Ford F650 Owners Manual
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9. Start your vehicle. Perform Steps 4 through 8 in reverse order, making sure to engage the hinge pivots between the upper and lower halves of the shroud. Keep slight pressure in the forward direction as you rotate the halves together. If Your Vehicle Gets Stuck In Mud or Snow Note: Do not rock your vehicle if the engine is not at normal operating temperature or damage to the transmission may occur. Note: Do not rock your vehicle for more than a minute or damage to the transmission and tires may occur, or the engine may overheat. If your vehicle is stuck in mud or snow, you may rock it out by shifting between forward and reverse gears, stopping between shifts in a steady pattern. Press lightly on the accelerator in each gear. POWER TAKE-OFF Auxiliary equipment called power take-off, or PTO, is often added to the engine or transmission to operate utility equipment. Examples include a wheel-lift for tow trucks, cranes, tools for construction or tire service and pumping fluids. PTO applications draw auxiliary horsepower from the powertrain, often while the vehicle is stationary or mobile. In the stationary condition, there is limited cooling air flow through the radiator and around the vehicle that normally occurs when a vehicle is moving. The aftermarket PTO system installer, having the most knowledge of the final application, is responsible for determining whether additional chassis heat protection or powertrain cooling is required and alerting the user to the safe and proper operation. Your vehicle is approved for use as a Stationary Mode, SplitShaft Mode or Mobile Mode power source within the limits and operating guidelines detailed in the Ford Truck Body Builders Layout Book, found at www.fleet.ford.com/truckbbas.com and through the Ford Truck Body Builders Advisory Service. The transmission power source modes are engine specific. 118 F650750 (TBC) , enUSA, Edition date: 201708, First Printing TransmissionE163186
GENERAL INFORMATION WARNING Exceeding these ratings by overloading can cause component failure resulting in property damage, personal injury or death. Fluid Temperature If the operating temperature exceeds 250°F (121°C), the rate of axle lubrication oxidation increases and shortens the life of the lubricant and seals, requiring axle lubrication changes to become more frequent to preserve the axle. Do not consistently run extreme pressure (EP) lubricants above 250°F (121°C). Axle Conversions WARNING When operating a loaded vehicle, the driver must keep all adjustable axles on the ground at all times, supporting their share of the vehicle ’s load. Failure to do so can overload other axles, tires, wheels, springs, steering components, brakes and frames, resulting in early component failure, loss of vehicle control, possible property damage and personal injury. We do not recommend, or approve, performing axle conversions. However, we understand that, on occasion, others install aftermarket add-on axles on the truck chassis that allow operator control for weight transfer from other axles (such as air lift axles). LIMITED SLIP DIFFERENTIAL (If Equipped) WARNING If both wheels are not raised off the ground, the one wheel that is not raised may pull the vehicle off its support, possibly resulting in personal injury. This axle provides added traction on slippery surfaces, particularly when one wheel is on a poor traction surface. Under normal conditions, the limited-slip axle functions like a standard rear axle. The axle may exhibit a slight noise or vibration during tight turns with low vehicle speed. This is normal behavior and indicates the axle is working. Both wheels must be raised off the ground should it be necessary to operate one wheel with your vehicle stationary. ELECTRONIC LOCKING DIFFERENTIAL (If Equipped) Driver-Controlled Locking Differential Note: Never use the differential lock at vehicle speeds above 25 mph (40 km/h). Some drive axles have a driver-controlled differential lock. The differential lock can lock or unlock the differential when your vehicle is moving or stopped. When extra traction is required, the differential lock provides full power to both wheels. When you lock the differential, your vehicle ’s turning radius increases (under-steer). Take care to avoid sudden accelerations when both drive wheels are on a slippery surface. 119 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Rear Axle
WARNING Sudden accelerations on slippery surfaces could cause the wheels to spin, the vehicle to turn sideways on a crowned road surface or in a turn, possibly resulting in loss of vehicle control and personal injury. Activating the Locking Differential You can lock and unlock the differential when your vehicle is moving at a constant speed of less than 25 mph (40 km/h) and while the wheels are not slipping. Do not lock the differential when your vehicle is traveling down steep grades and when traction is minimal. The differential lock and differential lock light automatically disengage at speeds above 25 mph (40 km/h). The differential lock remains off until either you restart your vehicle or you turn the differential lock switch off then back on. Servicing a Vehicle with a Locking Differential Turn the engine off and raise all drive wheels of the locker differential axle in order to prevent your vehicle from moving when servicing the wheels, tires or brakes. Axles equipped with a driver-controlled differential deliver power to both wheels even when only one wheel is on the ground. WARNING Failure to raise all drive wheels with this type of differential could cause the vehicle to move unexpectedly, resulting in property damage, personal injury or death. 