display FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

WARNING LIGHTS
Base cluster with standard measure shown; metric and optional
similar
Note:Some warning lights are reconfigurable telltale (RTT) indicator
lights and will illuminate in the message center display and function the
same as the other warning lights.
Glow plug pre-heat indicator:
With the key in the on position, this
light will illuminate if glow plug heat
is necessary as a starting aid. Wait until the light goes off before starting.
Refer toCold weather startingin theDrivingchapter of this
supplement. After the engine starts, the light should turn off. The light
should always illuminate at least momentarily when the engine is cold
and the ignition is turned to on.
04CHCHEF
RPMx1000
0204
060801001
2
01
4
0160
km/hMPH
Instrument Cluster
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ENGINE IDLE SHUTDOWN (IF EQUIPPED)
Your vehicle may be equipped with an engine idle shutdown system. This
system will automatically shut down your engine when it has been idling
in P (Park) or N (Neutral) for five minutes (parking brake set) or
15 minutes (parking brake not set). When the engine idle shutdown
process has started:
•A chime will sound and the message center will displayENGINE
TURNS OFF IN 30(seconds) and start counting down.
•The 5 or 15 minute timer can be restarted by changing the position of
the accelerator pedal, brake pedal or the park brake within the final
30 seconds.
•When the timer reaches zero, the engine shuts down and the message
center will displayENGINE TURNED OFF.
•One minute after the engine has shut down, the electrical system will
simulate key off, even though the ignition is still in the on position,
initiating normal accessory delay period.
•The ignition must be moved to the off position to reset the system
before restarting the vehicle.
Note:The engine idle shutdown idle timer will not start if:
•The engine is operating in power take-off (PTO) mode.
•The engine coolant temperature is below 60°F (16°C).
•The exhaust emission control device (DPF) is regenerating.
STOPPING THE ENGINE
Turn the ignition to the off position.
To prolong engine life (especially after extended high speed, high
ambient temperature, or high GVW/GCW operation, such as heavy loads
and/or heavy trailers), it is recommended that a hot engine be idled for
3-5 minutes which will allow the turbocharged engine to cool down. For
more information on GVW/GCW, seeVehicle loading – with and
without a trailerin theOwner guide
Driving
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Operation in standing water
Ingestion of water into the diesel engine can result in immediate and
severe damage to the engine. If driving through water, slow down to
avoid splashing water into the intake. If the engine stalls, and ingestion
of water into the engine is suspected, do not try to restart the engine.
Consult your dealer for service immediately.
Rapid heat supplemental heating system (if equipped)
The optional rapid heat feature is an electrically powered device that is
designed to provide supplemental heat during engine warm up. For
maximum effectiveness mid to low blower speed is recommended during
initial warm up. When operating in automatic mode (when equipped) the
climate control unit will determine the appropriate blower speed for
existing conditions.
Note:Additional aftermarket electrical loads operated during engine
warm up may impact the performance of the rapid heat supplemental
heater.
DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED)
If your vehicle is equipped with dual
fuel tanks, you will have a selector
control, located to the right of the
steering wheel, which allows you to
draw fuel from either tank. Your fuel
gauge and the DTE (distance to
empty) will display the amount of
fuel in the currently selected tank.
INTEGRATED ENGINE BRAKING
This feature increases engine braking at higher engine speeds to provide
better grade descent control with less brake and transmission wear and
tear.
This feature is integrated with the tow/haul mode feature. When tow/haul
mode is switched on, the integrated engine braking feature will also be
active. For more information on tow/haul, seeAutomatic transmission
operationin theOwner Guide.
Driving
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WARNING:If you do not use the proper fuel filler cap,
excessive pressure or vacuum in the fuel tank may damage the
fuel system or cause the fuel cap to disengage in a collision, which may
result in possible personal injury.
Selective Catalytic Reduction (SCR) System
Your vehicle is equipped with a selective catalytic reduction (SCR)
system to help reduce emission levels of oxides of nitrogen from the
exhaust of the diesel engine. The system automatically injects diesel
exhaust fluid (DEF) into the exhaust system to enable proper SCR
function.
Importance of maintaining the DEF level
In order for the SCR system to operate properly, the DEF level must be
maintained. Generally, the DEF tank should be filled during the oil
change service interval. See thescheduled maintenance informationin
this supplement for more information. However, certain conditions or
driving styles, such as trailer towing or fast rates of acceleration, will
require the refilling of the DEF tank more often.
