be lowered by briefly depressing the throttle, clutch, or brake pedal. If the
driver cancels the automatic cycle using the pedals, the system will restart the cycle 10 minutes
later with increased rpm until all of the deposits are removed from the DPF. If the vehicle cannot
perform an automatic cycle, the driver may be prompted with message to regenerate the DPF with
a "Do Not Drive" message. The driver must complete a regeneration before driving. If the "Do Not
Drive" message is ignored and a DPF regeneration is not fully completed before driving, there is a
high possibility of equipment damage.
If an engine must idle for an extended period of time, idle the engine at the lowest rpm that
maintains the engine coolant at 150°F (70°C), or above. Following these guidelines will help reduce
engine wear during idling and the frequency of DPF regenerations.

Selective Catalytic Reduction (SCR) System

The SCR system is composed of several main components:
1. Aftertreatment Control Module 1
2. DEF Dosing Unit (DEF Module)
3. DEF Dosing Valve
4. SCR Catalyst

1 Only for PACCAR MX powered vehicles.

SM043-001 (02/19) 35
CHAPTER 7: HOW IT WORKS - The 2017 Aftertreatment System General Schematic

CAUTION

It is unlawful to tamper with, modify, or remove any component of the SCR system. Failure to comply may result in equipment or
property damage.

The system uses DEF from the DEF tank and delivers it to the DEF Doser. The DEF doser sprays a
small amount of DEF into the exhaust upstream of the SCR Catalyst. The DEF vaporizes and
decomposes to form carbon dioxide and ammonia. The ammonia and SCR catalyst reacts with the
NOx in the exhaust to break down the Nitrogen Oxides (NOx) to form nitrogen and water.
DEF:
• may have a slight ammonia smell
• is colorless
• is non-toxic and non-polluting
• is non-flammable

The 2017 Aftertreatment System General Schematic

How to Enable an Automatic Regeneration of the DPF

Carefully read the following instructions to regenerate the DPF. If you have any problems or
difficulties contact your nearest authorized PACCAR dealer for assistance. If equipped with a three
position switch, make sure it is not in the STOP position.
The instrument cluster will illuminate various icons that indicate a regeneration is needed. See
Notification Regeneration is Required on page 54 . The EAS requires conditions typically found in
highway driving to regenerate the DPF. If you have a highway in your route with posted speeds
above 35 mph, take this route for about 30-45 min. Doing so will aid in a successful completion of
an automatic regeneration. If you do not have a route with highway, then perform a parked
regeneration How to Start a Parked Regeneration on page 55 .

36 SM043-001 (02/19)
 DEF Gauge - CHAPTER 7: HOW IT WORKS

DEF Gauge
The SCR system reduces Nitrogen Oxides (NOx) from the exhaust by mixing Diesel Exhaust Fluid
(DEF) with a catalyst. The DEF is contained in a separate tank on the vehicle and the level of fluid
in the tank is shown in a gauge on the dash.
Figure 8: Diesel Exhaust Fluid (DEF) Gauge

1 2

1. DEF Symbol
2. DEF gauge warning lamp
DEF is consumable and needs to be replenished, so monitor the DEF level gauge as you would the
fuel level gauge.

SM043-001 (02/19) 37
CHAPTER 7: HOW IT WORKS - DEF Gauge

38 SM043-001 (02/19)
Chapter 8 | MAINTENANCE
Aftertreatment System Maintenance Schedule ............................................................................... 40
Diesel Exhaust Fluid (DEF) Filter .................................................................................................... 40
Clean DPF/SCR Canister ................................................................................................................ 40
Diesel Exhaust Fluid (DEF) Tank Straps ......................................................................................... 40
Diesel Exhaust Fluid (DEF) Lamp ................................................................................................... 41
Emissions System Lamp ................................................................................................................. 41

SM043-001 (02/19) 39
CHAPTER 8: MAINTENANCE - Aftertreatment System Maintenance Schedule

Aftertreatment System Maintenance Schedule

Normal Duty/Line Haul
300,000 miles / 480,000 km / 6,750 hours / 36 months Clean DPF/SCR Canister on page 40
Diesel Exhaust Fluid (DEF) Filter on page 40

Severe Duty/Vocational
120,000 miles / 190,000 km / 3,600 hours / 24 months Clean DPF/SCR Canister on page 40
300,000 miles / 480,000 km / 6,750 hours / 36 months Diesel Exhaust Fluid (DEF) Filter on page 40

Diesel Exhaust Fluid (DEF) Filter

Perform these maintenance procedures according to the Preventative Maintenance Schedule.

