engine FORD F650 2005 11.G Owners Manual

Maintenance and specifications 162
Hood 169
Engine oil 170
Battery 180
Fuel information 189
Lubricant specifications 213
Refill capacities 222
General maintenance information 227
Index 263
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Copyright © 2004 Ford Motor Company
Table of Contents
3
2005 F650/750(f67)
Supplement
USA English(fus)

CALIFORNIA Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. In addition, certain fluids contained in vehicles and
certain products of component wear contain or emit chemicals known
to the State of California to cause cancer and birth defects or other
reproductive harm.
CONGRATULATIONS
Congratulations on acquiring your new vehicle. Please take the time to
get well acquainted with your vehicle by reading this handbook. The
more you know and understand about your vehicle the greater the safety
and pleasure you will derive from driving it.
Additional owner information is given in separate publications.
This Owner’s Guide describes every option and model variant available
and therefore some of the items covered may not apply to your
particular vehicle. Furthermore, due to printing cycles it may describe
options before they are generally available.
Remember to pass on the Owner’s Guide when reselling the vehicle. It is
an integral part of the vehicle.
2005 F650/750(f67)
Supplement
USA English(fus)
Introduction
Introduction
4

SPECIAL NOTICES
Emission warranty
The New Vehicle Limited Warranty includes Bumper-to-Bumper
Coverage, Safety Restraint Coverage, Corrosion Coverage, and 6.0L
Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible
for Emissions Defect and Emissions Performance Warranties. For a
detailed description of what is covered and what is not covered, refer to
theWarranty Guidethat is provided to you along with your Owner’s
Guide.
Special instructions
For your added safety, your vehicle is fitted with sophisticated electronic
controls.
By operating other electronic equipment (e.g. mobile telephone
without exterior aerial) electromagnetic fields can occur which
can cause malfunctions of the vehicle electronics. Therefore you should
observe the instructions of the equipment manufacturers
Service Data Recording
Service data recorders in your vehicle are capable of collecting and
storing diagnostic information about your vehicle. This potentially
includes information about the performance or status of various systems
and modules in the vehicle, such as engine, throttle, steering or brake
systems. In order to properly diagnose and service your vehicle, Ford
Motor Company, Ford of Canada, and service and repair facilities may
access vehicle diagnostic information through a direct connection to your
vehicle when diagnosing or servicing your vehicle.
Introduction
6

Power Windows
Front/RearPower Window Lockout
Child Safety Door
Lock/UnlockInterior Luggage
Compartment Release
Symbol
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
9

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.
Belts (Fan,
alternator, water
pump and A/C
compressor):Check for glazing, fraying or cracking. There
should be no more than five - seven cracks per
rib per inch.
Any leaks:Check for signs of fluid puddles, dripping fluid
on the ground under the engine or the
underside of the engine.
Vehicle inspection guide
Vehicle inspection guide
11

Engine compartment (with engine stopped)
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 (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.
Starting the engine:Verify the parking brake is set. Depress the
clutch (if equipped with a manual
transmission) and verify the transmission is in
neutral. Vehicles equipped with an automatic
transmission should be in N (Neutral).
When the WAIT TO START indicator light in
the instrument cluster turns off, turn the key
to START.
Vehicle inspection guide
12

Engine starting (parking brake applied)
Oil pressure builds:Make sure engine oil pressure is building to
normal operating range.
Air chime sounds (if
equipped with air
compressor):The low air pressure warning chime should
sound immediately after the engine starts but
before the compressor has built up pressure.
The low air pressure warning chime should
stop when the air pressure reaches 70 psi (483
kPa) (or more). Let the air pressure build to
governed cut-out pressure, which should occur
between 115–130 psi (793–896 kPa).
Accelerator:Depress the accelerator and verify that it
operates smoothly without any binding or
irregular feel. Remove your foot from the
pedal and make sure the engine returns to idle
speed immediately.
Ammeter/Voltmeter:Check the gauge to see if the alternator is
charging.
Steering linkage
free play:Check for excessive free play in the steering
linkages. The steering wheel should have less
than 2 inches (5 cm) of free play at rim of
steering wheel.
Hydraulic brake
check:Pump the brake pedal three times, then apply
firm pressure to the pedal and hold it for five
seconds. The pedal should move (due to the
HydroMax pump operation); if it does not,
there may be a leak or another problem. Do
not drive the vehicle until the problem is
fixed.
Vehicle inspection guide
13