The engine control unit will monitor the amount of fluid available in the
DEF tank. Running a system check in the message center will indicate
whether the DEF level is ok or if it is less than 1/2 full. A message will
automatically be displayed in the message center when the DEF level is
low and needs to be refilled. When you see this message you should refill
your tank. SeeMessage centerin theInstrument Clusterchapter of
yourOwner’s Guidefor message center functions. For instructions on
refilling your DEF tank, seeFilling the DEF tanklater in this section.
DEF warning messages and vehicle operations
WARNING:Diesel Exhaust Fluid (DEF) must be refilled when
low or replaced when contaminated or the vehicle speed will be
speed limited to 50 mph (80 km/h). In these conditions, drive with
caution and refill DEF immediately. If the DEF becomes empty or
contaminated fluid is not replaced, the vehicle will become limited to
idle speed only once stopped. In these conditions, be cautious where
you stop the vehicle because you may not be able to drive long
distances and will not be able to maintain highway speeds until DEF is
refilled or replaced.
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Your vehicle’s message center will display a series of messages regarding
the amount of DEF available. A systems check will display messages
indicating the amount of DEF available (OK or under
12full) or will
produce a warning message that displays the mileage (kilometers)
remaining as the fluid in the DEF tank nears empty. For more
information on warning messages, see theMessage centersection in the
Instrument Clusterchapter of yourOwner’s Guide.
As the DEF level nears empty, the
DEF warning symbol will be
displayed and chimes will sound
with the messages starting at
500 miles (805 km) remaining
before DEF is depleted. The
warning symbol and messages will
continue until the DEF tank is
refilled.
Continued driving without refilling will result in the following actions as
required by the California Air Resources Board (CARB) and /or U.S.
Environmental Protection Agency (EPA):
•Within a certain number of miles (kilometers) to empty, speed will be
limited upon vehicle restart. Prior to this occurring a message will
appear in the message center.
•Further vehicle operation without refilling your DEF tank will cause
the engine to enter an idle-only condition. This will only occur upon
vehicle refueling or extended idle and will be indicated by a message
in the message center indicating required actions to resume normal
operation. It is required to add a minimum of 0.5 gallons (1.9L) of
DEF to the tank to exit the idle-only condition, but the vehicle will
still be in the speed limiting mode until the tank is refilled completely.
For either vehicle speed limiting or idle-only condition, normal vehicle
operation will resume when the DEF tank is refilled.
Note:When filling the DEF tank from empty, there may be a short delay
before detecting the increased level of DEF. This must occur before full
power is returned.
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4. Make sure that the drain valve is fully tightened, then remove the
container from under the vehicle.
Note:A loose drain valve can allow air to enter the fuel system and
cause drivetrain issues. The engine will not operate properly. be sure
that the drain valve is fully tightened.
5. Restart the engine. TheWATER IN FUEL DRAIN FILTERor
WATER IN FUEL DRAIN FILTER SEE MANUALmessage and light
should not be illuminated. If they continues to illuminate, have the fuel
system checked and repaired.
LOW FUEL PRESSURE MESSAGE
The engine is equipped with a low fuel pressure detection system. If the
message center displays:LOW FUEL PRESSUREthe following
explains why and what to do:
•Cold start or cold operation (below 32°F (0°C): If this message
appears during a cold start or during cold operation up to 10 minutes
after the initial cold start, monitor the message center. If it disappears
and does not re-appear after the engine has fully warmed up, the low
fuel pressure message is most likely caused by waxed or gelled fuel.
Do not use alcohol based additives to correct fuel gelling. This may
result in damage to the fuel injectors/systems. Use an anti-gel additive
as listed inMaintenance product specifications and capacities
section in this chapter. The customer warranty may be void from using
additives that do not meet or exceed Ford specifications.
If the low fuel pressure message persistently appears after re-fueling
during the cold start and cold operation conditions defined previously
and then disappear when the engine has fully warmed up, consider
different fuel sources.
•Low fuel operation: If the message appears when the vehicle is warm
and during low fuel tank level operation, i.e. the tank level is at or
very near empty, refuel the vehicle and operate the vehicle. If the
message reappears after fueling, see below. If the message does not
come back, the low fuel pressure condition was due to low fuel levels
in the fuel tank.