Figure 9: Medium and Large DEF Tank Figure 10: Small DEF Tank Filter Access

1. Replace the aftertreatment DEF dosing unit (DEF module) filter according to the
maintenance schedule.
2. From the bottom of the tank, remove the cover plate by removing the various fasteners
holding it on, then allow the cover plate to drop down.

Clean DPF/SCR Canister

1. Clean or replace the canister. 2

Diesel Exhaust Fluid (DEF) Tank Straps

During normal operation of the truck, the DEF tank straps may relax. Inspect the spring on top of
the strap. If more than ½" (12.7mm) of the spring is exposed, the bolt will need to be re-torqued
between 70 – 80 in-lbs. (7.9 – 9 Nm). This distance (1) is measured from the washer at the end of
the spring to the edge of the tube at the top of the straps.

2 Depends on engine type.

40 SM043-001 (02/19)
 Diesel Exhaust Fluid (DEF) Lamp - CHAPTER 8: MAINTENANCE

1/2" (12.7 mm)

See Engine Operator's Manual for DEF filter maintenance interval.

Diesel Exhaust Fluid (DEF) Lamp

Engine aftertreatment system includes a diesel exhaust fluid (DEF) warning lamp on the DEF
gauge and additional warning lamps in the instrument cluster.
Figure 11: DEF Warning Lamp in Instrument Cluster

Figure 12: Diesel Exhaust Fluid (DEF) Gauge

1 2

1. DEF Symbol
2. DEF gauge warning lamp
The DEF lamp(s) will illuminate when the fluid in the DEF tank reaches a low level. If the lamp
illuminates but the level is full, seek service immediately for DEF fluid quality or DEF equipment
repair.

Emissions System Lamp

Perform the following steps if an emissions related derate occurs and the emissions lamp comes
on.

1. Add DEF fluid (more than 1/4 tank).

2. Perform parked regeneration.

SM043-001 (02/19) 41
CHAPTER 8: MAINTENANCE - Emissions System Lamp

3. Seek service at the next stop if the warning light is still on.

42 SM043-001 (02/19)
Chapter 9 | DISASSEMBLY AND ASSEMBLY
DEF Tank ......................................................................................................................................... 44
How to Remove DEF Pump Unit ..................................................................................................... 45
Special Considerations for DEF Supply Line ................................................................................... 46
Hose Routing RH Under Cab Canister with RH DEF Tank ............................................................. 46
Remove and Replace DEF Tank Coolant Loop ............................................................................... 47

SM043-001 (02/19) 43
CHAPTER 9: DISASSEMBLY AND ASSEMBLY - DEF Tank

DEF Tank
If the DEF tank has a metal cover, it can be removed to access the DEF tank retaining straps.

Once the retaining straps are accessible, they can be removed via nut and bolt on top and bottom
of each strap. These straps hold the tank onto the structure.

The DEF pump, its filter, tank vent, electronics and hoses are usually mounted to the rear of the
tank. Typically the first item to remove is the pump cover plate. The DEF pump itself is mounted to a
separate plate which has to be removed to separate the pump for replacement. The graphic below
is an example of a rectangular DEF tank; most tank assemblies have similar arrangements.
Figure 13: Rectangular DEF Tank

44 SM043-001 (02/19)
 How to Remove DEF Pump Unit - CHAPTER 9: DISASSEMBLY AND ASSEMBLY

How to Remove DEF Pump Unit

Removing the DEF pump unit will require a disconnection in system power. Before disconnecting
the battery power ensure that you have given the system enough time to complete the DEF
shutdown cycle. See Constant Power Requirements on page 27 .

