maintenance Ram 5500 Chassis Cab 2012 Diesel Supplement

TABLE OF CONTENTSSECTIONPAGE
1INTRODUCTION............................................................3
2THINGS TO KNOW BEFORE STARTING YOUR VEHICLE..............................7
3UNDERSTANDING YOUR INSTRUMENT PANEL................................... 13
4STARTING AND OPERATING.................................................31
5WHAT TO DO IN EMERGENCIES.............................................. 91
6MAINTAINING YOUR VEHICLE...............................................97
7MAINTENANCE SCHEDULES.................................................137
8INDEX...................................................................163
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A MESSAGE FROM CHRYSLER GROUP LLC
Chrysler Group LLC and Cumminswelcome you as a
Cummins turbocharged diesel-powered truck owner.
Your diesel truck will sound, feel, drive, and operate
differently from a gasoline-powered truck. It is important
that you read and understand this manual.
Almost 100% of the heavy duty trucks in the United
States and Canada are diesel-powered because of the fuel
economy, rugged durability, and high torque which per-
mits pulling heavy loads. Cummins engines power well
over half of these trucks. Now this same technology and
proven performance is yours in your truck equipped
with the Cummins turbocharged diesel engine.
You may find that some of the starting, operating, and
maintenance procedures are different. However, they are
simple to follow and careful adherence to them will
ensure that you take full advantage of the features of this
engine. NOTE:
Some aftermarket products may cause severe
engine/transmission and/or exhaust system damage.
Your vehicle’s Powertrain Control Systems can detect
and store information about vehicle modifications that
increase horsepower and torque output such as whether
or not performance-enhancing powertrain components,
commonly referred to as downloaders, power boxes, or
performance chips have been used.
This information cannot be erased and will stay in the
system’s memory even if the modification is removed.
This information can be retrieved by Chrysler Group
LLC, and service and repair facilities, when servicing
your vehicle. This information may be used to determine
if repair will be covered by New Vehicle Limited War-
ranty.
4 INTRODUCTION

As an added safety feature, your vehicle has been
equipped with a Tire Pressure Monitoring System
(TPMS) that illuminates a low tire pressure telltale when
one or more of your tires is significantly under-inflated.
Accordingly, when the low tire pressure telltale illumi-
nates, you should stop and check your tires as soon as
possible, and inflate them to the proper pressure. Driving
on a significantly under-inflated tire causes the tire to
overheat and can lead to tire failure. Under-inflation also
reduces fuel efficiency and tire tread life, and may affect
the vehicle’s handling and stopping ability.
Please note that the TPMS is not a substitute for proper
tire maintenance, and it is the driver ’s responsibility to
maintain correct tire pressure, even if under-inflation has
not reached the level to trigger illumination of the TPMS
low tire pressure telltale.Your vehicle has also been equipped with a TPMS
malfunction indicator to indicate when the system is not
operating properly. The TPMS malfunction indicator is
combined with the low tire pressure telltale. When the
system detects a malfunction, the telltale will flash for
approximately one minute and then remain continuously
illuminated. This sequence will continue upon subse-
quent vehicle start-ups as long as the malfunction exists.
When the malfunction indicator is illuminated, the sys-
tem may not be able to detect or signal low tire pressure
as intended. TPMS malfunctions may occur for a variety
of reasons, including the installation of replacement or
alternate tires or wheels on the vehicle that prevent the
TPMS from functioning properly. Always check the
TPMS malfunction telltale after replacing one or more
tires or wheels on your vehicle, to ensure that the
replacement or alternate tires and wheels allow the TPMS
to continue to function properly.
22 UNDERSTANDING YOUR INSTRUMENT PANEL

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.
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.
5. When the engine starts, release the key fob.
6. Check to see that there is oil pressure.
7. Release the parking brake.
36 STARTING AND OPERATING

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.
2. After the “Wait To Start Light” goes off, turn the
ignition switch to the START position. Do not press the
accelerator during starting.
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STARTING AND OPERATING 37

•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 Cumminsdiesel 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. 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.
40 STARTING AND OPERATING

*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.
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 dealer.
42 STARTING AND OPERATING

•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.
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.NOTE:
For EVIC messages related to the vehicle’s
exhaust system, refer to “Maintenance Procedures/
Intervention Regeneration Strategy – EVIC Message Pro-
cess Flow” in “Maintaining Your Vehicle” for further
information.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.
44 STARTING AND OPERATING

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.
Fuel Filler Cap
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.
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
84 STARTING AND OPERATING

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
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STARTING AND OPERATING 85