•
Normal operation: If the message appears during normal operation when
the vehicle / engine is fully warm, and fuel level is not low, the fuel
filters must be changed regardless of the maintenance schedule interval.
•If replacement of the fuel filter does not remedy the low fuel pressure
message during normal operation as defined above, take the vehicle to
your authorized dealer.
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10. Engine cooling system: Repeat Step 5 until the coolant level has
stabilized (is no longer dropping after each step) AND the upper radiator
hose at the radiator is warm to the touch (indicating that the engine
thermostat is open and coolant is flowing through the radiator).
Secondary cooling system: Repeat Step 5 until the coolant level has
stabilized (is no longer dropping after each step) AND the lower
passenger side of the secondary radiator is warm to the touch
(indicating secondary thermostat is open and coolant is flowing
through the entire system).
11. Reinstall the pressure relief cap. Shut the engine off and let it cool.
12. Check the coolant level in the reservoir before you drive your vehicle
the next few times (with the engine cool).
13. If necessary, add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir. After any coolant has been added, check the
coolant concentration. SeeEngine and secondary cooling system
coolantearlier. If the concentration is not 50/50, drain some coolant and
adjust the concentration. It may take several drains and additions to
obtain a 50/50 coolant concentration.
Whenever coolant has been added, the coolant level in the reservoir should
be checked the next few times you drive the vehicle. If needed, add a
50/50 concentration of coolant and distilled water to the proper level.
Coolant refill capacity
To find out how much fluid your vehicle’s cooling system can hold, refer
toMaintenance product specifications and capacitiesin this chapter.
Coolant additives
At specific mileage intervals of 15,000 miles (24,000 km), as listed in the
scheduled maintenance informationchapter, the coolant additive
should be checked. The optional message center, if equipped, will also
display the messageCHECK COOLANT ADDITIVEat this time. The
purpose of checking is to verify the correct concentration (freeze point
protection) and additive strength (corrosion inhibitor) levels of the
coolant for maximum engine performance and protection. Three
products are available for ensuring the life and health of the coolant: two
test kits and a coolant inhibitor additive:
•Rotunda 328-00007 (Matthew’s Water CoolCheck) – Evaluates water
quality (hardness, chloride, and pH) for 50/50 mixture of coolant and
distilled water. Use distilled water. If distilled water is unavailable,
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water meeting the requirements of Rotunda 328-00007, is sufficient
for vehicle use. Using water that fails to meet the requirements can
lead to coolant passage scaling and degrade the engine’s durability and
performance.
•Rotunda 328-00008 (Antifreeze Coolant ELC Contamination Kit) –
Evaluates the coolant concentration (freeze point protection) and
additive strength (corrosion inhibitor) for overall coolant health. Note
that the first step is to verify that the vehicle’s coolant concentration
is in the window of 40 – 60%. If the concentration falls outside of that
window, the evaluation of the corrosion inhibitor strength will not be
valid. If the report results in a pass, the cooling system does not show
excessive contamination, no action is required. If the report results as
insufficient, the corrosion inhibitor (additive) strength of the coolant
is too low. Add entire contents of one bottle of MotorcraftSpecialty
Orange Engine Coolant Revitalizer to the coolant reservoir. The
coolant can be recharged with this additive up to two times before the
coolant must be changed-out. When exchanging the full coolant
volume, the system must be flushed with Motorcraft Premium Cooling
System Flush and refilled with distilled water and coolant concentrate
(MotorcraftSpecialty Orange Engine Coolant).
•MotorcraftSpecialty Orange Engine Coolant Revitalizer – Additive to
boost the corrosion inhibitor level based upon the test results of the
Antifreeze Coolant ELC Contamination Kit. The revitalizer may be
added two times over the life of the coolant. If additional dosages are
required, the cooling system must be flushed with Motorcraft Premium
Cooling System Flush and refilled with distilled water and coolant
concentrate (MotorcraftSpecialty Orange Coolant).
Refer toMaintenance product specifications and capacitiesin this
chapter for the proper coolant and additive specifications.
Coolant change
At specific mileage intervals, as listed in thescheduled maintenance
information,the coolant should be changed. The optional message
center, if equipped, will also display the messageCOOLANT CHANGE
REQUIREDat this time.
Refer toMaintenance product specifications and capacitiesin this
chapter for the proper coolant.