1. Remove the pump cover.

2. Disconnect DEF hoses and wire harnesses.

3. Remove DEF pump from mounting bracket.

Installation is in reverse of removal.

SM043-001 (02/19) 45
CHAPTER 9: DISASSEMBLY AND ASSEMBLY - Special Considerations for DEF Supply Line

Special Considerations for DEF Supply Line

These guidelines will ensure continuous operation with the maximum performance.
Frame brackets and clips are used at the dosing unit and on the frame rail to ensure proper
orientation of the supply line relative to the doser injector.

NOTE

Improper routing may cause performance issues in the DEF system.

DEF lines should be routed with more than a 30 mm bend radius to avoid kinking of the hose. When
securing the DEF line, be sure to avoid crimping the line. When installing the line, avoid stretching
the line so that it does not pull off the connector during operation. The fluid connectors on the hoses
have a locking mechanism on the collar. Press the hose connector as if installing it (pushing) and
then press the collar tabs together to remove. To install, simply push the connector on, hear and
feel the collar lock into place and then pull the connector back to ensure that it is fully locked into
place. Visually the locking collar should sit directly against the connector flange. There should not
be any gaps between the locking collar and the flange.
In addition to the DEF supply line, the coolant hoses from the engine should have a general arch as
they approach the doser unit. Heat shields are installed in some applications where the DEF supply
line comes close to an exhaust component.

Hose Routing RH Under Cab Canister with RH DEF Tank

Please refer to these illustrations to help familiarize how the hoses are routed between the DEF
tank and the aftertreatment canister.
This illustration is reflecting applications where the DPF/SCR canister is located Right Hand Under
Cab and the DEF tank is mounted to the Right Hand Rail.

46 SM043-001 (02/19)
 Remove and Replace DEF Tank Coolant Loop - CHAPTER 9: DISASSEMBLY AND ASSEMBLY

This illustration is a cross section of the DPF/SCR canister framing. Primary emphasis is on the
DEF hose routing and its related brackets used to achieve the proper installation of the hose.

NOTE

There is a bracket located on the frame rail and the canister that ensures proper angles of the hose routing relative to the DEF doser.

Remove and Replace DEF Tank Coolant Loop

This task is specifically for the "Clear Back of Cab (CBOC)" style tank installed on Kenworth
vehicles. For the CBOC style tank, removing the DEF coolant loop or the DEF quality Sensor will
require each unit to be unbolted and manipulated to get either of the components out. The coolant
loop assembly wraps around the base of the quality sensor and it the loop is removed without
working the sensor, it will get caught on the bottom side of the sensor and restrict the movement.

1. Unbolt the coolant loop from the tank.

2. Unbolt the quality Sensor from the tank.

SM043-001 (02/19) 47
CHAPTER 9: DISASSEMBLY AND ASSEMBLY - Remove and Replace DEF Tank Coolant Loop

3. Lift the quality Sensor from the tank, rock it back and forth to enable the bottom of the
sensor to clear the bottom portion of the coolant loop.
If the quality sensor will not clear the coolant loop, the loop may need to be partially lifted
and tilted to help clear the loop from the quality sensor.

4. Lift the coolant loop and tilt it towards the quality sensor so that the bend of the coolant
loop can clear the opening in the tank.