2-SPEED REAR AXLE (If Equipped) WARNING Never shift a two-speed axle when descending a steep grade as this may cause loss of vehicle control and result in personal injury. Note: Do not shift between ranges when the speed control is on. A two-speed rear axle allows the driver to select a low range for greater pulling power and a high range for greater road speed and fuel economy. You can also use these ranges to provide extra steps between transmission shifts when driving on steep grades or fuel economy may be factors. Axle Shifting Note: Do not shift the axle to LOW when your vehicle is moving. Use LOW when you drive a fully loaded vehicle on a severe grade or in congested traffic. Use HIGH for all normal driving conditions with a lightly loaded or partially loaded vehicle. Note: The axle is set to HIGH by default. To shift the axle between HIGH and LOW with the vehicle stopped, place the transmission in position N, then press and hold the button for two seconds. 120 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Rear AxleE208228
GENERAL INFORMATION WARNINGS Do not drive with your foot resting on the brake pedal. This results in abnormally high brake temperatures, excessive lining wear and increased stopping distance. Continuous application of the brakes causes the brakes to overheat, resulting in temporary loss of braking. Note: Occasional brake noise is normal. If a metal-to-metal, continuous grinding or continuous squeal sound is present, the brake linings may be worn-out. Have the system checked by an authorized dealer. If your vehicle has continuous vibration or shudder in the steering wheel while braking, have it checked by an authorized dealer. All standard equipment brakes are self-adjusting. Automatic adjustment, when required, occurs whenever you apply and release the brakes during forward or reverse operation. Know the required stopping distances for all driving conditions you may encounter. For longer brake lining life, take full advantage of engine braking power when coming to a stop. See Warning Lamps and Indicators (page 60). Wet brakes result in reduced braking efficiency. Gently press the brake pedal a few times when driving from a car wash or standing water to dry the brakes. If brakes do not grip well: • Check brake adjustment. • Check brake linings for excessive wear. • Check system air pressure on vehicle equipped with air brakes. • Let the brakes cool if you have been using them excessively, as in mountain driving or after several fast, high-speed stops. • If you have been driving through deep water, gently apply the brakes several times while your vehicle is moving slowly. Brake Over Accelerator In the event the accelerator pedal becomes stuck or entrapped, apply steady and firm pressure to the brake pedal to slow the vehicle and reduce engine power. If you experience this condition, apply the brakes and bring your vehicle to a safe stop. Move the transmission to park (P), switch the engine off and apply the parking brake. Inspect the accelerator pedal for any interference. If none are found and the condition persists, have your vehicle towed to the nearest authorized dealer Anti-lock Brake System This system helps you maintain steering control during emergency stops by keeping the brakes from locking. This lamp momentarily illuminates when you turn the ignition on. If the light does not illuminate during start up, remains on or flashes, the system may be disabled. Have the system checked by an authorized dealer. If the system is disabled, normal braking is still effective. If the brake warning lamp illuminates when you release the parking brake, have the system checked by an authorized dealer. 121 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE209041 E209041
If you connect a PLC trailer with the ignition on, the trailer ABS light also illuminates. If the light fails to illuminate, if it remains on after you start the vehicle or continues to flash, have the system serviced immediately. HINTS ON DRIVING WITH ANTI-LOCK BRAKES The anti-lock braking system does not eliminate the risks when: • You drive too closely to the vehicle in front of you. • Your vehicle is hydroplaning. • You take corners too fast. • The road surface is poor. Note: If the system activates, the brake pedal may pulse and may travel further. Maintain pressure on the brake pedal. You may also hear a noise from the system. This is normal. PARKING BRAKE Hydraulic Brakes (If Equipped) WARNINGS Always set the parking brake and leave your vehicle with the transmission in park (P). This control is for parking only. Do not leave the vehicle unattended after setting the parking brake without placing the transmission in park (P). We recommend using wheel chocks for hilly or off-road circumstances. Unexpected and possibly sudden vehicle movement may occur if you do not take these precautions. WARNINGS If the parking brake is fully released, but the brake warning lamp remains illuminated, the brakes may not be working properly. Have your vehicle checked as soon as possible. Apply the parking brake whenever the vehicle is parked. To set the parking brake, pull the handle up until it snaps into the locked position. When the parking brake is out of adjustment, seek service immediately. The parking brake warning lamp in the instrument cluster illuminates, and remains illuminated (when you switch on the ignition), until you release the parking brake. Push the palm release lever (A) on the parking brake handle (B) and push down as far as possible to release the brake. Driving with the parking brake on causes the brakes to wear out quickly and reduces fuel economy. We recommend you not use the parking brake to stop a moving vehicle. However, if the normal brakes fail, you can use the parking brake to stop your vehicle in an emergency. Since the parking brake only applies retardation to the rear wheels, the vehicle's stopping distance increases greatly and the handling of your vehicle is adversely affected. 122 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE210335 E208810 E210347
