brake fluid FORD F650 2004 11.G Owners Manual

These are some of the symbols you may see on your vehicle.
Safety Alert
See Owner’s Guide
Fasten Safety BeltAir Bag-Front
Air Bag-SideChild Seat
Child Seat Installation
WarningChild Seat Lower
Anchor
Child Seat Tether
AnchorBrake System
Anti-Lock Brake SystemBrake Fluid -
Non-Petroleum Based
Traction ControlAdvanceTrac
Master Lighting SwitchHazard Warning Flasher
Fog Lamps-FrontFuse Compartment
Fuel Pump ResetWindshield Wash/Wipe
Windshield
Defrost/DemistRear Window
Defrost/Demist
Power Windows
Front/RearPower Window Lockout
2004 F650/750(f67)
Supplement
USA English(fus)
Introduction
6

To be sure your vehicle is ready to operate, conduct a pre-trip inspection
at the beginning of each work period. Follow the steps listed in this
section to assure a proper vehicle inspection procedure. The pages in
this section may be produced locally and used on a regular basis.
VEHICLE INSPECTION INFORMATION
Note:Always make sure the parking brake is applied before starting the
engine.
Engine compartment (with engine stopped)
Engine oil level:Use the engine oil dipstick to verify that the
engine oil level is between the FULL and ADD
marks.
Engine coolant
level:Look through the plastic reservoir or the clear
sight glass on the reservoir, depending upon
vehicle equipment, and make sure the fluid is
within the minimum and maximum fluid level
range as marked on the reservoir.Do not
remove pressure cap until the coolant has
cooled.
Power steering fluid:Verify that the fluid level is between the full
and refill marks.
Brake fluid (master
cylinder):Remove the master cylinder caps and inspect
the fluid level. The full mark is at the bottom
of the opening of the port ring.
Hydraulic clutch
fluid:Check for adequate amount of hydraulic clutch
fluid. Fluid level should be at the step of the
reservoir; refer toClutch fluid/linkage
adjustmentsin theMaintenance and
specificationschapter.
Fan, alternator,
water pump/drive
belt:Press belt to test that it is snug. Check for
frays, cracks, loose fibers or visible signs of
wear. If it deflects more than 1.25 cm–2cm
(1/2–3/4 inch), slippage is probably excessive.
Air compressor:Check belts (if equipped). Same for water
pump.
Refrigerant
compressor:Check belts (if equipped). Same for water
pump.
2004 F650/750(f67)
Supplement
USA English(fus)
Vehicle inspection guide
Vehicle inspection guide
9

Engine compartment (with engine stopped)
Any leaks:Check for signs of fluid puddles, dripping fluid
on the ground under the engine or the
underside of the engine.
HVAC air inlet:Check for debris, leaves, etc. that may have
collected on the HVAC air inlet grille or inside
the exterior module as this may cause reduced
system performance.
HVAC fresh air filter
(if equipped):Periodically check the HVAC fresh air filter for
cleanliness.
Exercise great caution when working on vehicle equipped with
an automatic fan clutch. The fan starts in motion only after the
engine coolant reaches a predetermined temperature or the refrigerant
pressure (if equipped with air conditioning) reaches a predetermined
setting. The fan will start at these point with no advance warning.
Never reach near, or permit objects to protrude into, the fan blade
radius while the engine is running as this could result in vehicle
damage, personal injury or death.
Engine starting (with parking brake applied)
Safety/Emergency
equipment:Prior to entering the cab, verify that the
vehicle is equipped with spare electrical fuses
(if used), three red reflective triangles, a
properly charged and rated fire extinguisher
and wheel chocks. Walk around the vehicle
and check that all steps and grab handles,
inside and out as well as behind, are tight and
clean. Use extreme caution and a three-point
stance at all times. Check door latches for
positive closing, latching and locking.
Clutch/Gearshift:Depress the clutch (if equipped with a manual
transmission) and verify the transmission is in
neutral before turning on the starter. Keep the
pedal depressed until the engine reaches idling
speed.
Oil pressure builds:Make sure engine oil pressure is building to
normal operating range.
2004 F650/750(f67)
Supplement
USA English(fus)
Vehicle inspection guide
10