48 SM043-001 (02/19)
Chapter 10 | TROUBLESHOOTING
Aftertreatment Harness Detailed Schematic for 2017 ..................................................................... 50
Emissions DEF Tank Harness Schematic for 2017 ......................................................................... 52
Warning Symbols Quick Reference ................................................................................................. 53
Notification of High Exhaust System Temperature .......................................................................... 54
Notification Regeneration is Required ............................................................................................. 54
How to Start a Parked Regeneration ............................................................................................... 55
DEF Level Warning – Non-Emergency Vehicles ............................................................................. 57
DEF Quality Warning – Non-Emergency Vehicles ........................................................................... 57
SCR Component Failure Warning – Non-Emergency Vehicles ....................................................... 58
DEF Level Warning – Emergency Vehicles ..................................................................................... 58
DEF Quality Warning – Emergency Vehicles .................................................................................. 59
SCR Component Failure Warning – Emergency Vehicles .............................................................. 59
Final Verification Test of OBD System ............................................................................................. 60
DEF Tank Level Programming Guide .............................................................................................. 61

SM043-001 (02/19) 49
CHAPTER 10: TROUBLESHOOTING - Aftertreatment Harness Detailed Schematic for 2017

Aftertreatment Harness Detailed Schematic for 2017

NOTE

Refer to Engine Rapido for aftertreatment-related troubleshooting and service information.

Figure 14: PACCAR MX Powered 2.1 meter Cab Platform Vehicles

50 SM043-001 (02/19)
 Aftertreatment Harness Detailed Schematic for 2017 - CHAPTER 10: TROUBLESHOOTING

SM043-001 (02/19) 51
CHAPTER 10: TROUBLESHOOTING - Emissions DEF Tank Harness Schematic for 2017

NOTE

missing: Cummins 2.1; all 1.9 and 2.3 harness schematics.

Emissions DEF Tank Harness Schematic for 2017

This schematic is generic and does not have pin locations at the J454 connector. Refer to the
specific harness on the vehicle to identify the pin locations manufactured on the vehicle.

DEF Tank Harness Cummins and PACCAR PX Powered Vehicles

52 SM043-001 (02/19)
 Warning Symbols Quick Reference - CHAPTER 10: TROUBLESHOOTING

DEF Tank Harness PACCAR MX Powered Vehicles

Warning Symbols Quick Reference

FOR INFORMATION SEEK SERVICE TAKE IMMEDIATE ACTION

Hot Exhaust - Stay Stop vehicle and idle

Check Engine
Clear Coolant engine.
Temperature

SM043-001 (02/19) 53
CHAPTER 10: TROUBLESHOOTING - Notification of High Exhaust System Temperature

FOR INFORMATION SEEK SERVICE TAKE IMMEDIATE ACTION

Regenerate DPF Engine - Emissions

Engine Oil
Pressure Stop the engine or
the engine may
automatically
shutdown. 3
See Diesel Exhaust See Emissions
1 2
Fluid (DEF) Lamp System Lamp on
on page 41 . page 41 .
Stop Engine
Symbols 4
Any of the above icons may appear alone or together to alert of necessary action to be taken as soon as possible. Warnings may be
either tell-tales or lights within the gauge associated with that fluid. These lights will start flashing to notify of the upcoming engine
derate.

Notification of High Exhaust System Temperature

These conditions will result in the High Exhaust System Temperature (HEST) indicator turning on.

Warning Indicator Condition Operator Actions

Any one or combination of these conditions:

• Exhaust outlet temperature is

elevated above normal (at least
450° C / 842° F) and vehicle Follow all warnings listed below. Use the STOP or
slows below 8 kph / 5 mph. DISABLE function of the DPF Switch (Or turn the
ignition off) if the situation requires. Follow the
On • Normal driving but engine is under instructions described under Stop an Automatic or
heavy loading. Parked Regeneration.
• Automatic Regeneration in
process
• Parked Regeneration in process

WARNING

Temperature of the tail pipe, exhaust pipe, the diesel particular filter (DPF)/selective catalytic reduction (SCR) device and surround-
ing components including enclosures and steps, will be elevated during and shortly after a regeneration event or normal vehicle
operation when engine is under high or heavy loading.

