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STARTING PROCEDURES Before starting your vehicle, adjust your seat, adjust both inside and outside mirrors, and fasten your seat belts. The starter should not be operated for more than 15- second intervals. Waiting a few minutes between such intervals will protect the starter from overheating.


WARNING!


• Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death. • Leaving children in a vehicle unattended is dan- gerous for a number of reasons. A child or others could be seriously or fatally injured. Children should be warned not to touch the parking brake, brake pedal or the shift lever. Do not leave the key in the ignition. A child could operate power win- dows, other controls, or move the vehicle.


Manual Transmission – If Equipped Apply the parking brake, place the shift lever in NEU- TRAL and press the clutch pedal to the floor before starting the vehicle. This vehicle is equipped with a clutch interlocking ignition system. It will not start unless the clutch is fully pressed. Automatic Transmission – If Equipped Start the engine with the shift lever in NEUTRAL or PARK position. Apply the brake before shifting to any driving range. Tip Start Feature Do not press the accelerator. Turn the ignition switch briefly to the START position and release it. The starter motor will continue to run but will automatically disen- gage when the engine is running.


Extreme Cold Weather The Cummins威 diesel engine is equipped with several features designed to assist cold weather starting and operation: • The engine block heater is a resistance heater installed in the water jacket of the engine just above and behind the oil filter. It requires a 110–115 Volt AC electrical outlet with a grounded, three-wire extension cord.


NOTE: The engine block heater cord is a factory in- stalled option. If your vehicle is not equipped, heater cords are available from your authorized MOPAR威 dealer. • A 12 Volt heater built into the fuel filter housing aids in preventing fuel gelling. It is controlled by a built-in thermostat.


STARTING AND OPERATING 37


• A heated intake air system both improves engine starting and reduces the amount of white smoke generated by a warming engine.


Normal Starting Procedure – Engine Manifold Air Temperature Above 66°F (19°C) Observe the instrument panel cluster lights when starting the engine. 1. Always apply the parking brake. 2. Shift into PARK for an automatic transmission. For vehicles equipped with a manual transmission, fully press and hold the clutch pedal and shift into NEUTRAL. 3. Turn the ignition switch to the ON position and watch the instrument panel cluster lights.


38 STARTING AND OPERATING


CAUTION!


CAUTION!


If the “Water in Fuel Indicator Light” remains on, DO NOT START the engine before you drain the water from the fuel filter to avoid engine damage. Refer to “Maintenance Procedures/Draining Fuel/Water Sepa- rator Filter” in “Maintaining Your Vehicle” for fur- ther information.


4. Turn the ignition switch to the START position and crank the engine. Do not press the accelerator during starting.


Do not crank engine for more than 15 seconds at a time or starter motor damage may result. Turn the ignition switch to the OFF position and wait at least two minutes for the starter to cool before repeating start procedure.


5. When the engine starts, release the key fob. 6. Check to see that there is oil pressure. 7. Release the parking brake. Starting Procedure – Engine Manifold Air Temperature 0°F To 66°F (–18°C to 19°C)


NOTE: The temperature displayed in the Electronic Vehicle Information Center (EVIC) does not necessarily reflect the engine manifold air temperature. Refer to


“Electronic Vehicle Information Center (EVIC)” in “Un- derstanding Your Instrument Panel” for further informa- tion. When engine temperatures fall below 66°F (19°C) the “Wait To Start Light” will remain on indicating the intake manifold heater system is active. Follow the steps in the “Normal Starting” procedure except: 1. The “Wait To Start Light” will remain on for a period of time (length of time depends on engine temperature).


CAUTION!


If the “Water in Fuel Indicator Light” remains on, DO NOT START engine before you drain the water from the fuel filter to avoid engine damage. Refer to “Maintenance Procedures/Draining Fuel/Water Sepa- rator Filter” in “Maintaining Your Vehicle” for fur- ther information.


STARTING AND OPERATING 39
2. After the “Wait To Start Light” goes off, turn the ignition switch to the START position. Do not press the accelerator during starting.


CAUTION!


Do not crank engine for more than 15 seconds at a time or starter motor damage may result. Turn the ignition switch to the OFF position and wait at least two minutes for the starter to cool before repeating start procedure.


3. After engine start-up, check to see that there is oil pressure. 4. Allow the engine to idle about three minutes until the manifold heaters have completed the post-heat cycle. 5. Release the parking brake and drive.


40 STARTING AND OPERATING NOTE: • Engine idle speed will automatically increase to 1,000
RPM and engage the Variable Geometry Turbocharger at low coolant temperatures to improve engine warm- up. • If the engine stalls, or if the ignition switch is left ON for more than two minutes after the “Wait To Start Light” goes out, reset the grid heaters by turning the ignition switch to the OFF position for at least five seconds and then back ON. Repeat steps 1 through 5 of “Starting Procedure – Engine Manifold Air Tempera- ture Below 66°F (19°C).”


Starting Procedure – Engine Manifold Air Temperature Below 0°F (-18°C) In extremely cold weather below 0°F (-18°C) it may be beneficial to cycle the manifold heaters twice before attempting to start the engine. This can be accomplished by turning the ignition OFF for at least five seconds and


then back ON after the “Wait To Start Light” has turned off, but before the engine is started. However, excessive cycling of the manifold heaters will result in damage to the heater elements or reduced battery voltage. NOTE: If multiple pre-heat cycles are used before starting, additional engine run time may be required to maintain battery state of charge at a satisfactory level. 1. If the engine stalls after the initial start, the ignition must be turned to the OFF position for at least five seconds and then to the ON position to recycle the manifold heaters. NOTE: Excessive white smoke and poor engine perfor- mance will result if manifold heaters are not recycled. 2. Heat generated by the manifold heaters dissipates rapidly in a cold engine. If more than two minutes pass between the time the “Wait To Start Light” turns off and


the engine is started, recycle the manifold heaters by turning the ignition switch to the OFF position for at least five seconds and then back ON. 3. If the vehicle is driven and vehicle speed exceeds 19 mph (31 km/h) before the manifold heater post-heat (after start) cycle is complete, the manifold heaters will shut off. 4. If the engine is started before the “Wait To Start Light” turns off, the preheat cycle will turn off. 5. If the engine is cranked for more than 10 seconds, the post-heat cycle will turn off. NOTE: • Engine idle speed will automatically increase to 1,000
RPM and engage the Variable Geometry Turbocharger at low coolant temperatures to improve engine warm- up.


STARTING AND OPERATING 41


• When a diesel engine is allowed to run out of fuel or the fuel gels at low temperatures, air is pulled into the fuel system. If your engine has run out of fuel, refer to “Maintenance Procedures/Priming If The Engine Has Run Out Of Fuel” in “Maintaining Your Vehicle” for further information.


Starting Fluids


WARNING!


Starting fluids or flammable liquids are never to be used in the Cummins威 diesel engine (see Warning label). Never pour diesel fuel, flammable liquid, starting fluids (ether) into the air cleaner canister, air intake piping, or turbocharger inlet in an attempt to start the vehicle. This could result in a flash fire and explosion causing serious personal injury and engine damage.


42 STARTING AND OPERATING The engine is equipped with an automatic electric air preheating system. If the instructions in this manual are followed, the engine should start in all conditions.


WARNING!


• Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death. • Leaving children in a vehicle unattended is dan- gerous for a number of reasons. A child or others could be seriously or fatally injured. Children should be warned not to touch the parking brake, brake pedal or the shift lever. Do not leave the key in the ignition. A child could operate power win- dows, other controls, or move the vehicle.


NORMAL OPERATION – DIESEL ENGINE Observe the following when the engine is operating. • All message center lights are off. • Malfunction Indicator Light (MIL) is off. • Engine oil pressure is above 10 psi (69 kPa) at idle. • Voltmeter operation: • The voltmeter may show a gauge fluctuation at various engine temperatures. This cycling operation is caused by the post-heat cycle of the intake mani- fold heater system. The number of cycles and the length of the cycling operation is controlled by the engine control module. Post-heat operation can run for several minutes, and then the electrical system and voltmeter needle will stabilize.


• The cycling action will cause temporary dimming of the headlamps, interior lamps, and also a noticeable reduction in blower motor speed.


Cold Weather Precautions Operation in ambient temperature below 32°F (0°C) may require special considerations. The following charts sug- gest these options: Fuel Operating Range NOTE: Use “Ultra Low Sulfur Diesel Fuels” ONLY.