Engine starting (with parking brake applied)
Air brake check:Check the air brakes in the following manner
(Chock the wheels, if necessary. Push in the
parking brake and on tractors, also push in the
tractor protection valve knob):
1. Check the air compressor or governor
cut-out pressure (approximately 305 kPa [120
psi]).
2. Cut-off the engine and turn the key back to
ON, without starting the engine.
3. Without the brake pedal applied, note the
air pressure drop for one minute. It should be
less than 5 kPa (2 psi) for single vehicle and 8
kPa (3 psi) for combination vehicles.
4. Depress and hold the brake pedal with 621
kPa (90 psi) or more and make sure there is
no more than a 8 kPa (3 psi) per minute leak.
For combination vehicles, no more than 10
kPa (4 psi) per minute.
5. Step on and off the brake pedal and check
for the warning light and chime to activate
between 163-193 kPa (64–76 psi).
6. Step on and off the brake pedal and make
sure the tractor protection and parking brake
knobs pop out between 138–310 kPa (20–45
psi)
7. Restart the engine, shift to a lower gear and
gently pull against the service and parking
brakes separately to make sure they hold.
Automatic
transmission fluid:With the engine idling (at normal operating
temperature) and the parking brake applied,
check the automatic transmission fluid. If fluid
needs to be added, place the transmission in
the appropriate gear as specified in the
transmission operator’s manual and refer to
Transmission fluidin theMaintenance and
specificationschapter.
2004 F650/750(f67)
Supplement
USA English(fus)
Vehicle inspection guide
12

Front of vehicle
Lights:Make sure all lights illuminate and are clean.
Make sure headlights function on both high
and low beams. Make sure reflectors are clean
and unbroken and of proper color (red on
rear, amber elsewhere). Make sure the running
lights are also clean and unbroken. Rear
running lights must be checked separately
from signal, flasher and brake lights.
Steering gear:Look for: missing or loose fasteners, power
steering fluid leaks and damage to power
steering hoses.
Steering linkage:Make sure connecting links, arms and rods are
not worn or cracked; joints, sockets and boot
seals are not worn or loose and that there are
no loose or missing cotter keys, nuts or bolts.
Tow hooks:Front and rear tow hooks should be inspected
for damage or loose mounting. This is
particularly important on vehicles where tow
hooks are frequently used.
Front suspension
Spring:Check for missing, broken or shifted leaves or
leaves that are in contact, or nearly contacting
a tire, rim, brake drum, frame or body
components.
Spring mount:Check/Inspect spring hangers, bolts, bushings,
axle mounting bolts and nuts for cracks,
breaks, wear, damage, tightness and correct
component quality.
Shock absorber:Check for cracks, leaks and missing or broken
bolts or bushings.
Note:Never apply grease to spring pads.
Do not operate the vehicle if any suspension conditions listed in
theFront suspensionchart are evident. Loss of steering or
suspension could result in property damage, personal injury or death.
2004 F650/750(f67)
Supplement
USA English(fus)
Vehicle inspection guide
13

STARTING PROCEDURES
Operating precautions
•Always shift to a lower gear at high altitudes to prevent engine
smoking.
•Avoid extended and unnecessary idling.
Diesel engine vapors are combustible. Do not operate the engine
in an enclosed area. These vapors can be sucked through the air
intake system and cause an explosion which may result in severe
bodily injury and extensive property damage.
Starting the engine
1. Ensure headlamps and all accessories are turned off, the parking
brake is applied and the transmission is in the neutral position (or P
[Park] for Allison 2400 transmissions).
If your vehicle is equipped with an
air intake heater, the heater will
activate in cooler weather. If the
Wait to startlight illuminates,do
notcrank the engine until the light
goes off.
If equipped with an air intake heater, DO NOT use ether or any
other starting fluids. The use of starting fluids (ether) in an
engine equipped with an air intake heater could cause an explosion
and result in property damage and/or personal injury.
2. Do not depress the accelerator during starting the engine.
3. Start the engine.
If the engine does not start after 30 seconds of cranking, allow two
minutes for the starter to cool before trying again. Excessive cranking
may damage the starter.
WAIT
TO
START
2004 F650/750(f67)
Supplement
USA English(fus)
Driving
Driving
86