Notification Regeneration is Required

Level Warning Indicators Condition Operator Actions

The soot level in the DPF is above the How to Enable an Automatic
1 On desired level and requires regeneration. Regeneration of the DPF on page 36

3 May not apply for fire or emergency vehicle applications.

4 Either symbol 1 or 2 will appear depending on engine make for the vehicle.

54 SM043-001 (02/19)
 How to Start a Parked Regeneration - CHAPTER 10: TROUBLESHOOTING

Level Warning Indicators Condition Operator Actions

Regenerate the DPF as soon as safely

The soot level in the DPF continues to possible. How to Enable an Automatic
2 stay above the desired level and Regeneration of the DPF on page 36 or
Flashing requires regeneration. How to Start a Parked Regeneration on
page 55

The soot level in the DPF continues to Regenerate the DPF immediately. How
Flashing stay above the desired level and to Enable an Automatic Regeneration of
3
requires regeneration. The engine the DPF on page 36 or How to Start a
On power will derate. Parked Regeneration on page 55

Flashing (MX engine only)

At this point, you CANNOT regenerate
The soot level in the DPF is now at full
On (MX engine only) capacity. Engine power derates
the DPF. Tow your vehicle to an
4 Authorized PACCAR Dealer to have the
(decrease rate depends on engine
DPF removed. They will either have to
make).
clean it or replace it.
1 Stop Engine Lamp
2

On – Dash chime

CAUTION

The engine derate sequence is engine specific; therefore, to learn how this system works on your vehicle, refer to the Engine Manu-
facturer's Operation and Maintenance Manual supplied with your vehicle. Failure to comply may result in equipment or property dam-
age.

WARNING

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

How to Start a Parked Regeneration

In applications or operations the DPF must be regenerated by initiating a Parked Regeneration.
Follow these steps to initiate a Parked Regeneration:
1. Pull the vehicle over to a safe location.
2. Ensure no one is in the immediate vicinity of the tail pipe.
3. Maintain a minimum of 5 ft. (1.5 m) of clearance to any combustible materials from the
edge and top of the vehicle.

WARNING

Parking the vehicle too close to any combustible materials or vapors may start a fire, ignite an explosion or burn
someone standing close by. Before pushing the DPF Switch on the dash, walk around your vehicle and ensure you
have at least 5 ft. (1.5 m) clearance from the sides and top of your vehicle to any combustibles. Ensure no one is in
the immediate vicinity of the tail pipe. Failure to comply could ignite a fire or cause an explosion, resulting in death,
personal injury, equipment or property damage.

SM043-001 (02/19) 55
CHAPTER 10: TROUBLESHOOTING - How to Start a Parked Regeneration

WARNING

Never initiate a regeneration in a closed building or enclosure. Always park your vehicle outside and ensure no one is
in the immediate vicinity. Failure to comply could ignite a fire or cause an explosion, resulting in death, personal injury,
equipment or property damage.

NOTE

Typical operation areas or materials that can contain explosive vapors, flammable ma-
terials or people 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
While the list above may appear comprehensive, it is your responsibility to take the
necessary precautions and be aware of your surroundings and ensure that no combus-
tibles (materials or vapors) or bystanders are close by before initiating a regeneration.
4. Verify that the following conditions are met before proceeding. A Parked Regeneration
will not initiate if any of these conditions are not met:
• Parking brake is applied / set
• Engine is at low idle
• DPF warning lamp is illuminated or flashing
• Coolant is at operating temperature
• No throttle, brake or clutch applied
• PTO is disengaged 5
• Transmission is in neutral or PARK
• Cruise control switch is OFF
5. Get out and walk all around vehicle to ensure that the vehicle is at least 1.5 m (5 ft) away
from all combustible materials and no one is in the immediate vicinity.
6. Climb back into the vehicle.
7. Push the DPF button at least 4-8 seconds to initiate a Parked Regeneration.

NOTE

Acknowledgment that a Parked Regeneration has initiated will vary by engine. The most predominant acknowledg-
ment to you will be an increase in engine rpm and overall engine noise.

NOTE

A Parked Regeneration may take 30 or more seconds to initiate as the Engine Aftertreatment System conducts vari-
ous self-checks to verify all the system requirements have been met.

Regeneration will automatically shut off if any of the conditions (in step 4) change or become
activated. Contact your nearest PACCAR dealer for assistance if you are unable to initiate a Parked
Regeneration and the DPF warning lamp is illuminated.