STARTING AND OPERATING 43
*No. 1 Ultra Low Sulfur Diesel Fuel should only be used where extended arctic conditions (-10°F/-23°C) exist. NOTE: • Use of Climatized Ultra Low Sulfur Diesel Fuel or Number 1 Ultra Low Sulfur Diesel Fuel results in a noticeable decrease in fuel economy. • Climatized Ultra Low Sulfur Diesel Fuel is a blend of Number 2 Ultra Low Sulfur and Number 1 Ultra Low Sulfur Diesel Fuels which reduces the temperature at which wax crystals form in fuel. • The engine requires the use of “Ultra Low Sulfur Diesel Fuel”. Use of incorrect fuel could result in engine and exhaust system damage. Refer to “Fuel Requirements” in “Starting and Operating” for further information.


44 STARTING AND OPERATING Engine Oil Usage Refer to “Maintenance Procedures” in “Maintaining Your Vehicle” for the correct engine oil viscosity. Winter Front Usage If a winter front or cold weather cover is to be used, a percentage of the total grille opening area must be left uncovered to provide sufficient air flow to the charge air cooler and automatic transmission oil cooler. The per- centage of opening must be increased with the increasing ambient air temperature and/or engine load. If the cooling fan can be heard cycling frequently, increase the size of the opening in the winter front. A suitable cold weather cover is available from your MOPAR威 dealer. Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decreases to 0°F (-18°C). For the same de- crease in temperature, the engine requires twice as much power to crank at the same RPM. The use of 120 VAC


powered battery blankets will greatly increase starting capability at low temperatures. Suitable battery blankets are available from your authorized MOPAR威 dealer. Engine Warm-Up Avoid full throttle operation when the engine is cold. When starting a cold engine, bring the engine up to operating speed slowly to allow the oil pressure to stabilize as the engine warms up. NOTE: High-speed, no-load running of a cold engine can result in excessive white smoke and poor engine performance. No-load engine speeds should be kept under 1,200 RPM during the warm-up period, especially in cold ambient temperature conditions. Your vehicle is equipped with a turbo speed limiter, this feature limits the engine speed to 1,200 RPM when engine coolant temperatures are below 70°F (21°C). This feature is designed to protect the turbocharger from damage and will only operate in PARK or NEUTRAL.


If temperatures are below 32°F (0°C), operate the engine at moderate speeds for five minutes before full loads are applied. NOTE: • If ambient


temperatures are low and the coolant temperature is below 180°F (82°C), the engine idle speed will slowly increase to 1,000 RPM after two minutes of idle, if the following conditions are met: • foot is off brake pedal and throttle pedal • automatic transmission is in PARK • vehicle speed is zero • Applying the throttle will cancel fast idle • If the engine is equipped with an exhaust brake, operating the exhaust brake at idle will greatly im- prove warm up rate and will help keep the engine close to operating temperature during extended idle.


STARTING AND OPERATING 45


Engine Idling Avoid prolonged idling, long periods of idling may be harmful to your engine because combustion chamber temperatures can drop so low that the fuel may not burn completely. Incomplete combustion allows carbon and varnish to form on piston rings, engine valves, and injector nozzles. Also, the unburned fuel can enter the crankcase, diluting the oil and causing rapid wear to the engine. If the engine is allowed to idle, under some conditions the idle speed may increase to 900 RPM then return to normal idle speed. This is normal operation. For EVIC messages related to the vehicle’s NOTE: exhaust system, refer to “Maintenance Procedures/ Intervention Regeneration Strategy – EVIC Message Pro- cess Flow” in “Maintaining Your Vehicle” for further information.


46 STARTING AND OPERATING Idle-Up Feature – Automatic Transmission Only The driver-controlled high idle speed feature will help increase cylinder temperatures and provide additional cab heat, however, excessive idling may still cause the exhaust aftertreatment system to not properly regenerate. Extended periods of idle time should be avoided. The Idle-Up feature uses the speed control switches to increase engine idle speed and quickly warm the vehi- cle’s interior. 1. With the transmission in PARK, the parking brake applied, and the engine running, press the speed control switch to the ON position, then press the SET switch. 2. The engine RPM will go up to 1100 RPM. To increase the RPM, press and hold the ACCEL/RESUME switch and the idle speed will increase to approximately 1500


RPM. To decrease the RPM, press and hold the DECEL switch and the idle speed will decrease to approximately 1100 RPM. 3. To cancel the Idle–Up feature, either press the CAN- CEL switch, press the ON/OFF switch, or press the brake pedal. Stopping The Engine Idle the engine a few minutes before routine shutdown. After full load operation, idle the engine three to five minutes before shutting it down. This idle period will allow the lubricating oil and coolant to carry excess heat away from the combustion chamber, bearings, internal components, and turbocharger. This is especially impor- tant for turbocharged, charge air-cooled engines.


it


transmissions,


NOTE: • During engine shut down on vehicles equipped with manual is normal for the diesel engine to resonate heavily for a moment during engine shut off. When the engine is connected to a manual transmission, this resonance causes load gear rattle from the transmission. This is commonly referred to as “shut down rattle.” The manufacturer recommends performing engine shut down with the clutch pedal pushed to the floor (clutch disengaged). When engine shut down is performed in this manner the rattle is reduced (not eliminated).


to the following chart


for proper engine


• Refer


shutdown.


STARTING AND OPERATING 47


Driving Condition


Stop and


Go


Stop and


Go


Highway Speeds


Load


Turbo- charger


Temperature


Empty


Cool


Medium


Medium


Warm


City Traffic Maximum


GCWR


Highway Speeds Uphill Grade


Maximum


GCWR


Maximum


GCWR


Hot


Idle Time (min.) Be- fore Engine Shutdown Less than


One One


Two


Three


Four


Five


48 STARTING AND OPERATING Engine Speed Control


CAUTION!


Prevent overspeeding the engine going downhill. When descending steep grades, use a combination of gears and service brakes to control vehicle/engine speed. Overspeed can cause severe engine damage.


Snow Plow Mode Snow Plow Mode can be activated when the vehicle has a snow plow installed. This mode fully engages the fan clutch to increase the airflow when the plow is attached to the vehicle. NOTE: There may be an increase in fan noise and a decrease in fuel economy may result when using this feature. The fan clutch operation can be initiated by performing the following button sequence.


1. Turn the ignition key to the on position or start the vehicle. 2. Pull in the Cruise Control “Cancel” button/lever and hold. While holding the Cruise Control “Cancel”, push the “Exhaust Brake” button twice within five seconds. Repeat this sequence four times. The chime will sound twice as an audible indicator that the function is engaged. 3. To disable the function, repeat Step 2. The chime will sound four times as an audible indicator that the function is disengaged. Operating Precautions


Avoid Overheating The Engine The temperature of the engine coolant (antifreeze) (a mixture of 50% ethylene-glycol and 50% water) must not exceed the normal range of the temperature gauge 240°F (116°C) with a 16 psi (110 kPa) radiator cap.


Usually the engine coolant (antifreeze) temperature indi- cated during operation will be to the left of center in the normal range of the gauge. Avoid Low Coolant Temperature Operation Continual operation at low engine coolant (antifreeze) temperature below the normal range on the gauge 140°F (60°C) can be harmful to the engine. Low engine coolant (antifreeze) temperature can cause incomplete combus- tion which allows carbon and varnish to form on piston rings and injector nozzles. Also, the unburned fuel can enter the crankcase, diluting the lubricating oil and causing rapid wear to the engine. Cooling System Tips – Automatic Transmission To reduce potential for engine and transmission over- heating in high ambient temperature conditions, take the following actions:


STARTING AND OPERATING 49


• City Driving — When stopped, shift the transmission into NEUTRAL and increase engine idle speed. • Highway Driving — Reduce your speed. • Up Steep Hills — Select a lower transmission gear, but try and keep the torque converter clutch engaged. • Air Conditioning — Turn it off temporarily. Do Not Operate The Engine With Low Oil Pressure When the engine is at normal operating temperature, the minimum oil pressures required are:


Idle 700 to 800 RPM . . . . . . . . . . . . . . . 10 psi (69 kPa) Full speed and load . . . . . . . . . . . . . . 30 psi (207 kPa)


50 STARTING AND OPERATING


CAUTION!