Hydraulic brake booster system (Hydromax)
The Hydromax systems receive fluid pressure from the power steering
pump to provide power assist during braking.
The Hydromax booster receives backup pressure from the reserve
system electric pump whenever the fluid in the power steering system is
not flowing. When the engine is OFF, the pump will turn on if the brake
pedal is applied, or if the ignition is turned to the ON position.
The sound of the pump operating may be heard by the driver, but this is
a normal characteristic of the system.
The reserve system provides reduced braking power, so the vehicle
should be operated under these conditions with caution, and only to seek
service repair and remove the vehicle from the roadway.
For Hydromax, under normal operating conditions noise of the fluid
flowing through the booster may be heard whenever the brake is applied.
This condition is normal. Vehicle service is not required.
If braking performance or pedal response becomes very poor, even when
the pedal is strongly applied, this may indicate the presence of air in the
hydraulic system or fluid leakage. Stop the vehicle safely as soon as
possible and seek service immediately.
If the red BRAKE warning lamp in
the instrument cluster remains
illuminated after engine start up,
this indicates a system failure in the
master cylinder of the brake system. Stop the vehicle safely as soon as
possible and seek service immediately.
If the yellow BRAKE RESERVE
(E-motor) warning light remains on
while the engine is running, this
indicates inadequate hydraulic
booster pressure or reserve pump
system failure. Stop the vehicle safely as soon as possible and seek
service immediately.
BRAKE
2004 F650/750(f67)
Supplement
USA English(fus)
Driving
92

Continuous application of the brakes will cause the brakes to
overheat, resulting in a temporary loss of braking.
Occasional or intermittent brake squeal or groan may result from
environmental conditions such as cold, hot, wet, snow, salt, mud, etc.
This condition will not affect braking effectiveness. The brakes should be
checked only if squeal occurs continuously with every application.
If brakes do not grip well
•If you have been driving through deep water, gently apply the brakes
several times while the vehicle is moving slowly.
•Let the brakes cool if you have been using them excessively, as in
mountain driving or after several fast, high speed stops.
•Check brake adjustment.
•Check brake linings for excessive wear.
•Check system air pressure.
Air brake reservoir draining
Failure to drain air brake reservoirs can result in a reduction or
loss of braking ability due to fluid accumulation in the reservoir
and/or possible freeze-up during cold weather.
Drain all the air brake reservoirs
daily, completely to 0 kPa/psi, by
opening the draincock at the ends
of the tanks (where accessible.
Pull-chains are used when the
drains are undercab or otherwise
inaccessible). Close draincock after
complete draining. Air tanks
equipped with automatic moisture
ejector valves may also be drained
manually as required to maintain a
dry air system. Contact your dealer if you are unsure of the air reservoir
locations or the draining procedure.
Air brakes
After starting the engine, give the air compressor time to build up the air
pressure to 414 kPa (60 psi) before moving the vehicle.
2004 F650/750(f67)
Supplement
USA English(fus)
Driving
98

If the engine speed is above idle when a gear is selected using the
shifter, the vehicle will not move. To move the vehicle, the shifter must
be moved to re-select a gear after the engine speed returns to idle.
Note:For more information regarding the Allison MD-WT, refer to the
separate Allison MD-WT Operator’s Manual.
Torque lock
If your vehicle is parked on an incline and P (Park) is not properly
engaged (The parking brake is not applied before the transmission is
shifted into P [Park]), the weight of the vehicle may generate an
excessive amount of torque on the park pawl. In this situation, it may be
difficult to shift the transmission out of P (Park). Hold the brake pedal
down while shifting out of P (Park), then release the parking brake.
Allison MD (Medium Duty) push-button shifter
To shift the transmission into R
(Reverse) or D (Drive), depress the
brake pedal, then press R or D, then
release the brake pedal. To select a
lower range when in D (Drive),
press the down-arrow button. To
select a higher range when in D
(Drive), press the up-arrow button.
To place the transmission in N
(Neutral), press N.
Automatic transmission operating temperatures
Allison 2000/2400–The sump/fluid reservoir temperatures should not
exceed 120°C (250°F). The converter temperature should not exceed
144°C (300°F).
Power take-off (PTO) operation with an Allison automatic
transmission (except MD applications and vehicles equipped with
a Caterpillar 3126E engine)
The power take-off 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) - this stops the rotation of the PTO drive gear in the
transmission - then engage the PTO.
2004 F650/750(f67)
Supplement
USA English(fus)
Driving
117

PAINT CHIPS
Your dealer has touch-up paint and sprays to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jam) to
your dealer to ensure you get the correct color.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND COVERS
Aluminum wheel rims or covers are coated with a clearcoat paint finish.
In order to maintain their shine:
•Clean with Motorcraft Wheel and Tire Cleaner (ZC-37–A), which is
available from your dealer.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Chemical-strength cleaners, or cleaning
chemicals, in combination with brush agitation to remove brake dust
and dirt, could wear away the clearcoat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•To remove tar and grease, use Ford Extra Strength Tar and Road Oil
Removal (B7A-19520–AA), available from your dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
•Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
2004 F650/750(f67)
Supplement
USA English(fus)
Cleaning
155