engine FORD F650 2009 12.G Workshop Manual

pressure on the gearshift lever will help the synchronizer perform its job
more quickly. If the gearshift lever is forced into position, this action
defeats the purpose of the synchronizer by causing gear clash.
Shifting with a non-synchronized transmission
Refer toClutch brakeandDouble clutch proceduresin theClutch
section of this chapter.
Operating the Eaton FS-5205A 5–speed transmission
The 5-speed transmission is
equipped with five forward gears
and one reverse. The 2nd, 3rd, 4th
and 5th gears are synchronized. The
shift pattern is embossed on the
gear shift knob.
Do not shift the transmission into R (Reverse) while the vehicle is
moving as this could damage the transmission.
To go forward
With the engine idling, depress the clutch pedal and shift into 1 (First).
Engage the clutch while pressing the accelerator to start forward.
Operate the clutch and upshift as required by driving conditions.
To go backward
Reverse is obtained by putting the gearshift lever in R (Reverse) and
engaging the clutch while pressing lightly on the accelerator.
Operating the Eaton FS–5406A, FS–5406N, FS–6406A and
FSO–6406A 6-speed transmissions
These 6-speed transmissions are
equipped with six forward gears and
one reverse. All the forward gears
are synchronized. The shift pattern
is embossed on the gear shift knob.
Do not shift the transmission into 1 (First) or R (Reverse) while the
vehicle is moving as this could damage the transmission.
R 2 4
3 5 1
R 1 3 5
4
6 2
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To go forward
With the engine idling, depress the clutch pedal and shift into 1 (First).
Engage the clutch while pressing the accelerator to start forward.
Operate the clutch and upshift as required by driving conditions.
To go backward
Reverse is obtained by putting the gearshift lever in R (Reverse) and
engaging the clutch while pressing lightly on the accelerator.
Operating the Spicer ES56-7B and ES066-7B 7-speed
transmissions
These 7-speed transmissions are
equipped with seven forward gears
and one reverse. The 2nd, 3rd, 4th,
5th, 6th and 7th gears are
synchronized. The shift pattern is
embossed on the gear shift knob.
Do not shift the transmission into 1 (First) or R (Reverse) while the
vehicle is moving as this could damage the transmission.
To go forward
With the engine idling, depress the clutch pedal and shift into 1 (First).
Engage the clutch while pressing the accelerator to start forward.
Operate the clutch and upshift as required by driving conditions.
To go backward
Reverse is obtained by putting the gearshift lever in R (Reverse) and
engaging the clutch while pressing lightly on the accelerator.
POWER TAKE-OFF (PTO) OPERATION (IF EQUIPPED)
Vehicles equipped with an Allison automatic transmission
(except Allison 3000 Series applications and vehicles
equipped with a Caterpillar engine)
The PTO can be operated while the vehicle is standing or moving. To
engage the PTO, apply the brakes and shift to any gear other than N
(Neutral), then engage the PTO.
2 4 6
3 5 71 R
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If engagement is prevented by the gear teeth not meshing properly,
release the brakes and allow the vehicle to creep slightly or shift the
selector to N (Neutral) and then back into gear. The PTO should never
be engaged by clashing the gear teeth as this may damage the PTO unit
and the transmission PTO drive gear teeth. This could result in further
damage to the transmission and PTO.
PTO operation with vehicle stationary
Stop the vehicle, idle the engine and set the parking brake. Make sure
the gear selector is in any forward drive range, then engage the PTO.
After the PTO is engaged, move the range selector to N (Neutral).
Increase the engine speed until the desired power take-off operation
speed is obtained. To disengage the PTO after operation with the vehicle
standing, release the throttle, allow the drive equipment to come to a
stop, and then disengage the PTO.
WARNING:When the PTO is operated with the vehicle
stationary, the transmission must be placed in N (Neutral) with
the parking brake set. If the transmission is not in N (Neutral) and is
equipped with a remote throttle control, an increase in engine speed
can overpower the parking brake and cause the vehicle to move,
possibly resulting in personal injury and/or property damage.
PTO operation while vehicle is moving
After the PTO is engaged for driven vehicle operation, shift to the
desired range and drive the vehicle. The speed of the PTO, during this
period of operation, will always maintain direct relation to vehicle speed.
PTO speed will decrease in relation to vehicle (transmission output)
speed as shifts to a higher gear occur. When operating the PTO while the
vehicle is moving, the PTO may be disengaged whenever it is no longer
required. When there is no load on the PTO gear, it can be pulled out of
engagement.