If oil pressure falls to less than normal readings, shut the engine off immediately. Failure to do so could result in immediate and severe engine damage.


Do Not Operate The Engine With Failed Parts Practically all failures give some warning before the parts fail. Be on the alert for changes in performance, sounds, and visual evidence that the engine requires service. Some important clues are: • engine misfiring or vibrating severely • sudden loss of power • unusual engine noises • fuel, oil or coolant leaks • sudden change, outside the normal operating range, in


the engine operating temperature


• excessive smoke • oil pressure drop ENGINE BLOCK HEATER — IF EQUIPPED The engine block heater warms engine coolant and permits quicker starts in cold weather. Connect the heater cord to a ground-fault interrupter protected 110–115 Volt AC electrical outlet with a grounded, three-wire exten- sion cord. The engine block heater cord is routed under the hood to the right side and can be located just behind the grille near the headlamp. NOTE: The engine block heater cord is a factory in- stalled option. If your vehicle is not equipped, heater cords are available from your authorized MOPAR威 dealer. The block heater must be plugged in at least one hour to have an adequate warming effect on the coolant.


WARNING!


Remember to disconnect the cord before driving. Damage to the 110–115 Volt electrical cord could cause electrocution.


NOTE: The block heater will require 110 Volts AC and 6.5 Amps to activate the heater element. Block Heater Usage For ambient temperatures below 0°F (-18°C), engine block heater usage is recommended. For ambient temperatures below –20°F (-29°C), engine block heater usage is required.


DIESEL EXHAUST BRAKE (ENGINE BRAKING) — IF EQUIPPED The exhaust brake feature will only function when the driver turns the exhaust brake switch to the ON position.


STARTING AND OPERATING 51


Exhaust Brake Switch


Once the switch is in the ON position and the vehicle is moving faster than 5 mph (8 km/h); the exhaust brake will automatically operate when the driver removes pressure from the accelerator pedal. Exhaust braking is most effective when the engine RPM is higher. The automatic transmission has been programmed in TOW/


52 STARTING AND OPERATING HAUL mode only to downshift more aggressively when the exhaust brake is enabled to increase brake perfor- mance.


CAUTION!


Use of aftermarket exhaust brakes is not recom- mended and could lead to engine damage


WARNING!


Do not use the exhaust brake feature when driving in icy or slippery conditions as the increased engine braking can cause the rear wheels to slide and the vehicle to swing around with the possible loss of vehicle control, which may cause an accident possi- bly resulting in personal injury or death.


NOTE: For optimum braking power it is recommended to use the exhaust brake while in TOW/HAUL mode. The purpose of the exhaust brake (engine braking) fea- ture is to supply negative (braking) torque to the engine. Typically, the engine braking is used for, but not limited to, vehicle towing applications where vehicle braking can be achieved by the internal engine power, thereby spar- ing the mechanical brakes of the vehicle. Benefits of the exhaust brake are: • vehicle driving control • reduced brake fade • longer brake life • faster cab warm-up.


STARTING AND OPERATING 53


CAUTION! (Continued)


• Shift into or out of REVERSE only after the vehicle has come to a complete stop and the engine is at idle speed. • Do not shift between PARK, REVERSE, NEU- TRAL, or DRIVE into any forward gear when the engine is above idle speed. • Before shifting into any gear, make sure your foot


is firmly pressing on the brake pedal.


The exhaust brake feature can also be used to reduce the engine warm up time. To use the exhaust brake as a warm-up device, the vehicle must be stopped or moving less than 5 mph (8 km/h), the exhaust brake switch must be in the ON position, and the coolant temperature must be below 180°F (82°C) and ambient temperature below 60°F (16°C).


AUTOMATIC TRANSMISSION — IF EQUIPPED


CAUTION!


Damage to the transmission may occur if the follow- ing precautions are not observed: • Shift into PARK only after the vehicle has come to


a complete stop.


(Continued)


54 STARTING AND OPERATING


WARNING!


• Unintended movement of a vehicle could injure those in and near the vehicle. As with all vehicles, you should never exit a vehicle while the engine is running. Before exiting a vehicle, apply the park- ing brake, shift the transmission into PARK, and remove the key fob. Once the key fob is removed, the shift lever is locked in the PARK position, securing the vehicle against unwanted movement. Furthermore, you should never leave unattended children inside a vehicle.


(Continued)


WARNING! (Continued)


• Leaving children in a vehicle unattended is dan- gerous for a number of reasons. A child or others could be seriously or fatally injured. Children should be warned not to touch the parking brake, brake pedal or the shift lever. Do not leave the key fob in the vehicle. A child could operate power windows, other controls, or move the vehicle. • It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly pressing on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or some- thing. Only shift into gear when the engine is idling normally and when your right foot is firmly pressing on the brake pedal.


Key Ignition Park Interlock This vehicle is equipped with a Key Ignition Park Inter- lock which requires the shift lever to be placed in PARK before the ignition switch can be turned to the LOCK/ OFF position. The key fob can only be removed from the ignition when the ignition is in the LOCK/OFF position and once removed the shift lever is locked in PARK. Brake/Transmission Shift Interlock System This vehicle is equipped with a Brake Transmission Shift Interlock System (BTSI) that holds the shift lever in the PARK position when the ignition switch is in the LOCK/ OFF position. To move the shift lever out of the PARK position, the ignition switch must be turned to the ON/RUN position (engine running or not) and the brake pedal must be pressed.


STARTING AND OPERATING 55
Six-Speed Automatic Transmission – If Equipped (Ram Truck Only) The shift lever position display (located in the instrument panel cluster) indicates the transmission gear range. The shift lever is mounted on the right side of the steering column. You must press the brake pedal to move the shift lever out of the PARK position (refer to “Brake/ Transmission Shift Interlock System” in this section). To drive, move the shift lever from PARK or NEUTRAL to the DRIVE position. Pull the shift lever toward you when shifting into REVERSE or PARK, or when shifting out of PARK. The electronically-controlled transmission provides a precise shift schedule. The transmission electronics are self-calibrating; therefore, the first few shifts on a new vehicle may be somewhat abrupt. This is a normal condition, and precision shifts will develop within a few hundred miles (kilometers).


56 STARTING AND OPERATING Shifting from DRIVE to PARK or REVERSE should be done only after the accelerator pedal is released and the vehicle is stopped. Be sure to keep your foot on the brake pedal when moving the shift lever between these gears. The transmission shift lever has only Park, Reverse, Neutral, and Drive shift positions. Manual downshifts can be made using the Electronic Range Select (ERS) shift control (described later). Pressing the ERS (-/+) buttons while in the DRIVE position will select the highest available transmission gear, and will display that gear in the instrument cluster as 6, 5, 4, 3, 2, 1. Gear Ranges DO NOT race the engine when shifting from PARK or NEUTRAL into another gear range.


PARK This range supplements the parking brake by locking the transmission. The engine can be started in this range. Never attempt to use PARK while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. When parking on a level surface, you may place the shift lever in the PARK position first, and then apply the parking brake. When parking on a hill, apply the parking brake before placing the shift lever in PARK, otherwise the load on the transmission locking mechanism may make it difficult to move the shift lever out of PARK. As an added precau- tion, turn the front wheels toward the curb on a downhill grade and away from the curb on an uphill grade.


STARTING AND OPERATING 57


WARNING!


• Never use the PARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. • Your vehicle could move and injure you and others if it is not completely in PARK. Check by trying to move the shift lever clockwise without first pull- ing it toward you after you have placed it in PARK. Make sure the transmission is in PARK before leaving the vehicle.


WARNING! (Continued)


• It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly pressing on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or some- thing. Only shift into gear when the engine is idling normally and when your foot is firmly pressing on the brake pedal.


(Continued)


(Continued)


58 STARTING AND OPERATING


WARNING! (Continued)


• Unintended movement of a vehicle could injure those in and near the vehicle. As with all vehicles, you should never exit a vehicle while the engine is running. Before exiting a vehicle, always apply the parking brake, shift the transmission into PARK, and remove the key fob. Once the key fob is removed, the shift lever is locked in the PARK position, securing the vehicle against unwanted movement. Furthermore, you should never leave unattended children inside a vehicle. • Never leave children alone in a vehicle. Leaving unattended children in a vehicle is dangerous for a number of reasons. A child or others could be seriously or fatally injured. Do not leave the key fob in the vehicle. A child could operate power windows, other controls, or move the vehicle.


