FORD F650 2007 11.G Owners Manual

When disconnecting the trailer:
•Lower the landing gear, then press the lower portion of the switch.
• Disconnect the brake hoses, trailer-side and rear light connectors,
then pull the release lever on the fifth wheel.
The upper portion of the switch must be pressed before operating with a
trailer or operating in the bobtail mode.
Suspension conversions
It is not recommended, or approved, that suspension conversions be
performed. However, it is understood that, on occasion, aftermarket add-on
suspensions are installed by others on the truck chassis which allow
operator control for weight transfer from other axles (i.e., air lift axles).
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.
AUTOMATIC TRANSMISSION OPERATION (IF EQUIPPED)
Main transmission, auxiliary transmission, transfer case and power take-off
(PTO) control shift patterns can be found on a placard or decal on the
driver’s sun visor, on the instrument panel or on the shift control itself.
The main transmission control is used to select the various gear ratios or
speeds of the transmission. Selecting D (Direct Drive), does not change
the transmission gear ratio, but is used where the gear ratios in the main
transmission are adequate to handle the vehicle operation.
If the transmission fails to shift properly, check the inline 10A fuse
located in the battery cables above the battery.
Hold the brake pedal down while you move the gearshift lever
between positions. If you don’t hold the brake pedal down, your
vehicle may move unexpectedly and cause property damage, personal
injury or death.
Allison 2200 automatic transmission with park pawl feature
Note: For Allison automatic transmission-equipped vehicles, also refer to
the separate Allison Transmission Operator’s Manual.
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A parking pawl effectively grounds the transmission’s output shaft
preventing rotation of the driveline. If the vehicle is stationary, selecting
the P (Park) position places the transmission in neutral and engages the
parking pawl (always use the parking brake, also).
Note:If the P (Park) position is selected when the vehicle is in motion,
the parking pawl mechanism will ratchet and NOThold the truck.
Always set the parking brake fully. Do not use the gearshift in
place of the parking brake.
To avoid sudden, unexpected vehicle movement and
possible personal injury or death:
1. Bring the vehicle to a complete stop.
2. Shift the transmission into P (Park). Slowly lift your foot from the
brake pedal to engage the transmission parking pawl mechanism.
3. Apply the parking brake and make sure it is holding properly. Do not
rely solely on the parking mechanism of the transmission.)
4. Turn the engine off when you leave the vehicle. Never leave the
vehicle unattended when the engine is running.
Allison 2500 automatic transmission
This transmission is available with a column-mounted gearshift lever. The
gear positions are displayed on the RNDL in the instrument cluster.
To avoid sudden, unexpected vehicle movement and
possible personal injury or death:
1. Bring the vehicle to a complete stop.
2. Shift the transmission into N (Neutral).
3. Apply the parking brake and make sure it is holding properly.
4. Turn the engine off when you leave the vehicle. Never leave the
vehicle unattended when the engine is running.
Allison 3000 Series automatic transmission
Two modes are available for the Allison 3000 Series: Performance and
Economy. Performance mode will give you the best all-around
transmission operation; Economy provides operation at lower engine
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RPM while maintaining adequate performance. The transmission will
automatically default to Performance mode when you start the engine.
Pressing MODE on the shifter will activate the Economy mode; this will
also illuminate the Mode ON lamp.
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 3000 Series, refer to
the separate Allison 3000 Series 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 3000 Series 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 2200/2500 – The sump/fluid reservoir temperatures should not
exceed 250°F (120°C). The converter temperature should not exceed
300°F (144°C).
CLUTCH (IF EQUIPPED)
Do not ride or slip the clutch as this will cause unnecessary heat and
wear. Maintain the specified clutch adjustment to prolong its life and
regularly inspect the clutch control linkage for tightness. Refer to the
Scheduled Maintenance Guide chapter for other maintenance
information. When adjustment of the clutch is necessary, it is very
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important that the work be performed properly or early clutch failure
may result and a costly clutch overhaul may become necessary. Clutch
work should only be performed by a qualified technician.
Engaging the clutch
•Always start in the proper gear. An empty vehicle can start in a
higher gear than a fully loaded vehicle. Starting in too high a gear can
cause clutch slippage and excessive heat and wear on the clutch. A
gear that will start the vehicle moving at idle speed is the correct gear.
If the engine has to be revved to get the vehicle going, the gear
selection is too high.
• Do not shift until the vehicle has reached the proper speed.
Upshifting before the vehicle has reached the proper speed can cause
clutch slippage and excessive heat and wear on the clutch.