Releasing Spring Manually WARNINGS Do not attempt to disassemble the parking brake air chamber under any circumstances as this may cause serious injury. Block the wheels to help prevent the vehicle from moving. Unexpected and possibly sudden vehicle movement may occur if you do not take these precautions. If you release hydraulic pressure from the spring brake chamber, the power spring applies the brake. If the hydraulic pressure can be re-established, you must release the spring brake in order to move your vehicle. Air Brakes (If Equipped) WARNING This control is for parking only. Do not leave the vehicle unattended after setting the parking brake without placing the transmission in park (P). We recommend using wheel chocks for hilly or off-road circumstances. If the service brakes fail to operate while your vehicle is moving, you can make an emergency stop with the parking brake. Since the parking brake only applies stopping power to the rear wheels, your vehicle ’s stopping distance greatly increases and the handling of your vehicle is adversely affected. Make repairs immediately to an inoperative air brake system circuit. Pull the yellow, dash-mounted parking brake knob to apply the parking brake. The parking brake light illuminates and remains illuminated (when you switch the ignition to the on position) until you release the parking brake. Releasing the Parking Brake WARNING When your vehicle is stationary, keep the brake pedal fully pressed when shifting gears. Failure to follow this instruction could result in personal injury, death or property damage. Note: Read and understand the following steps and perform them whenever you prepare to drive the vehicle. Note: The parking brake does not disengage unless sufficient system air pressure is available. 1. Press and hold the service brake pedal while the engine is running. 2. Select the appropriate drive gear. 3. Push and hold the yellow dash-mounted parking brake knob until the parking brake light turns off, then release. 123 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE210341 E208810
Parking Brake Light Illumination Due to Low Air Pressure If the air pressure becomes too low at any time during vehicle operation, the parking brake may apply and the parking brake light turns on. If the parking brake applies due to low air pressure, immediate service is required to the parking brake system. Releasing Spring Brake with Air Pressure The air system in all vehicles with spring-actuated rear wheel parking brakes has a valve on the governor for connection to an outside air supply. The valve lets you recharge the system with air from an outside source, releasing the spring-actuated parking brakes. Your vehicle is now ready to tow in an emergency. You can only use an outside air source if the protected system is in operating condition. If you cannot restore air pressure in the protected air system, you must release the spring-actuated brakes manually. Releasing Spring Manually Do not use impact wrenches as they may damage the piston and prevent proper caging of the spring. Do not apply more than 50 lb.ft (68 Nm) to the release bolt nut. 1. Remove the stud tool and nut from the carrying pocket on the brake chamber assembly. 2. Remove the access plug from the end of the spring chamber. 3. Insert the release stud through the opening in the chamber and into the spring pressure plate. 4. Turn the release stud ¼ turn to engage the stud tangs with the slot in the pressure plate. Keep the stud engaged and install the nut on the release stud. 5. Tighten the nut until the spring is fully caged and brakes released. Do not loosen or remove the release stud and nut unless you completely assemble and securely clamp the brake chamber. 6. After restoring the air pressure, unscrew and remove the release stud and install in the carrying pocket. Install the access plug. 124 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE210365 E210366
AIR BRAKES (If Equipped) WARNINGS Do not drive or continue to drive if the low air pressure buzzer is sounding or the brake warning light is lit. These warnings indicate that air pressure is not to normal operating level. Continued use of the vehicle could result in loss of braking ability. Avoid repeated light application of the brake pedal. This depletes air pressure faster and could result in loss of braking capability. Do not move the vehicle when the air pressure is insufficient because the brake system may be inoperative. After starting the engine, give the air compressor time to build up the air pressure to 60 psi (414 kPa) before moving your vehicle. Periodically check the air pressure gauge while driving. Pressure should range between approximately 100 psi (690 kPa) to 130 psi (896 kPa). The air compressor governor cut-in and cutout pressure settings are set at the factory and are not adjustable. When air pressure is insufficient (below 60 psi (414 kPa)), a warning light illuminates and a buzzer sounds when the ignition is in the on position. This may happen because excessive brake applications are depleting the system air