5 Parked regeneration with PTO engaged is dependant on vehicle configuration.

56 SM043-001 (02/19)
 DEF Level Warning – Non-Emergency Vehicles - CHAPTER 10: TROUBLESHOOTING

DEF Level Warning – Non-Emergency Vehicles

Some vehicles may have a notification/information screen in addition to these icons.
Level Warnings \ Indicators Condition Effect on Engine

DEF level
0 None None
sufficient

DEF level fallen

DEF warning
1 below initial None
lamp On
warning

DEF level fallen

DEF warning Engine derated
2 below initial
lamp On Check engine 25%
warning
lamp On

DEF level fallen

DEF warning Engine derated
3 below initial
lamp flashing Check engine 40%
warning
lamp On

Engine has been Engine power

shut down, idled derated and/or
DEF warning
4 for 1-hour or a vehicle speed
lamp flashing Check engine 1 2 Stop engine lamp may fuel re-fill has significantly
lamp On be On occurred limited

DEF Quality Warning – Non-Emergency Vehicles

The DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX
Engines.
Level Warnings \ Indicators Condition Effect on Engine

No DEF quality
0 None None
issue

DEF warning Quality issue

1 None
lamp On Check engine detected
lamp On
MIL may be
ON

80 km (50 mi) or
DEF warning Engine power
2 1 hour after
lamp flashing Check engine derated 25%
lamp On
MIL may be detected
ON

241 km (150 mi) Continue to 40%

DEF warning
3 or 3 hours after engine power
lamp flashing Check engine
lamp On
MIL may be detected derate
ON

SM043-001 (02/19) 57
CHAPTER 10: TROUBLESHOOTING - SCR Component Failure Warning – Non-Emergency Vehicles

Level Warnings \ Indicators Condition Effect on Engine

Engine has been Engine power

shut down, idled derated and/or
DEF warning
Final for 1-hour or a vehicle speed
lamp flashing Check engine 1 2
lamp On
MIL may be Stop engine lamp
fuel re-fill has significantly
occurred limited
ON may be On

SCR Component Failure Warning – Non-Emergency Vehicles

The DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX
Engines.
Level Warnings \ Indicators Condition Effect on Engine

0 None No Issue None

DEF warning
1 Failure detected None
lamp On Check engine
lamp On
MIL may be
ON

80 km (50 mi) or
DEF warning Engine power
2 1 hour after
lamp flashing Check engine derated 25%
lamp On
MIL may be detected
ON

322 km (200 mi) Continue to 40%

DEF warning
3 or 4 hours after engine power
lamp flashing Check engine
lamp On
MIL may be detected derate
ON

Engine has been Engine power

shut down, idled derated and/or
DEF warning
Final 1 2 for 1-hour or a vehicle speed
lamp flashing Check engine
lamp On
MIL may be Stop engine lamp fuel re-fill has reduced to 8 kph
occurred (5 mph)
ON may be On

DEF Level Warning – Emergency Vehicles

Some vehicles may have a notification/information screen in addition to these icons.
Level Warnings \ Indicators Condition Effect on Engine

DEF level
0 None None
sufficient

DEF level fallen

DEF warning
1 below initial None
lamp On
warning

DEF warning DEF level less

2 None
lamp On Check engine than 25 %
lamp On

58 SM043-001 (02/19)
 DEF Quality Warning – Emergency Vehicles - CHAPTER 10: TROUBLESHOOTING

Level Warnings \ Indicators Condition Effect on Engine

DEF warning
3 DEF Level empty. None
lamp flashing Check engine
lamp On

DEF Level empty

and vehicle has
DEF warning
Final been shut down None
lamp flashing Check engine 1 2 Stop engine lamp may or stationary for
lamp On be On 1-hour

DEF Quality Warning – Emergency Vehicles

The DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX Engines.