Vehicles equipped with an Eaton UltraShift transmission
Refer to the operationTransmission Power Take Offsection of the
UltraShift Driver Instructions Manual.
Vehicles equipped with an Allison 3000 Series automatic
transmission
The PTO drive gear is engine-driven and provides direct engine power.
The PTO can be operated when the vehicle is either stationary or
moving.
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The PTO gear is in constant mesh with the drive gear in the torque
converter housing. A friction clutch or constant drive is used to transmit
power to the PTO.
Vehicles equipped with a Caterpillar engine
The PTO will only operate if the transmission is in N (Neutral). This
feature can be overridden by a special service tool; see your dealer or
service representative for more information.
Vehicles equipped with a manual transmission
Transmission-mounted PTO units are available for local installation on
your vehicle. See yourBody Builder’s Layout Bookfor restrictions on
use and installation of PTO units.
To engage the PTO unit, stop the vehicle and place the transmission in N
(Neutral). Depress the clutch and allow the gears to stop rotating, then
engage the PTO unit. The PTO can also be selected with the
transmission in gear as long as the clutch is depressed.
When operating the PTO with the vehicle stationary, first set the parking
brake (chock the wheels if the vehicle is on a hill or another uneven
surface).
REAR AXLE INFORMATION
Axle operating temperature normally will not exceed 100°F (38°C). If
the operating temperature exceeds 230°F (110°C), the rate of axle
lubrication oxidation will increase and shorten the life of the lubricant
and seals, requiring axle lubrication changes to become more frequent to
preserve the axle. Extreme Pressure (EP) lubricants should not be run
consistently above 230°F (110°C).
Gross axle weight
Your truck has gross axle weight, gross vehicle weight and gross
combination weight ratings. Do not exceed these ratings.
WARNING:Exceeding these ratings by overloading can cause
component failure resulting in property damage, personal injury
or death.
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Rear axles with locking or limited-slip differentials (if equipped)
If your vehicle is equipped with a locking or limited-slip differential, note
the following:
•Power will be transmitted to the opposite wheel should one of the
wheels begin to slip.
•Both wheels must be raised off the ground should it be necessary to
operate one wheel with the vehicle stationary.
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
Driver-controlled differential lock
To prevent the vehicle from moving when servicing the wheels, tires or
brakes, turn the engine off and raise all drive wheels of the locker
differential axle. Axles equipped with NoSPIN Detroit Locker differentials
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.
Care should be taken to avoid sudden accelerations when both drive
wheels are on a slippery surface.
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.
Some Dana/Spicer drive axles have a driver-controlled differential lock.
The differential lock can lock or unlock the differential when the vehicle
is moving or stopped. When extra traction is required, the differential
lock will provide full power to both axles.
When the differential is locked, the vehicle’s turning radius will increase
(vehicle will “under-steer”)
The differential can be locked or unlocked when the vehicle is moving at
a constant speed of less than 25 mph (40 km/h) and while the wheels
are not slipping. The differential must not be locked when the vehicle is
traveling down steep grades and traction is minimal.
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WARNING:When operating empty or lightly loaded, sudden or
hard braking may induce wheel lockup with loss of vehicle
control and the possibility of accident and serious injury, especially on
wet or slippery road surfaces.
TRAILER TOWING
Towing a trailer places an additional load on your vehicle’s engine,
transmission, axle, brakes, tires and suspension. Inspect these
components carefully prior to and after any towing operation.
Your vehicle’s load capacity is designated by weight, not by volume, so
you cannot necessarily use all available space when loading a vehicle.
2nd unit bodies are not included in maximum trailer weight ratings. The
weight of the additional “body” must be subtracted from the maximum
trailer weight.
Note:Do not exceed the GVWR or the GAWR specified on the
certification label.
WARNING:Towing trailers beyond the maximum recommended
gross trailer weight exceeds the limit of the vehicle and could
result in engine damage, transmission damage, structural damage, loss
of vehicle control, vehicle rollover and personal injury.
Model Maximum
GVWR - lb.
(kg)Maximum
GCWR - lb.
(kg)*
F-650 Regular/Super/Crew Cab 26000 (11793) 40000 (18143)
F-750 Regular/Super/Crew Cab 30000 (13608) 45000 (20412)
F-750 Regular/Super/Crew Cab 33000 (14969) 60000 (27216)
* Figures shown are the maximum available for each model. Actual
ratings may be less, depending on your transmission. Check with your
sales consultant for the exact rating on your vehicle.