pressure. If this condition occurs, stop driving your vehicle until the compressor has fully recharged the air system. Select a gear ratio to help slow your vehicle before descending grades. Supplementing with brakes, as required, help to safely slow the vehicle and avoids overspeeding the engine. Air Chamber Stroke Indication Air chamber push rods have orange stroke indicator markers that warn when the braking system requires adjustment or repair. The painted orange indicator is on the air chamber push rod at the slack adjuster stroke dimension that requires service when visible during brake application. A qualified service technician should perform air brake inspection and adjustment or repairs keeping to the instructions in the service manual. Cam Brakes - Automatic Slack Adjusters WARNING Do not manually adjust the automatic slack adjusters to correct excessive push rod stroke as it may result in reduced brake effectiveness and a vehicle crash. Excessive push rod stroke indicates that a problem exists with the automatic adjuster, with the installation of the adjuster, or with foundation brake components that manual adjustment does not remedy. Seek service from a qualified facility for excessive push rod stroke. 125 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE210336 E206772
Standard air brakes (cam) are equipped with automatic brake adjusters. Automatic adjustment occurs during brake applications. Inspect brakes for proper adjustment at the specified intervals. See Scheduled Maintenance (page 320). Emergency Air Brake WARNING Do not continue to operate the vehicle with a failure of one of the brake systems. Take the vehicle to your dealer for service immediately. All vehicles are equipped with a dual brake system. In the unlikely event of a failure of one system, the second system functions for emergency stopping. The brake pedal controls all these systems in the same manner as for normal stops. EXHAUST BRAKE (If Equipped) WARNINGS Do not use tow/haul when the road surface is slippery. Failure to follow this instruction could result in the loss of control of your vehicle. WARNINGS Do not use diesel engine exhaust braking when the road surface is slippery. Failure to follow this instruction could result in the loss of control of your vehicle. Note: Installing an exhaust or auxiliary brake does not necessarily protect the engine from exceeding the maximum governed speed. Use the primary brakes to make sure the engine never exceeds the maximum governed speed under any circumstance. Note: Before starting the engine, make sure that the exhaust brake is off. Do not switch the exhaust brake on until the engine has reached normal operating temperature. Note: Maximum exhaust brake performance relates to the type of transmission your vehicle has. Note: Engine speed has a major influence on limiting performance. When engine speed stays at the maximum allowable level, the exhaust brake operates at peak performance. Note: Exhaust brakes operate effectively with automatic transmissions. However, performance varies with engine speed and the gear selected by the transmission. An exhaust brake is an auxiliary braking system that assists, but does not replace, the primary brake system. It helps control vehicle speed. It is not a vehicle-stopping device. Use the button on the instrument panel, in combination with the accelerator and clutch pedals, to maximize the use of the exhaust brake in the following conditions: • Off-highway driving. • Mountain driving. • Heavy traffic. • High-speed highway driving. 126 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE210337
To switch the exhaust brake on, press the button. A light on the instrument cluster indicates the system is on. Press the button again to switch it off. While approaching a steep grade, make sure that the exhaust brake switch is on. The exhaust brake begins working as soon as you remove your foot from the accelerator pedal. Before descending a hill or steep grade, always select the proper gear. If you take the transmission out of gear while descending, you may not be able to select another gear because of maximum governed RPM. Make sure the engine speed does not exceed the maximum allowable engine RPM. Exceeding the maximum allowable engine RPM can result in damage to the engine. Apply the service brakes to reduce the engine RPM or make a slower descent by using a lower gear. While driving down a grade, use a low enough gear to descend safely with a minimum application of the service brakes. As a general guideline, use the same gear as you use to ascend the hill. Exhaust Brake Operating Characteristics The exhaust brake switches on when you remove your feet from both the accelerator and clutch pedals and the exhaust brake is on. If the brake is working properly, there will be: • A slight change in engine sound when the exhaust brake turns on. • A smooth braking effect. Do not expect a retarding effect similar to sudden, hard application of the service brakes. • A retarding force possibly felt acting against your body during brake application (depending on the grade and vehicle load). This force prevents the vehicle from going much faster. • Engine temperatures remaining in the normal operating range. • A drop in engine RPM (depending on grade and vehicle load) during a descent. • A decrease in road speed when applying the exhaust brake during a descent, except when your vehicle is carrying a heavy load or the grade is extremely steep. In these instances, you may need to apply the service brakes occasionally. 127 F650750 (TBC) , enUSA, Edition date: 201708, First Printing BrakesE215226