Level Warnings \ Indicator Condition Effect on Engine

No DEF quality
0 None None
issue

DEF warning Quality issue

1 None
lamp On Check engine detected
lamp On
MIL may be
ON

Vehicle speed
DEF warning 10-hours after
2 limited to 88 kph
lamp flashing Check engine detected
lamp On
MIL may be (55 mph)
ON

20-hours after
detected, engine Vehicle speed
DEF warning
Final 1 2 has been shut limited to 40 kph
lamp flashing Check engine
lamp On
MIL may be Stop engine lamp down or idled for (25 mph)
1-hour
ON may be On

SCR Component Failure Warning – Emergency Vehicles

The DEF Warning Lamp described in this table only applies to vehicles powered by PACCAR MX
Engines.
Level Warnings \ Indicators Condition Effect on Engine

0 None No Issue None

DEF warning
1 Failure detected None
lamp On Check engine
lamp On
MIL may be
ON

SM043-001 (02/19) 59
CHAPTER 10: TROUBLESHOOTING - Final Verification Test of OBD System

Level Warnings \ Indicators Condition Effect on Engine

Vehicle speed
DEF warning 10-hours after
2 limited to 88 kph
lamp flashing Check engine detected
lamp On
MIL may be (55 mph)
ON

40-hours after
detected, engine Vehicle speed
DEF warning
Final 1 2 has been shut limited to 40 kph
lamp flashing Check engine
lamp On
MIL may be Stop engine lamp down or idled for (25 mph).
1-hour
ON may be On

Final Verification Test of OBD System

For PACCAR MX engines, a final test procedure must be performed to verify if a fault code has
been resolved. This requires the engine to perform test duty cycles. If the fault does not appear
after successful cycles, then the fault has been resolved. The MX On-Board Diagnostic (OBD)
system is designed to monitor the performance of emission-related components and report
detected conditions that impact emissions compliance. The verification cycles represented here
have been aligned to the specific OBD fault codes to enable a service completion check for a
particular fault condition following corrective actions. In the event a verification cycle must be
interrupted due to weather or traffic conditions, the verification cycle can be resumed, and in the
majority of instances, the diagnostic will still achieve its verification process.

NOTE

Strict observance of posted speed limits, traffic laws, and road conditions are required when performing these verification drive cy-
cles.

There are 8 primary sections of this verification cycle:

Power-Up/Electrical Step 1
Start-Up Step 2
System Initiation Step 3
Transient Step 4
Steady State Step 5 and 6
Over Run Steps 7 through 13
DPF & DOC Steps 14 through 17
Cold Soak Steps 18 through 20

1. With the brakes set, turn the key to the ON position with the engine off, and allow 10
seconds for the system to initialize and run diagnostics.
2. Start the engine and allow it to run at idle for 2 minutes.
3. Drive the truck under normal conditions until the coolant temperature reaches a minimum
of 150°F. This cycle can be conducted with a loaded trailer or bobtail.
4. Under moderate engine load (A/C and Fan both ON), perform a series of brief
accelerations, progressing from a lower to a higher speed until reaching a top speed of
40 mph. Once the top speed has been reached, perform several decelerations from a

60 SM043-001 (02/19)
 DEF Tank Level Programming Guide - CHAPTER 10: TROUBLESHOOTING

higher to a lower speed until reaching a bottom speed of 10 mph. Repeat this cycle 5
times.
5. This cycle is best performed on a level grade road (least amount of incline possible) and
under load using a trailer. If a loaded trailer is unavailable, produce engine load by
turning the A/C and fan to ON.
6. Proceed to a road with a minimum speed limit of 50 mph, then get to the highest gear
possible with the engine speed between 1100-1500 rpm, and set the cruise control.
• Continue this cycle for roughly 3 to 5 miles
• Continue this cycle in three separate 1-mile increments
7. Proceed to a road with minimum speed limit of 50 mph. While remaining within the
legally posted speed limit, get the truck in the highest gear possible with the engine
speed at a minimum of 1800 rpm.

NOTE

do not complete this section if the vehicle has Alison Autoshift transmission.