Preparing to tow
Use the proper equipment for towing a trailer and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use hitches that clamp onto the vehicle’s bumper or attach to the
axle. You must distribute the load in your trailer so that 10–15% of the
total weight of the trailer is on the tongue.
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Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to yourScheduled Maintenance Guide
for more information.
Trailer towing tips
•Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
•Allow more distance for stopping with a trailer attached.
•If you are driving down a long or steep hill, shift to a lower gear. Do
not apply the brakes continuously, as they may overheat and become
less effective.
•The trailer tongue weight should be 10–15% of the loaded trailer
weight.
•If you will be towing a trailer frequently in hot weather, hilly
conditions, at GCW, or any combination of these factors, consider
refilling your rear axle with synthetic gear lube if not already so
equipped. Refer toLubricant specificationsin theMaintenance and
Specificationschapter for the lubricant specification. Remember that
regardless of the rear axle lube used, do not tow a trailer for the first
500 miles (800 km) of a new vehicle, and that the first 500 miles
(800 km) of towing be done at no faster than 70 mph (112 km/h) with
no full throttle starts.
•After you have traveled 50 miles (80 km), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•To aid in engine/transmission cooling and A/C efficiency during hot
weather while stopped in traffic, place the gearshift lever in P (Park)
(if available on your automatic transmission) or N (Neutral) (manual
transmissions and automatic transmissions without a P [Park]
position).
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
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Fuse/Relay
LocationFuse Amp
RatingFuse Description
15 10A Interior lamp relay, GEM, Vanity mirrors
16 15A High beams, Indicator
17 — Not used
18 5A Headlamp switch interior lighting
19 15A Engine control
20 5A Starting system
21 10A DRL resistor
22 15A Air horn, Air suspension dump, Two-speed
axle, Driver-controlled locking differential
23 10A Flasher
24 15A ABS, Air dryer, Vacuum pump, Fuel heater
relay
25 10A Function selector switch
26 10A RH low beam headlamp
27 — Not used
28 10A LH low beam headlamp
29 10A Cluster warning lamps, Gauges, GEM,
Hydraulic ABS
30 15A Allison electronic transmission
31 — Not used
Relay 1 — Interior lamps
Relay 2 — Not used
Relay 3 — Horn
Relay 4 — One-touch down window
Relay 5 — Not used
Power distribution box
WARNING:Always disconnect the battery before servicing high
current fuses.
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WARNING:To reduce risk of electrical shock, always replace
the cover to the Power Distribution Box before reconnecting the
battery or refilling fluid reservoirs.
Fuse/Relay
LocationFuse Amp
RatingFuse Description
1 15A* Main light switch
2 30A* Power seat (driver)
3 30A* Power seat (passenger)
4 15A* Washer pump relay, Washer pump motor
5 5A* Full power brake switch
6 15A* Air intake heater (Caterpillar engine only)
7 15A* Stoplamp switches (Air brake vehicles only)
8 25A* Fuel heater relay (Caterpillar
engine-equipped vehicles with dual fuel tanks
only)
9 20A* Inhibit relay, Engine ECM, Cluster,
Transmission TCM
10 15A* Heated drain valve
11 30A* Electric trailer brake
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Fuse/Relay
LocationFuse Amp
RatingFuse Description
12 20A* Daytime Running Lamps (DRL), Blend door
actuator, Climate mode, Back-up, Heated
seats, Trailer ABS, Exhaust brake
13 10A* Park brake switch
14 — Not used
15 7.5A* Body builder - trailer adapter stoplamps
16 5A* Bendix Air ABS (Air brake vehicles only)
WABCO ABS (Hydraulic brake vehicles only)
17 — Not used
18 10A* Fuel transfer pump (duel fuel tanks only)
19 — Not used
20 — Not used
21 — Not used
22 — Not used
23 — Not used
24 — Not used
101 30A** Bendix Air ABS relay (Air brake vehicles
only)
WABCO ABS modulator relay (Hydraulic
brake vehicles only)
102 20A** Ignition switch to customer access
103 20A** Ignition switch (Junction box fuses 8, 9, 10,
11, 19, 29 and 30)
104 20A** Power point
105 20A** Power door locks
106 30A** Main light switch, Multifunction switch, CJB
fuses 16, 26 and 28, Headlamps, DRL relays
107 50A** Junction box fuses 1, 2, 3, 4, 12, 13, 14 and
15
108 40A** Fuel heater relay (Cummins engine only)
109 40A** Power window relay
110 30A** Wiper power relay (Park, Low/High speed)
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