Engine starting (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 parking brake knob):
1. Check the air compressor or governor cut-out
pressure (approximately 120 psi [827 kPa]).
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 2 psi (14 kPa) for single vehicle and
3 psi (21 kPa) for combination vehicles.
4. Depress and hold the brake pedal with 90
psi (621 kPa) or more and make sure there is
no more than a 3 psi (21 kPa) per minute
leak. For combination vehicles, no more than 4
psi (28 kPa) per minute.
5. Pump the brake pedal to deplete the system
air pressure. The warning light and chime
should activate 57 psi (393 kPa).
6. Pump the brake pedal and make sure the
parking brake and trailer parking brake knobs
knobs pop out at 20 psi (138 kPa) or higher.
Parking brake:Check that the parking brake will hold the
vehicle by gently trying to pull forward with
the parking brake applied.
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.
Vehicle inspection guide
14

Driver/Fuel area
Fuel tank:Make sure the fuel tank and caps are secure.
Make sure there is no damage to the tank.
Leaks:Check for any leaks from the fuel tanks.
Underbody of vehicle
Driveshaft:Make sure that the driveshaft is not bent or
cracked. Ensure all driveshaft couplings are
secure.
Exhaust system:Make sure the outside visible parts are
securely mounted. Make sure there are no
cracks, holes or severe dents.
Frame:Check for cracks or bends in longitudinal
frame members. Make sure there are no loose,
cracked, bent, broken or missing
crossmembers or crossmember fasteners.
Maintain adequate clearance between all parts of the exhaust
system and all hoses, wires and lines for engine cooling, brake
system, fuel system, power steering system and electrical system, Heat
damage to hoses, wires or lines may cause vehicle malfunction that
could result in property damage, personal injury or death.
Rear of vehicle
Air/Electric lines:
Make sure that air hoses are not cut, cracked,
chafed or worn. Listen for audible air leaks,
Make sure air and electrical lines are not
tangled, crimped or pinched or being dragged
against any truck parts. Electrical line insulation
should not be cut, cracked, chafed or worn.
None of the air or electrical line should be
spliced or taped. Check for corrosion on pins
and in electrical sockets to ensure continuity
and reduced heat build-up potential.
Deck plate:Make sure deck plate is clean, securely bolted
to the frame and clear of loose objects.
Vehicle inspection guide
17

Rear wheels
Spacers:Make sure dual wheels are evenly separated
and that tires are not touching one another.
Rims:Check for damaged or bent rims. Rims should
not have welding repairs and no rust trails that
indicate it is loose on the wheel.
Lug nuts:Make sure all lug nuts are present and not
loose (look for rust trails around the lug nuts).
There should be no cracks radiating from the
lug bolt holes or distortion of the bolt holes.
TRAILER
If you are pulling a trailer, an inspection of the trailer similar to that of
the tractor should be done. Such an inspection should follow trailer
manufacturer recommendation and should include at a minimum: general
condition, landing gear, doors, sides, lights, reflectors, suspension,
brakes, tires, wheels, cargo placement, stability and tie-downs.
TRANSMISSION
If your vehicle is equipped with an automatic transmission, regularly
check the transmission’s neutral start switch. The engine should only
start in the N (Neutral) or P (Park) positions.
If the unit starts in gear and/or the neutral start switch is not
functioning correctly, the vehicle may inadvertently move which
could result in property damage, personal injury or death.
Check the transmission fluid level and shift linkage for proper operation.
Vehicle inspection guide
20