CAUTION!


• Before moving the shift lever out of PARK, you must turn the ignition switch from the LOCK/OFF position to the ON/RUN position, and also press the brake pedal. Otherwise, damage to the shift lever could result. • DO NOT race the engine when shifting from PARK or NEUTRAL into another gear range, as this can damage the drivetrain.


The following indicators should be used to ensure that you have engaged the shift lever into the PARK position: • When shifting into PARK, pull the shift lever toward you and move it all the way counterclockwise until it stops. • Release the shift lever and make sure it is fully seated


in the PARK gate.


• Look at the shift lever position display and verify that • With brake pedal released, verify that the shift lever


it indicates the PARK position.


will not move out of PARK.


REVERSE This range is for moving the vehicle backward. Shift into REVERSE only after the vehicle has come to a complete stop. NEUTRAL Use this range when the vehicle is standing for prolonged periods with the engine running. The engine may be started in this range. Set the parking brake and shift the transmission into PARK if you must leave the vehicle.


STARTING AND OPERATING 59


WARNING!


Do not coast in NEUTRAL and never turn off the ignition to coast down a hill. These are unsafe practices that limit your response to changing traffic or road conditions. You might lose control of the vehicle and have an accident.


CAUTION!


Towing the vehicle, coasting, or driving for any other reason with the transmission in NEUTRAL can result in severe transmission damage. Refer to “Recre- ational Towing” in “Starting And Operating” and “Towing A Disabled Vehicle” in “What To Do In Emergencies” for further information.


60 STARTING AND OPERATING DRIVE This range should be used for most city and highway driving. It provides the smoothest upshifts and down- shifts, and the best fuel economy. The transmission automatically upshifts through underdrive first, second, and third gears, direct fourth gear and overdrive fifth and sixth gears. The DRIVE position provides optimum driv- ing characteristics under all normal operating conditions. When frequent transmission shifting occurs (such as when operating the vehicle under heavy loading condi- tions, in hilly terrain, traveling into strong head winds, or while towing heavy trailers), use the Electronic Range Select (ERS) feature (refer to “Electronic Range Select (ERS)” in this section) to select a lower gear range. Under these conditions, using a lower gear range will improve performance and extend transmission life by reducing excessive shifting and heat buildup.


If the transmission operating temperature exceeds nor- mal operating limits, the powertrain controller will modify the transmission shift schedule and expand the range of torque converter clutch engagement. This is done to prevent transmission damage due to overheat- ing. If the transmission becomes extremely hot, the “Trans- mission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. NOTE: Use caution when operating a heavily loaded vehicle at low speeds (such as towing a trailer up a steep grade, or in stop-and-go traffic) during hot weather. In these conditions, torque converter slip can impose a significant additional heat load on the cooling system. Downshifting the transmission to the lowest possible


gear (when climbing a grade), or shifting to NEUTRAL (when stopped in heavy traffic) can help to reduce this excess heat generation. During cold temperatures, transmission operation may be modified depending on engine and transmission temperature as well as vehicle speed. This feature im- proves warm up time of the engine and transmission to achieve maximum efficiency. Engagement of both the torque converter clutch and the top overdrive gear are inhibited until the transmission fluid is warm (refer to the “Note” under “Torque Converter Clutch” in this section). During extremely cold temperatures (-16°F [-27°C] or below), operation may briefly be limited to first and direct gears only. Normal operation will resume once the transmission temperature has risen to a suitable level. Transmission Limp Home Mode Transmission function is monitored electronically for abnormal conditions. If a condition is detected that could


STARTING AND OPERATING 61
result in transmission damage, Transmission Limp Home Mode is activated. In this mode, the transmission remains in fourth gear regardless of which forward gear is selected. PARK, REVERSE, and NEUTRAL will continue to operate. Limp Home Mode allows the vehicle to be driven to an authorized dealer for service without dam- aging the transmission. In the event of a momentary problem, the transmission can be reset to regain all forward gears by performing the following steps: 1. Stop the vehicle. 2. Shift the transmission into PARK. 3. Turn the ignition switch to the LOCK/OFF position. 4. Wait approximately 10 seconds. 5. Restart the engine.


You can switch between DRIVE and ERS mode at any vehicle speed. When the shift lever is in the DRIVE position, the transmission will operate automatically, shifting between all available gears. Tapping the ERS (-) switch will activate ERS mode, display the current gear in the instrument cluster, and maintain that gear as the top available gear. Once in ERS mode, tapping the ERS (-) or (+) switch will change the top available gear.


62 STARTING AND OPERATING 6. Shift into the desired gear range. If the problem is no longer detected, the transmission will return to normal operation. NOTE: Even if the transmission can be reset, we recom- mend that you visit your authorized dealer at your earliest possible convenience. Your authorized dealer has diagnostic equipment to determine if the problem could recur. If the transmission cannot be reset, authorized dealer service is required. Electronic Range Select (ERS) Operation The Electronic Range Select (ERS) shift control allows the driver to limit the highest available gear when the shift lever is in the DRIVE position. For example, if you shift the transmission into 3 (third gear), the transmission will never shift above third gear, but will shift down into second and first gear normally.


STARTING AND OPERATING 63


WARNING!


Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid, causing an accident or personal injury.


1-5


1-4


1-3


1-2


Screen Display Actual Gear(s) Allowed NOTE: To select the proper gear position for maximum deceleration (engine braking), simply press and hold the ERS (-) switch down. The transmission will shift to the range from which the vehicle can best be slowed down.


1-6


1-6


Column Shift Lever


To exit ERS mode, simply press and hold the ERS (+) switch until “D” is once again displayed in the shift lever position indicator in the instrument cluster.


perature,


64 STARTING AND OPERATING Overdrive Operation The automatic transmission includes an electronically controlled Overdrive (fifth and sixth gears). The trans- mission will automatically shift into the Overdrive gear if the following conditions are present: • the shift lever is in the DRIVE position, • the transmission fluid has reached an adequate tem- • the engine coolant has reached an adequate tempera- • vehicle speed is sufficiently high, and • the TOW/HAUL switch has not been activated. When To Use TOW/HAUL Mode When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the TOW/HAUL switch to select TOW/


ture,


HAUL mode. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting. When operating in TOW/HAUL mode, transmission upshifts are delayed, and the trans- mission will automatically downshift (for engine brak- ing) during steady braking maneuvers.


TOW/HAUL Switch


The “TOW/HAUL Indicator Light” will illuminate in the instrument cluster to indicate that TOW/HAUL mode has been activated. Pressing the switch a second time restores normal operation. If the TOW/HAUL mode is desired, the switch must be pressed each time the engine is started.


WARNING!


Do not use the “TOW/HAUL” feature when driving in icy or slippery conditions. The increased engine braking could cause the rear wheels to slide, and the vehicle to swing around with the possible loss of vehicle control, which could cause an accident possi- bly resulting in personal injury or death.


Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle.


STARTING AND OPERATING 65
A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in the upper gears. When the vehicle speed drops or during some accelerations, the clutch automatically disengages. NOTE: • The torque converter clutch will not engage, and the transmission will not shift to sixth gear, until the transmission fluid and engine coolant are warm [usu- ally after 1 to 3 miles (1.6 to 4.8 km) of driving]. Because sixth gear is disabled, and engine speed is higher when the torque converter clutch is not en- gaged, it may seem as if the transmission is not shifting properly when cold. This is normal. Using the Electronic Range Select (ERS) feature, when the trans- mission is sufficiently warm, will demonstrate that the transmission is able to shift into and out of Overdrive.


66 STARTING AND OPERATING


• If the vehicle has not been driven for several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds after starting the engine.


