•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.
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 system
could result from using an improper fuel tank filler
tube cap. A poorly fitting cap could let impurities 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 maintenance 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 the fuel filtration system 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.
5
STARTING AND OPERATING 163
4. Reinstall cap onto DEF tank.
Filling The Def Tank In Cold Climates
Since DEF will begin to freeze at 12°F (-11°C), your vehicle
is equipped with an automatic DEF heating system. This
allows the DEF injection system to operate properly at
temperatures below 12°F (-11°C). If your vehicle is not in
operation for an extended period of time with tempera-
tures below 12°F (-11°C), the DEF in the tank may freeze. If
the tank is overfilled and freezes, it could be damaged.
Therefore, do not overfill the DEF tank.
The DEF tank on these vehicles is designed with a large
amount of full reserve. So the level sensor will indicate a
Full reading even before the tank is completely full. To put
it another way, there’s additional storage capacity in the
tank above the Full mark that’s not represented in the
gauge. You may not see any movement in the reading –
even after driving up to 2,000 miles in some cases.
The difference this makes varies by vehicle. Heavy-duty
pickup trucks have a 5.7-gallon (21.5 liter) tank that will
display a Full reading when about 90 percent full. This
means that drivers can consume at least 10 percent of a
truly full DEF tank without seeing any visible change in the
gauge reading. Chassis cabs have a larger 9-gallon (34 liter)
tank, and will display a Full reading when about 75 percentfull. So drivers can consume 25 percent of a truly full DEF
tank without seeing any visible change in the gauge
reading.
Extra care should be taken when filling with portable
containers to avoid overfilling. Note the level of the DEF
gauge in your instrument cluster. On pickup applications,
you may safely add a maximum of 2 gallons (7.5 liters) of
DEF from portable containers when your DEF gauge is
reading ½ full. On Chassis Cab applications a maximum of
2 gallons (7.5 liters) may be added when the DEF gauge is
reading ¾ full.
DIESEL EXHAUST FLUID
Your vehicle is equipped with a Selective Catalytic Reduc-
tion system to meet the very stringent diesel emissions
standards required by the Environmental Protection
Agency.
The purpose of the SCR system is to reduce levels of NOx
(oxides of nitrogen emitted from engines) that are harmful
to our health and the environment to a near-zero level.
Small quantities of Diesel Exhaust Fluid (DEF) is injected
into the exhaust upstream of a catalyst where, when
vaporized, it converts smog-forming nitrogen oxides
(NOx) into harmless nitrogen (N2) and water vapor (H2O),
5
STARTING AND OPERATING 167
Engine Air Cleaner Filter
CAUTION!
All air entering the engine intake must be filtered. The
abrasive particles in unfiltered air will cause rapid
wear to engine components.
WARNING!
The air induction system (air cleaner, hoses, etc.) pro-
vides a measure of protection. Do not remove the air
induction system (air cleaner, hoses, etc.) unless such
removal is necessary for repair or maintenance. Make
sure that no one is near the engine compartment before
starting the vehicle with the air induction system (air
cleaner, hoses, etc.) removed. Failure to do so can result
in serious personal injury.
The condition of the air cleaner filter is monitored by the
Engine Control Module. The “SERVICE AIR FILTER”
message will display in the instrument cluster when ser-
vice is required. Refer to “Instrument Cluster Display” in
“Understanding Your Instrument Panel” for further infor-
mation. The “SERVICE AIR FILTER” message could be displayed
periodically. This is because engine air flow requirements
change based on driving conditions. As the filter becomes
more restrictive and air flow requirements increase the
“SERVICE AIR FILTER” message will be displayed. The
message may not be displayed in subsequent drive cycles
if the same conditions are not met. The air filter element
should be replaced within 250 miles (402 km) from the first
time this message is displayed to ensure proper engine
operation during all driving conditions.
CAUTION!
Driving with a restricted air filter can cause engine
damage. Driving in dusty environments for extended
periods will lead to rapid air filter plugging. Action
should be taken as soon as the “SERVICE AIR FIL-
TER” message is displayed.
180 MAINTAINING YOUR VEHICLE
•A maximum blend of 20% biodiesel, meeting ASTM
specification D-7467 may be used with your Cummins
diesel engine. (Pickup models and Chassis Cab models
configured with B20 capability.)
• Use of biodiesel mixture in excess of 20% can negatively
impact the fuel filter’s ability to separate water from the
fuel, resulting in high pressure fuel system corrosion or
damage.
• Ethanol blends are not recommended or approved for
use with your Cummins diesel engine.
• In addition, commercially available fuel additives are
not necessary for the proper operation of your Cummins
diesel engine.
Intervention Regeneration Strategy — Message
Process Flow
The Cummins diesel engine meets all EPA Heavy Duty
Diesel Engine Emissions Standards, resulting in one of the
lowest emitting diesel engines ever produced.