8. Once the target engine speed has been reached, leave the truck in gear and release the
accelerator pedal, allowing the truck to coast until the engine speed has reached 900
rpm. For Eaton Ultrashift transmissions, idle drop can only go to 1000 rpm
9. Repeat this cycle 4 times.
10. Perform the same procedure outlined for the Steady State cycle.
11. Connect the vehicle to DAVIE
12. In DAVIE, select the following Monitor values to record
• Exhaust Temperature Before SCR
• Exhaust Temperature After SCR
• Pump Module
13. Once the SCR temperatures have reached a minimum of 536°F (280°C), continue the
remainder of this cycle with the high idle. The monitored Pump Module value will indicate
when dosing starts. Allow dosing to occur for a minimum of 15 minutes. Check the
recorded values after the driving has been completed to verify temperatures and dosing.
14. This test can take up to 45 minutes to 1 hour to complete.
15. Start the truck and using cruise control, bump and set the idle to 1,500 rpm.
16. Connect DAVIE, and go to DPF Regeneration test.
17. Follow the prompts to complete a Stationary Regeneration.
18. The truck must remain off (key to OFF and the engine OFF) for 8-10 consecutive hours.
Wait for this time to elapse before continuing.
19. Perform the Electrical & Power-Up cycle.
20. Perform the Start-Up cycle.

DEF Tank Level Programming Guide

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CHAPTER 10: TROUBLESHOOTING - DEF Tank Level Programming Guide

62 SM043-001 (02/19)
Chapter 11 | FREQUENTLY ASKED QUESTIONS

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CHAPTER 11: FREQUENTLY ASKED QUESTIONS -

64 SM043-001 (02/19)
Chapter 12 | APPENDIX

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CHAPTER 12: APPENDIX -

66 SM043-001 (02/19)
 | Glossary | 67

Glossary
Cab Electronic Control Unit - Cab control located inside the cab on vehicles with
Namux 4 architecture between 2010 and 2018. It is replaced by the VECU controller that
was phased in starting in 2018.
CECU VECU Multiplex - New vehicle multiplex architecture that uses both a CECU
and a VECU to handle CAN communication.
Vehicle Electronic Control Unit - Control unit, computer, installed inside the cab and
processes all input and output from the driver controls to the cab and chassis.
68 | Glossary |
 Index

Index
A Selective Catalytic Reduction (SCR) System 35

Aftertreatment CanisterOrientation 21 V
Aftertreatment Control Module Exploded View 14
Aftertreatment System (ATS) 34 Vehicles this book applies to 12
Aftertreatment System Overview 20 Verification Cycle 60
Verification Test 60

B
W
Build Information for Models with VECU 12
Warning Symbols Quick Reference 53

C
Contamination / Incorrect Fluid 29

D
DEF Handling 28
DEF Level Warning – Emergency Vehicles 58
DEF Level Warning – Non-Emergency Vehicles 57
DEF Quality Warning – Emergency Vehicles 59
DEF Quality Warning – Non-Emergency Vehicles 57
DEF Storage 28
DEF TankExploded View 15, 44
DEF Volume Derate 30
Diesel Exhaust Fluid (DEF) Lamp 41
Diesel Exhaust Fluid filter 40
Diesel Exhaust Fluid tank maintenance 40
Diesel Particulate Filter (DPF) System 34
Diesel Particulate Filter (DPF) Warning Lamp 21
DPF Regeneration 36

F
Freezing Conditions 27

H
High Exhaust System Temperature (HEST) Warning Lamp 21

I
Idling in Freezing Temperatures, Extended 34
Introduction 37

M
Malfunction Indicator Lamp 20

N
Notification of High Exhaust System Temperature 54
Notification Regeneration is Required 54

O
OBD Verification 60

P
Parked Regeneration 55

R
Recommendations and Specifications 26

S
SCR Component Failure Warning – Emergency Vehicles 59
SCR Component Failure Warning – Non-Emergency Vehicles 58

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Index

70 SM043-001 (02/19)