Six-Speed Automatic Transmission – If Equipped (Chassis Cab Only) The shift lever position display (located in the instrument panel cluster) indicates the transmission gear range. The shift lever is mounted on the right side of the steering column. You must press the brake pedal to move the shift lever out of the PARK position (refer to “Brake/ Transmission Shift Interlock System” in this section). To drive, move the shift lever from PARK or NEUTRAL to


the DRIVE position. Pull the shift lever toward you when shifting into REVERSE or PARK, or when shifting out of PARK. The electronically-controlled transmission provides a precise shift schedule. The transmission electronics are self-calibrating; therefore, the first few shifts on a new vehicle may be somewhat abrupt. This is a normal condition, and precision shifts will develop within a few hundred miles (kilometers). Shifting from DRIVE to PARK or REVERSE should be done only after the accelerator pedal is released and the vehicle is stopped. Be sure to keep your foot on the brake pedal when moving the shift lever between these gears. The transmission shift lever has only PARK, REVERSE, NEUTRAL, and DRIVE shift positions. Manual down- shifts can be made using the Electronic Range Select (ERS) shift control (described later). Pressing the ERS (-/+) switches (on the shift lever) while in the DRIVE


position will select the highest available transmission gear, and will display that gear in the instrument cluster as 6, 5, 4, 3, 2, 1. Gear Ranges DO NOT race the engine when shifting from PARK or NEUTRAL into another gear range. PARK This range supplements the parking brake by locking the transmission. The engine can be started in this range. Never attempt to use PARK while vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. When parking on a level surface, you may place the shift lever in the PARK position first, and then apply the parking brake. When parking on a hill, apply the parking brake before placing the shift lever in PARK, otherwise the load on the


STARTING AND OPERATING 67
transmission locking mechanism may make it difficult to move the shift lever out of PARK. As an added precau- tion, turn the front wheels toward the curb on a downhill grade and away from the curb on an uphill grade.


WARNING!


• Never use the PARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. • Your vehicle could move and injure you and others if it is not completely in PARK. Check by trying to move the shift lever clockwise without first pull- ing it toward you after you have placed it in PARK. Make sure the transmission is in PARK before leaving the vehicle.


(Continued)


68 STARTING AND OPERATING


WARNING! (Continued)


• It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly pressing on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or some- thing. Only shift into gear when the engine is idling normally and your foot is firmly pressed on the brake pedal.


(Continued)


WARNING! (Continued)


• Unintended movement of a vehicle could injure those in and near the vehicle. As with all vehicles, you should never exit a vehicle while the engine is running. Before exiting a vehicle, always apply the parking brake, shift the transmission into PARK, and remove the key fob. Once the key fob is removed, the shift lever is locked in the PARK position, securing the vehicle against unwanted movement. Furthermore, you should never leave unattended children inside a vehicle. • Never leave children alone in a vehicle. Leaving unattended children in a vehicle is dangerous for a number of reasons. A child or others could be seriously or fatally injured. Do not leave the key fob in the vehicle. A child could operate power windows, other controls, or move the vehicle.


CAUTION!


• Before moving the shift lever out of PARK, you must turn the ignition switch from the LOCK/OFF position to the ON/RUN position, and also press the brake pedal. Otherwise, damage to the shift lever could result. • DO NOT race the engine when shifting from PARK or NEUTRAL into another gear range, as this can damage the drivetrain.


The following indicators should be used to ensure that you have engaged the shift lever into the PARK position: • When shifting into PARK, pull the shift lever toward you and move it all the way counterclockwise until it stops. • Release the shift lever and make sure it is fully seated


in the PARK gate.


STARTING AND OPERATING 69


• Look at the shift lever position display and verify that • With brake pedal released, verify that the shift lever


it indicates the PARK position.


will not move out of PARK.


REVERSE This range is for moving the vehicle backward. Shift into REVERSE only after the vehicle has come to a complete stop. NEUTRAL Use this range when the vehicle is standing for prolonged periods with the engine running. The engine may be started in this range. Set the parking brake and shift the transmission into PARK if you must leave the vehicle.


70 STARTING AND OPERATING


WARNING!


Do not coast in NEUTRAL and never turn off the ignition to coast down a hill. These are unsafe practices that limit your response to changing traffic or road conditions. You might lose control of the vehicle and have an accident.


CAUTION!


Towing the vehicle, coasting, or driving for any other reason with the transmission in NEUTRAL can result in severe transmission damage. Refer to “Recre- ational Towing” in “Starting And Operating” and “Towing A Disabled Vehicle” in “What To Do In Emergencies” for further information.


DRIVE This range should be used for most city and highway driving. It provides the smoothest upshifts and down- shifts, and the best fuel economy. The transmission automatically upshifts through underdrive first, second, and third gears, direct fourth gear and overdrive fifth and sixth gears. The DRIVE position provides optimum driv- ing characteristics under all normal operating conditions. When frequent transmission shifting occurs (such as when operating the vehicle under heavy loading condi- tions, in hilly terrain, traveling into strong head winds, or while towing heavy trailers), use the Electronic Range Select (ERS) feature (refer to “Electronic Range Select (ERS)” in this section) to select a lower gear range. Under these conditions, using a lower gear range will improve performance and extend transmission life by reducing excessive shifting and heat buildup.


If the transmission operating temperature exceeds nor- mal operating limits, the powertrain controller will modify the transmission shift schedule and expand the range of torque converter clutch engagement. This is done to prevent transmission damage due to overheat- ing. If the transmission becomes extremely hot, the “Trans- mission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. NOTE: Use caution when operating a heavily loaded vehicle at low speeds (such as towing a trailer up a steep grade, or in stop-and-go traffic) during hot weather. In these conditions, torque converter slip can impose a significant additional heat load on the cooling system. Downshifting the transmission to the lowest possible


STARTING AND OPERATING 71
gear (when climbing a grade), or shifting to NEUTRAL (when stopped in heavy traffic) can help to reduce this excess heat generation. During cold temperatures, transmission operation may be modified depending on engine and transmission temperature as well as vehicle speed. This feature im- proves warm up time of the engine and transmission to achieve maximum efficiency. Engagement of the torque converter clutch is inhibited until the transmission fluid is warm (refer to the “Note” under “Torque Converter Clutch” in this section). On cold starts below 41°F (5°C), fifth and sixth gears may be inhibited briefly. During very cold temperatures (-4°F [-20°C] or below), operation may briefly be limited to third gear only. During this condi- tion, the ability of the vehicle to accelerate under heavily loaded conditions may be reduced. Normal operation will resume once the transmission temperature has risen to a suitable level.


72 STARTING AND OPERATING Transmission Limp Home Mode Transmission function is monitored electronically for abnormal conditions. If a condition is detected that could result in transmission damage, Transmission Limp Home Mode is activated. In this mode, the transmission remains in third gear regardless of which forward gear is selected. If the vehicle enters Limp Home Mode at highway speeds, it will initially engage fifth gear, until the vehicle slows to a speed where third gear can be engaged. PARK, REVERSE, and NEUTRAL will continue to operate. Limp Home Mode allows the vehicle to be driven to an authorized dealer for service without damaging the transmission. In the event of a momentary problem, the transmission can be reset to regain all forward gears by performing the following steps: 1. Stop the vehicle.


2. Shift the transmission into PARK. 3. Turn the ignition switch to the LOCK/OFF position. 4. Wait approximately 10 seconds. 5. Restart the engine. 6. Shift into the desired gear range. If the problem is no longer detected, the transmission will return to normal operation. NOTE: Even if the transmission can be reset, we recom- mend that you visit your authorized dealer at your earliest possible convenience. Your authorized dealer has diagnostic equipment to determine if the problem could recur. If the transmission cannot be reset, authorized dealer service is required.


Electronic Range Select (ERS) Operation The Electronic Range Select (ERS) shift control allows the driver to limit the highest available gear when the shift lever is in the DRIVE position. For example, if you shift the transmission into 3 (third gear), the transmission will never shift above third gear, but will shift down into second and first gear normally. You can switch between DRIVE and ERS mode at any vehicle speed. When the shift lever is in the DRIVE position, the transmission will operate automatically, shifting between all available gears. Tapping the ERS (-) switch will activate ERS mode, display the current gear in the instrument cluster, and maintain that gear as the top available gear. Once in ERS mode, tapping the ERS (-) or (+) switch will change the top available gear.


STARTING AND OPERATING 73


Column Shift Lever


To exit ERS mode, simply press and hold the ERS (+) switch until “D” is once again displayed in the shift lever position indicator in the instrument cluster.


74 STARTING AND OPERATING


WARNING!


Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid, causing an accident or personal injury.


1-2


1-6


1-6


1-5


1-4


1-3


Screen Display Actual Gear(s) Allowed NOTE: To select the proper gear position for maximum deceleration (engine braking), simply press and hold the ERS (-) switch down. The transmission will shift to the range from which the vehicle can best be slowed down. Overdrive Operation The automatic transmission includes an electronically controlled Overdrive (fifth and sixth gears). The trans- mission will automatically shift into the Overdrive gear if the following conditions are present:


ture,


perature,


• the shift lever is in the DRIVE position, • the transmission fluid has reached an adequate tem- • the engine coolant has reached an adequate tempera- • vehicle speed is sufficiently high, and • the “TOW/HAUL” switch has not been activated. When To Use TOW/HAUL Mode When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the TOW/HAUL switch to select TOW/ HAUL mode. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting.