To achieve these emissions standards, your vehicle is
equipped with a state-of-the-art engine and exhaust sys-
tem. The engine and exhaust after-treatment system work
together to achieve the EPA Heavy Duty Diesel Engine Emissions Standards. These systems are seamlessly inte-
grated into your vehicle and managed by the Cummins
Powertrain Control Module (PCM). The PCM manages
engine combustion to allow the exhaust system’s catalyst
to trap and burn Particulate Matter (PM) pollutants, with
no input or interaction on your part.
If the engine is allowed to idle or the truck is driven on low
engine speed drive cycles for more than 2 hours, the
system will automatically enter an emissions operating
mode that will increase the engine idle speed to 900 RPM
(1050 RPM for Chassis Cab). While in this mode, which is
designed to help maintain the diesel particulate filter, the
engine idle speed will return to normal when the brake
pedal is applied. A small change in engine tone or a slight
change in engine performance while accelerating may also
be noticeable at speeds below 20 mph (32 kmh). This
operating mode may last for up to an hour of idle time, or
around 20 minutes of driving time.
Additionally, your vehicle has the ability to alert you to
additional maintenance required on your truck or engine.
Refer to “Instrument Cluster Display” in “Understanding
Your Instrument Panel” for further information.
7
MAINTAINING YOUR VEHICLE 189
MAINTENANCE SCHEDULE — DIESEL ENGINE
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop For Fuel
Check the engine oil level at least 30 minutes after a fully
warmed engine is shut off. Checking the oil level while the
vehicle is on level ground will improve the accuracy of the
oil level reading. Add oil only when the level is at or below
the ADD or MIN mark.
Once A Month
• Inspect the batteries, and clean and tighten the terminals
as required.
• Check the fluid levels of the coolant reservoir, brake
master cylinder, and automatic transmission (if
equipped), and add as needed.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect engine air filter. •
Check the coolant level, hoses, and clamps.
• Lubricate outer tie rod ends.
Inspection and service should also be performed anytime a
malfunction is observed or suspected. Retain all receipts.
Oil Change Indicator System — Cummins Diesel
Your vehicle is equipped with an engine oil change indi-
cator system. This system will alert you when it is time to
change your engine oil by displaying the words “Oil
Change Due” in your instrument cluster display. The oil
change reminder will remind the owner to change the
engine oil every 15,000 miles or 500 hours, whichever
comes first, except for the Chassis Cab models and Pickup
models configured with optional B20 capability that are
using B20 biodiesel, which are 12,500 miles or 400 hours,
whichever comes first. Failure to change the engine oil per
the maintenance schedule can result in internal engine
damage.
Your authorized dealer will reset the oil change indicator
message after completing the scheduled oil change. If a
scheduled oil change is performed by someone other than
your authorized dealer, the message can be reset by
210 MAINTENANCE SCHEDULE
Maintenance Chart — Cummins Diesel Engine
Mileage or time passed (which-ever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Change engine oil every 15,000
miles (24 000 km) or six months or
500 Hours or sooner if prompted by
the oil change indicator system,
whichever comes first. ** XXXXXXXXXXXXXXXXX X XX
Additional Inspections
Check the Diesel Exhaust Fluid
(DEF) tank, refill if necessary. XXXXXXXXXXXXXXXXX X XX
Rotate the tires. X X X X X X X X X X X X X X X X X X X X
Lubricate front drive shaft fitting
(4x4). XXXXXXXXXXXXXXXXX X XX
Lubricate outer tie rod ends. X X X X X X X X X X X X X X X X X X X X
Inspect engine air filter, replace if
necessary. **** XX XX XX XX X X
212 MAINTENANCE SCHEDULE
Mileage or time passed (which-ever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Replace chassis mounted fuel filter
element. XX XX XX XX X X
Inspect the front and rear axle
surfaces. If gear oil leakage is
suspected, check the fluid level. If
using your vehicle for police, taxi,
fleet, off-road or frequent trailer
towing change the axle fluid. *
Inspect the transfer case fluid (4x4),
change for any of the following:
police, taxi, fleet, or frequent trailer
towing. XXXX X
Change the transfer case fluid (4x4).XX
Change automatic transmission
fluid (AS69RC transmission only). XXXX X
Change the automatic transmission
fluid and sump filter (AS69RC
transmission only). XX
214 MAINTENANCE SCHEDULE
Mileage or time passed (which-ever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Change automatic transmission
fluid and filter(s) if using your
vehicle for any of the following:
police, fleet, or frequent trailer
towing (68RFE transmission only). XX
Change automatic transmission
fluid and filter(s). X
Change the manual transmission
fluid if using your vehicle for any of
the following: police, fleet, or
frequent trailer towing. XX
Replace Crankcase Ventilation
Filter (CCV). XX
Flush and replace power steering
fluid. X
Flush and replace engine coolant.
*** X
Adjust valve lash clearance. X
8
MAINTENANCE SCHEDULE 215