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CAUTION!
Do not crank engine for more than 15 seconds at a
time or starter motor damage may result. Turn key to
OFF and wait at least 2 minutes for starter to cool
before repeating start procedure.
•The WAIT TO START light will remain on for a period
of time (length of time depends on engine tempera-
ture).
•After the WAIT TO START light goes off, turn the
ignition key to START. Do not press the accelerator
during starting.
•After engine start-up, check to see that there is oil
pressure.
•Allow the engine to idle about three minutes until
the manifold heaters have completed the post-heat
cycle.
•Release the parking brake and drive.
NOTE: Engine idle speed will automatically increase to
1000 rpm at low coolant temperatures to improve engine
warm-up.
NOTE: If the engine stalls or if the ignition switch is left
On for more than 2 minutes after the WAIT TO START
light goes out, reset the grid heaters by turning the
ignition switch to Off for at least 5 seconds and then back
On. Repeat steps 3 through 7 of the normal starting
procedure.
For Extremely Cold Weather Starting — 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
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Starting Fluids
WARNING!
STARTING FLUIDS or flammable liquids are
NEVER TO BE USED in the Cummins Diesel (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.
NORMAL OPERATION (DIESEL ENGINE)
Observe the following when the engine is operating.
•All message center lights are off.
•Check Engine Lamp is off.
•Engine Oil Pressure is above 10 psi (69 kPa) at idle.
•Low Oil Pressure light is off.
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Block Heater Usage
A.Temperatures below 0°F (-18°C)
•Block Heater Required for 15W-40
•Block Heater Recommended for 5W-40
B. Temperatures below - 20°F (-29°C)
•Block Heater Required for 5W-40
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.
Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). 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 dealer.
Arctic Operation
Where there are no provisions to keep the engine warm
when it is operating in ambient temperatures consistently
below (-10°F/-23°C), use 5W-40 syntheticengine oil and
fuel that meets the requirements in Section 7, “Mainte-
nance Procedures,” Engine Oil Selection.
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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.
If temperatures are below 32°F (0°C), operate the engine
at moderate speeds for 5 minutes before full loads are
applied.
Engine Idling — In Cold Weather
Avoid prolonged idling in ambient temperatures below
0°F. 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 and injector nozzles. Also, the
unburned fuel can enter the crankcase, diluting the oil
and causing rapid wear to the engine.
NOTE: An optional driver-controlled high idle speed is
available on automatic transmission equipped vehicles
with speed control. This feature allows the driver to
select an elevated idle speed between 1100 and 1500
rpms. Your dealer can enable this feature.
NOTE:
•If ambient temperatures are low and the coolant
temperature is below 200°F (93°C), the engine idle
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speed will slowly increase to 1000 RPM after 2 minutes
of idle, if the following conditions are met:
•foot is off brake pedal and throttle pedal
•automatic transmission is in Park (P)
•vehicle speed is zero
•Applying the throttle will cancel fast idle
•If the engine is equipped with an aftermarket exhaust
brake (manual transmissions only), operating the ex-
haust brake at idle will greatly improve warm up rate
and will help keep the engine close to operating
temperature during extended idle.
Stopping The Engine
Idle the engine a few minutes before routine shutdown.
After full load operation, idle the engine 3 to 5 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 important for turbo-
charged, charge air cooled engines.
NOTE:
During engine shutdown on vehicles equipped
with manual transmissions, it 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).
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Avoid Low Coolant Temperature Operation
Continual operation at low coolant temperature below
the normal range on the gauge (140°F/60°C) can be
harmful to the engine. Low coolant temperature can
cause incomplete combustion 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:
•City Driving —
when stopped, put transmission in 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 locked.
•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 ............... 10psi(69kPa)
Full speed and load .............. 30psi (207 kPa)
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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
TRANSMISSION SHIFTING
Automatic Transmission with Overdrive— If
Equipped
The gear shift selector display, located in the instrument
panel cluster, indicates the transmission gear range (the
selector is illuminated for night driving). The selector
lever is mounted on the right side of the steering column.
You must depress the brake pedal, to pull the selector
lever out of park (P) position (Brake Interlock System). To
drive, move the selector lever from Park or Neutral to the
desired drive position. Pull the selector lever toward you
when shifting into Reverse, Second, First or Park, or
when shifting out of Park.
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CAUTION!
3500 Dual Rear Tires have only one approved direc-
tion of rotation. This is to accommodate the asym-
metrical design (tread pattern) of the ON/OFF road
tire and the use of Outline White Letter (OWL) tires.
•When replacing a flat, the spare tire may have to
be remounted on the rim or installed at a different
location to maintain the correct placement of the
tire on the wheel relative to the tire/wheel posi-
tion on the truck. For example, if the spare is used
to replace an outer rear tire it will have to be
remounted on the rim so that the wheel is dished
inward. That way the tread design of asymmetri-
cal tires and the white writing of the OWL tires
will maintain proper position.
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. Shut off engine ignition switch.
2. Using a CO
2or 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
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