STARTING AND OPERATING 75


WARNING!


Do not use the “TOW/HAUL” feature when driving in icy or slippery conditions. The increased engine braking can cause the rear wheels to slide, and the vehicle to swing around with the possible loss of vehicle control, which could cause an accident possi- bly resulting in personal injury or death.


Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle. A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in the upper gears. When the vehicle speed drops or during some accelerations, the clutch automatically disengages.


TOW/HAUL Switch


The “TOW/HAUL Indicator Light” will illuminate in the instrument cluster to indicate that TOW/HAUL mode has been activated. Pressing the switch a second time restores normal operation. If the TOW/HAUL mode is desired, the switch must be pressed each time the engine is started.


76 STARTING AND OPERATING NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1 to 3 miles (1.6 to 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmission is not shifting into Overdrive when cold. This is normal. Using the Electronic Range Select (ERS) feature, when the transmission is sufficiently warm, will demonstrate that the transmission is able to shift into and out of Overdrive. • If the vehicle has not been driven for several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds after starting the engine.


MANUAL TRANSMISSION — IF EQUIPPED


WARNING!


You or others could be injured if you leave the vehicle unattended without having the parking brake fully applied. The parking brake should al- ways be applied when the driver is not in the vehicle, especially on an incline.


CAUTION!


Never drive with your foot resting on the clutch pedal, or attempt to hold the vehicle on a hill with the clutch pedal partially engaged, as this will cause abnormal wear on the clutch.


NOTE: During cold weather, you may experience in- creased effort in shifting until the transmission fluid warms up. This is normal.


Shifting


Shift Pattern


Truck models with manual transmission are equipped with a clutch interlocking ignition system. The clutch pedal must be fully pressed to start the vehicle.


STARTING AND OPERATING 77
Fully press the clutch pedal before shifting gears. As you release the clutch pedal, lightly press the accelerator pedal. This transmission has a “creeper” first gear which should be used to start from a standing position when carrying a payload or towing a trailer. Damage to the clutch can result from starting in second or third gear with a loaded vehicle. An unloaded vehicle may be launched in second gear. Use each gear in numerical order – do not skip a gear. NOTE: When loaded, pulling a trailer or on a grade, the truck should always start in first gear and not skip gears. Recommended Vehicle Shift Speeds To utilize your manual transmission efficiently for both fuel economy and performance, it should be upshifted as listed in recommended shift speed chart. Shift at the


78 STARTING AND OPERATING vehicle speeds listed for acceleration. When heavily loaded or pulling a trailer these recommended up-shift speeds may not apply. Maximum Recommended Up-Shift Speeds


Gear Selec- tion Maxi- mum Speed


1 to 2


2 to 3


3 to 4


4 to 5


5 to 6


7 mph


15 mph


25 mph


40 mph


45 mph


(11


(24


(40


(64


(72


km/h)


km/h)


km/h)


km/h)


km/h)


Downshifting


Moving from a high gear down to a lower gear is recommended to preserve brakes when driving down steep hills. In addition, downshifting at the right time provides better acceleration when you desire to resume speed. Downshift progressively. Do not skip gears to avoid overspeeding the engine and clutch.


WARNING!


Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid.


CAUTION!


When descending a hill, be very careful to downshift one gear at a time to prevent overspeeding the engine which can cause valve damage, and/or clutch disc damage even if the clutch pedal is pressed.


Maximum Recommended Downshift Speeds


CAUTION!


Failure to follow the recommended downshifting speeds may cause the engine to overspeed and/or damage the clutch disc even if the clutch pedal is pressed.


Maximum Recommended Downshifting Speeds


Gear Selec- tion Maxi- mum Speed


6 to 5


5 to 4


4 to 3


3 to 2


2 to 1


68 mph


(109
km/h)


50 mph


32 mph


19 mph


10 mph


(80


(51


(31


(16


km/h)


km/h)


km/h)


km/h)


STARTING AND OPERATING 79


Reverse Shifting To shift into REVERSE (R), bring the vehicle to a com- plete stop. Press the clutch and pause briefly to allow the gear train to stop rotating. Beginning from the NEUTRAL (N) position, move the shift lever in one quick smooth motion straight across and into the REVERSE (R) area (the driver will feel a firm “click” as the shifter passes the “knock-over”). Complete the shift by pulling the shift lever into REVERSE (R). The “knock-over” prevents the driver from accidentally entering the REVERSE (R) shift area and warns the driver that they are about to shift the transmission into RE- VERSE (R). Due to this feature, a slow shift to REVERSE (R) can be perceived as a high shift effort. To shift out of REVERSE bring the vehicle to a complete stop and press the clutch. Shifting out of REVERSE prior to a complete stop may cause high shift effort.


80 STARTING AND OPERATING POWER TAKE OFF OPERATION — IF EQUIPPED (CHASSIS CAB ONLY) This vehicle when equipped with either the AS68RC automatic six-speed or G-56 manual six-speed transmis- sions, will allow for an aftermarket upfit with a transmis- sion driven PTO (power take off). The customer will have the ability to operate the PTO in either a “stationary” or “mobile” mode. The vehicles will be factory set to the “stationary” mode. In order to select the “mobile” mode an authorized dealership is required to modify the vehi- cle’s settings using their proprietary authorized dealer service tool. AS68RC Six-Speed Automatic Transmission Only The PTO drive gear (part of the AS68RC) operates at torque converter turbine speed. The turbine speed will be less than engine speed when the torque converter clutch is not engaged and will be same as engine speed when the torque converter clutch is engaged.


Stationary Mode


matic transmission)


To operate the PTO in this mode the vehicle must meet the following conditions: • Be in PARK position (vehicles equipped with auto- • Upfitter provider (on/off) switch has been activated • Parking brake applied (vehicles equipped with • Brake pedal must not be applied • Vehicle engine must be running • No vehicle, brake or clutch switch faults present • PTO must be correctly installed using the vehicle


manual transmission)


provided circuits


The customer has the choice to operate the PTO by utilizing the cruise control switches or by utilizing a remote control (provided by the PTO supplier). To oper- ate the feature using the cruise control switches, the customer must first activate the upfitter-provided on/off switch which will turn on the PTO. In order to increase or decrease the engine idle speed, to optimize the PTO function, the “RESUME/ACCEL” and “DECEL” cruise switches can be used respectively. To disengage PTO operation and return to “standard vehicle operation” simply turn the upfitter-provided on/off switch to the OFF position. The torque converter lockup clutch will automatically engage at engine speeds above 1,200 RPM (engine speed) in PTO stationary mode. Once engaged, the lockup clutch will remain on and not disengage until the engine speed is below 1,000 RPM. Lockup clutch engagement is desir- able for certain types of PTO applications (AS68RC Six-Speed Automatic Transmission Only).


STARTING AND OPERATING 81
To operate the PTO via a remote switch, the customer must make sure the above conditions are met. It is vital for proper operation that the PTO and remote have been installed correctly, paying special attention to ensure the vehicle provided wiring has been connected properly. This is the responsibility of the installer of the PTO and switches/remote system. It is the responsibility of the PTO manufacturer to ensure that their electrical (switches and remote) system is compatible with the vehicle’s electrical architecture and software functionality. If you desire a single PTO speed, your vehicle NOTE: must be wired to use a remote PTO switch. For instruc- tions on programming the SET speed, refer to the LEARNING SET SPEED section of the Body Builder’s Guide which can be found at www.ramtrucks.com.