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DIESEL EXHAUST SYSTEM: OXIDATION CATALYST/DIESEL
PARTICULATE FILTER SYSTEM
Your vehicle is equipped with a diesel particulate filter (DPF). The DPF
is an inline filter in the exhaust system which reduces carbon emissions
by trapping exhaust particles before they reach the tailpipe. The DPF
looks similar to a traditional exhaust catalyst, except larger, and is part
of the exhaust system under the vehicle. The DPF is coupled to a diesel
oxidation catalyst, that reduces the amount of harmful exhaust emitted
from the tailpipe. As soot gathers in the system it begins to restrict the
filter. The soot gathered inside the filter needs to be periodically cleaned.
The soot can be cleaned in two different ways; passive regeneration and
active regeneration. Both methods occur automatically and require no
actions from the driver/operator. During either one of these regeneration
methods you may notice an increase/change in exhaust noise/tone. At
certain times, the message center will display various messages related
to the DPF. SeeMessage centerin theInstrument Clusterchapter in
theOwner Guidefor more information.
Passive regeneration
In passive regeneration, the exhaust constituents / temperature are at an
appropriate level where some soot can be reduced or oxidized (burned)
thus cleaning the filter. This method occurs naturally as a result of
normal engine operating conditions (at varying levels due to drive
patterns).
Active regeneration
Once the DPF is full of exhaust particles, the engine control module will
command the exhaust system to clean the DPF through a process called
active regeneration. Active regeneration requires the engine computer to
raise the exhaust temperature to eliminate the particles. During cleaning,
the particles are converted to harmless gasses, and the DPF will then be
clean and ready to continue trapping exhaust particles.
The regeneration process operates more efficiently when the vehicle is
safely operated at least 30 mph (48 km/h) with a steady pedal for
approximately 20 minutes to complete the process. The frequency and
duration of regeneration will fluctuate as both are determined by how
you drive your vehicle, outside air temperature, and altitude. For most
driving, regeneration frequency will vary from 100 - 500 miles (161 -
805 km) between occurrences and each occurrence will last from 9 -
20 minutes. The duration of regeneration is usually reduced if a constant
speed above 30 mph (48 km/h) is maintained.
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When the engine control module detects that the DPF is nearly full of
particulates and that the vehicle is not being operated in a manner to
allow effective automatic cleaning, the message center will display
DRIVE TO CLEAN EXHAUST FILTERfor base message center and
Drive to Clean Exhaust Systemfor the optional message center,
guiding the vehicle operator to drive in order to clean the DPF. If the
vehicle is operated in a manner to allow effective automatic cleaning, the
message center will display a cleaning exhaust filter message, which is
the normal regeneration process. SeeMessage centerin theInstrument
Clusterchapter of theOwner Guidefor more information.
Note:You can also choose OCR to clean the exhaust system at this
point. SeeHow to start operator commanded regeneration (OCR)
later in this chapter.
If the operator is not able to drive in manner that allows effective
automatic cleaning (active regeneration) or the operator instead wishes
to perform regeneration of the DPF (cleaning) while at idle (stationary),
then OCR (operator commanded regeneration) will need to be
performed. SeeOperator commanded regeneration (OCR)following.
Note:Do not disregard theDRIVE TO CLEAN EXHAUST FILTERor
Drive to Clean Exhaust Systemmaintenance message for extended
periods of time. Failure to perform active or operator commanded
regeneration (OCR) (if equipped) when instructed may result in a
clogged DPF. If your DPF fills beyond what can be safely regenerated,
active regeneration and OCR will be disabled. This could cause
irreversible damage to the DPF, requiring service and possible
replacement that may not be covered by your warranty.
Operator commanded regeneration (OCR) (if equipped)
If your vehicle is operated with significant stationary operation, passive
and active regeneration may not sufficiently clean the DPF system. OCR
allows you to manually start regeneration of the diesel particulate filter
(DPF) at idle (while stationary) to clean the DPF. If you are not sure
whether your vehicle is equipped with this feature, contact your
authorized dealer.
When to perform OCR
Use the OCR feature when theDRIVE TO CLEAN EXHAUST FILTER
message appears in the message center and:
•the operator is not able to drive in manner that allows effective
automatic cleaning (active regeneration),
•or the operator instead wishes to manually start regeneration
(cleaning) of the DPF while the vehicle is idle (stationary).
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