• Never hold a vehicle on a grade with the clutch. This will cause
the clutch to slip and can actually burn up the clutch.
• Never coast with the clutch disengaged. The high RPM
(sometimes over 10,000), can actually burst the facing material of the
clutch.
• Never engage the clutch while coasting. Re-engaging the clutch
after coasting may not only cause a great shock to the clutch, but the
whole drivetrain. Internal engine damage and/or clutch and flywheel
failure can result from this.
If your vehicle’s transmission is equipped with a ceramic clutch, you
must start the vehicle moving in first gear and engage the clutch before
pressing the accelerator at idle. Also, don’t try to slip the clutch by
raising engine RPM and riding or feathering the clutch pedal since the
vehicle will experience erratic engagement. Erratic engagement can
cause the engine stalling and potential serious damage to the vehicle’s
driveline components.
Clutch brake (vehicles equipped with a non-synchronized
transmission) - Vehicle stationary
A clutch brake is used to stop the transmission input shaft rotation so
that the initial 1 (First) or R (Reverse) gear selection can be
accomplished when the vehicle is stationary and the engine is running at
idle speed. Clutch brake application occurs in the last inch (25 mm) of
clutch pedal travel.
When using the clutch brake, fully depress the clutch pedal and shift the
transmission into 1 (First) or R (Reverse). If the transmission won’t go
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into one of these gears, slowly release the clutch pedal while applying
light pressure on the transmission shift lever until it shifts into gear.
Note:After engagement of 1 (First) gear, do notuse the clutch brake
for upshifting or downshifting. If you do, clutch brake life will shorten
and gear selection shift efforts may increase.
Double-clutch procedures - vehicles equipped with a
non-synchronized transmission
In order to properly upshift or downshift, perform the following steps:
1. Depress the clutch pedal to disengage the clutch.
2. Shift the transmission into neutral.
3. Release the clutch pedal.
If upshifting , wait until the engine speed matches the transmission
speed of the gear you are selecting.
If downshifting, accelerate the engine until the engine speed matches
the input speed of the gear you are selecting. Depress the clutch pedal
immediately and shift into the desired gear, then release the clutch
pedal.
MANUAL TRANSMISSION OPERATION (IF EQUIPPED)
Note: Continued use of a damaged or worn clutch, prolonged clutch
slippage or downshifting at excessive speeds can result in a failure of the
engine, transmission or clutch components.
Note: To avoid premature clutch wear and failure, do not drive with
your foot resting on the clutch pedal or use it to hold the vehicle at a
standstill on an upgrade as when waiting for a traffic light.
Manual transmission shift patterns
are displayed on either the shift
lever knob or the sun visor.
Study this information carefully before you drive the vehicle even though
you may be familiar with similar units. Do not attempt to drive the
vehicle without knowing the exact shift pattern of the transmission.
Consult your authorized dealer if any questions exist as to the shifting
instructions posted in your vehicle.
R 1 3 5
4
6
2
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Do not coast the vehicle with the clutch pedal depressed or with
the transmission in neutral. This practice could result in loss of
vehicle control.
Driving hints
The following driving hints are provided as a brief, general guide in
operating the different manual transmissions used in your vehicle.
• When shifting into 1 (First) or R (Reverse) with vehicle standing still,
quickly release and depress the clutch pedal (if necessary to complete
gear engagement).
• Always use the lowest (or most appropriate) gear to start the vehicle.
• Always use a gear ratio low enough to allow the engine to operate
above the minimum engine operation speed range.
• Do not lug the engine.
• Do not slam or jerk the gearshift lever into gear.
• When more power is required, shift to a lower gear and accelerate the
engine near the governed speed.
Shifting with a synchronized transmission
With the clutch pedal depressed, use 2 (Second) gear synchronizer to
stop the clutch disc rotation; this allows smooth engagement of 1 (First)
or R (Reverse) To complete the gear engagement, it may be necessary to
apply light pressure to the gearshift lever during initial engagement of
the clutch. It takes a second or two to match gear speeds; steady
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 to Clutch brake andDouble clutch procedures in theClutch
section of this chapter.
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Operating the Eaton FS-5205A 5–speed transmissions
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.
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.
R 2 4 3 5 1
R 1 3 5
4
6
2
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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
Vehicles equipped with an Allison automatic transmission (except
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.
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.
2 4 6 3 5 7 1
R
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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.
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 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.
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 your Body Builder’s Layout Book for 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
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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.
Exceeding these ratings by overloading can cause component
failure resulting in property damage, personal injury or death.
Rear axles with locking or limited-slip differentials
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.
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.
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