82 STARTING AND OPERATING Mobile Mode


via authorized dealer proprietary service tool


To operate the PTO in this mode the vehicle must meet the following conditions: • Authorized dealer-selected “mobile” mode activated • Upfitter-provided (on/off) switch has been activated • Vehicle must be in PARK or DRIVE position (vehicles • Parking brake must not be applied • Brake pedal must not be applied • No vehicle, brake or clutch switch faults present • Vehicle engine must be running • PTO must be correctly installed using the vehicle


equipped with automatic transmission)


provided circuits


The customer may choose to use the PTO while the vehicle is moving. To do so, the PTO function must be activated prior to taking the vehicle out of PARK. This is accomplished by activating the upfitter-provided PTO on/off switch. At this point, the customer may place the vehicle in a forward or reverse gear and have PTO operation once the vehicle begins to move. To disengage PTO operation and return to “standard vehicle opera- tion” simply turn the upfitter-provided on/off switch to the OFF position. NOTE: For application specific information with respect to PTO and pump requirements and additional vehicle information (wiring schematics, preset idle values, en- gine speed limits, and vehicle hardware and software requirements) please refer to the Body Builders Guide by accessing www.ramtrucks.com and choosing the appro- priate links.


Power Take Off – Aftermarket Installation If you did not order the PTO (Power Take Off) Prep Package from the factory and want to convert your vehicle, refer to the Body Builder’s Guide at ww- w.ramtrucks.com or contact the manufacturer directly at (866) 205–4102 (toll free).


ENGINE RUNAWAY


WARNING!


In case of engine runaway due to flammable fumes from gasoline spills or turbocharger oil leaks being sucked into the engine, do the following to help avoid personal injury and/or vehicle damage: 1. Turn the ignition switch to the OFF position.


(Continued)


STARTING AND OPERATING 83


WARNING! (Continued)


2. Using a CO2 or dry chemical type fire extin- guisher, direct the spray from the fire extinguisher into the grille on the passenger side so that the spray enters the engine air intake. The inlet for the engine air intake is located behind the passenger side headlamp and receives air through the grille.


FUEL REQUIREMENTS Use good quality diesel fuel from a reputable supplier in your vehicle. Federal law requires that you must fuel this vehicle with Ultra Low Sulfur Highway Diesel fuel (15
ppm Sulfur maximum) and prohibits the use of Low Sulfur Highway Diesel fuel (500 ppm Sulfur maximum) to avoid damage to the emissions control system. For most year-round service, No. 2 diesel fuel meeting ASTM


84 STARTING AND OPERATING specification D-975 Grade S15 will provide good perfor- mance. If the vehicle is exposed to extreme cold (below 20°F or -7°C), or is required to operate at colder-than- normal conditions for prolonged periods, use climatized No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax-plugging of the fuel filters.


WARNING!


Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and hazardous or explosive when mixed with diesel fuel.


Diesel fuel is seldom completely free of water. To prevent fuel system trouble, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should


not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold-starting and warm-up performance. Fuel Specifications The Cummins威 diesel engine has been developed to take advantage of the high energy content and generally lower cost No. 2 Ultra Low Sulfur diesel fuel or No. 2
Ultra Low Sulfur climatized diesel fuels. Experience has shown that it also operates on No. 1 Ultra Low Sulfur diesel fuels or other fuels within specification. NOTE: • A maximum blend of 5% biodiesel meeting ASTM specification D-6751 may be used with your Cum- mins威 diesel engine. • In addition, commercially available fuel additives are not necessary for the proper operation of your Cum- mins威 diesel engine.


• No. 1 Ultra Low Sulfur diesel fuel should only be used where extended arctic conditions (-10°F or -23°C) exist.


ADDING FUEL


CAUTION!


STARTING AND OPERATING 85


WARNING!


A fire may result if fuel is pumped into a portable container that is on a truck bed. You could be burned. Always place fuel containers on the ground while filling.


To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling.


Fuel Filler Cap


tank is full.


NOTE: • When the fuel nozzle “clicks” or shuts off, the fuel • Tighten the fuel filler cap until you hear a “clicking” sound. This is an indication that the fuel filler cap is properly tightened. • Make sure that the fuel filler cap is tightened each time


the vehicle is refueled.


If the fuel filler cap is lost or damaged, be sure the replacement cap is for use with this vehicle.


CAUTION!


Damage to the fuel system or emission control sys- tem could result from using an improper fuel tank filler tube cap. A poorly fitting cap could let impuri- ties into the fuel system.


86 STARTING AND OPERATING


WARNING!


• Never have any smoking materials lit in or near the vehicle when the fuel filler cap is removed or the tank filled. • Never add fuel to the vehicle when the engine is


running.


Avoid Using Contaminated Fuel Fuel that is contaminated by water or dirt can cause severe damage to the engine fuel system. Proper main- tenance of the engine fuel filter and fuel tank is essential. Refer to “Maintenance Procedures” in “Maintaining Your Vehicle” for further information. Bulk Fuel Storage – Diesel Fuel If you store quantities of fuel, good maintenance of the stored fuel is also essential. Fuel contaminated with water will promote the growth of “microbes.” These


microbes form “slime” that will clog fuel filters and lines. Drain condensation from the supply tank and change the line filter on a regular basis. NOTE: When a diesel engine is allowed to run out of fuel, air is pulled into the fuel system. If the vehicle will not start, refer to “Maintenance Procedures/Priming If The Engine Has Run Out Of Fuel” in “Maintaining Your Vehicle” for further information.


WARNING!


Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.


Diesel Exhaust Fluid Storage Diesel Exhaust Fluid (DEF) is considered a very stable product with a long shelf life. If DEF is kept in tempera- tures between 10° to 90°F (-12° to 32°C), it will last a minimum of one year. DEF is subject to freezing at the lowest temperatures. For example, DEF may freeze at temperatures at or below 12° F (-11° C). The system has been designed to operate in this environment. NOTE: When working with DEF, it is important to know that: • Any containers or parts that come into contact with DEF must be DEF compatible (plastic or stainless steel). Copper, brass, aluminum, iron or non-stainless steel should be avoided as they are subject to corrosion by DEF. • If DEF is spilled, it should be wiped up completely


STARTING AND OPERATING 87
Adding Diesel Exhaust Fluid – Chassis Cab Only The DEF gauge (located on the EVIC display) will display the level of DEF remaining in the tank. Refer to “Electronic Vehicle Information Center (EVIC)” in “Un- derstanding Your Instrument Panel” for further informa- tion. • When the DEF gauge reads 75%, add approximately • When the DEF gauge reads 50%, add approximately • When the DEF gauge reads 25%, add approximately


2 gallons (7.5 Liters) to fill the DEF tank.


4 gallons (15 Liters) to fill the DEF tank.


6 gallons (23 Liters) to fill the DEF tank.


NOTE: Driving conditions (altitude, vehicle speed, load, etc.) will effect the amount of DEF that is used in your vehicle.


88 STARTING AND OPERATING DEF Fill Procedure NOTE: Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for the correct fluid type. 1. Remove cap from DEF tank (located on drivers side of the vehicle).


2. Insert DEF fill adapter/nozzle into DEF tank filler neck.


Filling the DEF Tank


DEF Filler Cap


CAUTION!


• To avoid DEF spillage, and possible damage to the DEF tank from overfilling, do not “top off” the DEF tank after filling. • When DEF is spilled, clean the area immediately with water or use an absorbent material to soak up and spills on the ground.


3. Stop filling the DEF tank immediately when any of the following happen: DEF stops flowing from the fill bottle into the DEF tank, DEF splashes out the filler neck, or a DEF pump nozzle automatically shuts off. 4. Reinstall cap onto DEF tank.


DIESEL EXHAUST FLUID — CHASSIS CAB ONLY Your vehicle is equipped with a Selective Catalytic Re- duction system in order to meet the very stringent diesel


STARTING AND OPERATING 89
emissions standards required by the Environmental Pro- tection Agency. Selective Catalytic Reduction (SCR) is the first and only technology in decades to be as good for the environment as it is good for business and vehicle performance. The purpose of the SCR system is to reduce levels of NOx (oxides of nitrogen emitted from engines) that are harm- ful to our health and the environment to an almost near-zero level. Small quantities of Diesel Exhaust Fluid (DEF) are injected into the exhaust upstream of a catalyst where, when vaporized, convert smog-forming nitrogen oxides (NOx) into harmless nitrogen (N2) and water vapor (H2O), two natural components of the air we breathe. You can operate with the comfort that your vehicle is contributing to a cleaner, healthier world environment for this and generations to come.


90 STARTING AND OPERATING System Overview This vehicle is equipped with a Diesel Exhaust Fluid (DEF) injection system and a Selective Catalytic Reduc- tion (SCR) catalyst to meet the emission requirements. The DEF injection system consists of the following com- ponents: • DEF tank • DEF pump • DEF injector • Electronically-heated DEF lines • DEF control module • NOx sensors • Temperature sensors • SCR catalyst


The DEF injection system and SCR catalyst enable the achievement of diesel emissions requirements; while maintaining outstanding fuel economy, drivability, torque and power ratings. Refer to “Electronic Vehicle Information Center (EVIC)” in “Understanding Your Instrument Panel” for system messages and warnings. NOTE: The DEF pump will run for a period of time after engine shutdown to purge the DEF system. This is normal operation.


WHAT TO DO IN EMERGENCIES


CONTENTS


䡵 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 92


▫ With Portable Starting Unit


. . . . . . . . . . . . . . 95


92 WHAT TO DO IN EMERGENCIES JUMP STARTING


WARNING!


• To prevent personal injury or damage to clothing, do not allow battery fluid to contact eyes, skin or fabrics. Do not lean over a battery when connect- ing jumper cables or allow cable clamps to touch each other. Keep open flames or sparks away from battery vent holes. Always wear eye protection when working with batteries. • Do not use a booster battery or any other booster source that has a greater than 12 Volt system, i.e., do not use a 24 Volt power source.


NOTE: Replacement batteries should both be of equal size to prevent damage to the vehicle’s charging system.


Your vehicle is equipped with two 12 Volt batteries. If it becomes necessary to use a booster battery with jumper cables to start a vehicle’s engine because its batteries are discharged, the following procedure should be used: Set the parking brake and place an automatic transmis- sion in PARK (or NEUTRAL for a manual transmission). Turn off lights, heater and other electrical loads. Observe charge indicator (if equipped) in both batteries. If the indicator (if equipped) is light or yellow on either battery, replace that battery.


CAUTION!


WARNING!


WHAT TO DO IN EMERGENCIES 93


Use the jump start procedure only when the charge indicator (if equipped) in both batteries is dark in the center. Do not attempt jump starting when either battery charge indicator (if equipped) is bright or yellow. If the charge indicator (if equipped) has a green dot in the center, failure to start is not due to a discharged battery and cranking system should be checked.


1. Attach one jumper cable to the positive terminal of booster battery and the other end of the same cable to the positive terminal of the discharged battery.


Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result.


94 WHAT TO DO IN EMERGENCIES


Attaching Booster Cables


1 — Discharged Battery 2 — Booster Battery 2. Connect one end of the other jumper cable to negative (-) post of booster battery. Connect the other end of the jumper cable to a good ground on the engine block of the


vehicle with the discharged battery. Make sure a good connection is made, free of dirt and grease.


WARNING!


• Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. • During cold weather when temperatures are be- low freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting to jump start.


3. Take care that the clamps from one cable do not inadvertently touch clamps from the other cable. Do not lean over the battery when making connection. The negative connection must provide good electrical con- ductivity and current carrying capacity.


4. After the engine is started or if the engine fails to start, cables must be disconnected in the following order:


a. Disconnect the negative cable at the engine ground. b. Disconnect the negative cable at the negative post on booster battery. c. Disconnect the cable from the positive post of both batteries.


WARNING!


WHAT TO DO IN EMERGENCIES 95


With Portable Starting Unit There are many types of these units available. Follow the manufacturer’s instructions for necessary precautions and operation.


CAUTION!


It is very important that the starting unit operating voltage does not exceed 12 Volts DC or damage to battery, starter motor, alternator, or electrical system may occur.


the battery vent;


Any procedure other than above could result in: • Personal injury caused by electrolyte squirting out • Personal injury or property damage due to battery • Damage to charging system of booster vehicle or


explosion;


of immobilized vehicle.


MAINTAINING YOUR VEHICLE


CONTENTS


䡵 Engine Compartment — 6.7L Diesel . . . . . . . . . 99
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . 100
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 100
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . 104
▫ Draining Fuel/Water Separator Filter . . . . . . 106
▫ Fuel Filter Replacement . . . . . . . . . . . . . . . . 108
▫ Priming If The Engine Has Run Out Of


Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110


▫ Intervention Regeneration Strategy – EVIC


Message Process Flow . . . . . . . . . . . . . . . . . . 111


▫ Diesel Exhaust Fluid – Chassis Cab Only . . . 114
▫ Maintenance-Free Batteries . . . . . . . . . . . . . 114
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 115
▫ Charge Air Cooler – Inter-Cooler . . . . . . . . . 121
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 121
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . 123
▫ Transfer Case – If Equipped . . . . . . . . . . . . . 123
▫ Manual Transmission – If Equipped . . . . . . . 123
▫ Automatic Transmission – If Equipped . . . . . 124


98 MAINTAINING YOUR VEHICLE


▫ Noise Control System Required Maintenance


& Warranty . . . . . . . . . . . . . . . . . . . . . . . . 127
䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . 132
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . 133


▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 135


ENGINE COMPARTMENT — 6.7L DIESEL


MAINTAINING YOUR VEHICLE 99


1 — Battery 2 — Engine Coolant Reservoir 3 — Automatic Transmission Dipstick (If Equipped) 4 — Engine Oil Dipstick 5 — Brake Fluid Reservoir


6 — Washer Fluid Reservoir 7 — Integrated Power Module 8 — Engine Oil Fill 9 — Coolant Pressure Cap 10 — Air Cleaner Filter


100 MAINTAINING YOUR VEHICLE MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides those maintenance items specified in the fixed maintenance schedule, there are other components which may require servicing or replacement in the future.


CAUTION!


• Failure to properly maintain your vehicle or per- form repairs and service when necessary could result in more costly repairs, damage to other components or negatively impact vehicle perfor- mance. Immediately have potential malfunctions examined by an authorized Chrysler Group LLC dealership or qualified repair center.


(Continued)


CAUTION! (Continued)


• Your vehicle has been built with improved fluids that protect the performance and durability of your vehicle and also allow extended maintenance intervals. Do not use chemical flushes in these components as the chemicals can damage your engine, transmission, power steering or air condi- tioning. Such damage is not covered by the New Vehicle Limited Warranty. If a flush is needed because of component malfunction, use only the specified fluid for the flushing procedure.


Engine Oil


Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals. The best time to check the oil level is before starting the engine after it has been


parked overnight. When checking oil after operating the engine, first ensure the engine is at full operating tem- perature, then wait for 30 minutes after engine shutdown to check the oil.


1 — ADD Range 2 — Full Mark 3 — SAFE Range


MAINTAINING YOUR VEHICLE 101
Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Add oil only when the level on the dipstick is below the “ADD” mark. The total capacity from the low mark to the high mark is 2 qts (1.9L).


CAUTION!


Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.


Never operate the engine with oil level below the “ADD” mark or above the upper “SAFE” mark. Change Engine Oil Refer to the “Maintenance Schedule” for the proper maintenance intervals.


102 MAINTAINING YOUR VEHICLE Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API CJ-4 certified and meet the requirements of Chrysler Group LLC. Use MOPAR威 or an equivalent oil meeting Chrysler Material Standard MS-10902. Products meeting Cummins威 CES 20081 may also be used. The identification of these engine oils are typically located on the back of the oil container. American Petroleum Institute (API) Engine Oil Identification Symbol


This symbol means that the oil has been certified by the American Petro- leum Institute (API). The manufac- turer only recommends API Certified engine oils.


Oils with a high ash content may produce damaging deposits on engine valves and/or aftertreatment system damage. A maximum sulfated ash content of 1.00 mass % is recommended for all oil used in the engine. The same oil change interval is to be followed for synthetic oil as for petroleum based oil. Also, synthetic oil must meet the same performance specifications as petro- leum oil.


CAUTION!


Do not use chemical flushes in your engine oil as the chemicals can damage your engine. Such damage is not covered by the New Vehicle Limited Warranty.


Engine Oil Viscosity (SAE Grade) Use SAE 15W-40 MOPAR威 or an equivalent engine oil meeting Chrysler Material Standard MS-10902. Products meeting Cummins CES 20081 may also be used. The identification of these engine oils is typically located on the back of the oil container. In ambient temperatures below 0°F (-18°C), SAE 5W-40
synthetic engine oil that meets Chrysler Materials Stan- dard MS-10902 and the API CJ-4 engine oil category is required.


CAUTION!


Failure to use SAE 5W-40 synthetic engine oil in ambient temperatures below 0°F (-18°C) could result in severe engine damage.


MAINTAINING YOUR VEHICLE 103


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