engine FORD F650 2009 12.G Owner's Guide

•Do not increase engine speed
until the oil pressure gauge
indicates normal pressure (as
indicated by the arrows); this
should be indicated on the gauge
within 15 seconds after starting.
•Idle the engine for three to five
minutes before operating with a
full load.
•Try to limit engine idle to
10 minutes. Excessive idling reduces fuel economy.
•When starting a cold engine, increase the engine speed (RPM) slowly
to make sure adequate lubrication is available to the bearings.
Cold weather operation
WARNING:Do not use volatile starting aids such as ether,
propane or gasoline in the engine air intake system. Glow plugs
may ignite vapors which can cause engine damage or personal injury.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they’re in
optimum condition.
•Use a permanent-type engine coolant solution to protect the engine
against damage from freezing.
•If your vehicle is equipped with a water-fuel separator, drain it daily.
Fill the fuel tank at the end of daily operation to prevent condensation
in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level.
•At temperatures of –4°F (–20°C) or below, it is recommended that you
use a crankcase-mounted coolant heater to improve cold engine
starting.
•If operating in arctic temperatures of –20°F (–29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
94

Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling in cold weather can cause
a build-up of heavy deposits of carbon and rust on valve stems causing
them to stick which, in turn, can cause valvetrain damage.
Winter fronts
The use of winter fronts, or other air-restrictive devices mounted in front
of the radiator on vehicles with chassis-mounted charge air coolers, are
not recommended unless extremely cold weather conditions exist. Air
flow restriction can cause high exhaust temperatures, power loss,
excessive fan usage and a reduction in fuel economy. If you must use a
winter front, the device should have a permanent opening of at least 120
sq in. (774 sq. cm) directly in line with the fan hub.
Hot weather operation
•Keep the engine cooling system filled with a clean, permanent coolant
solution to protect against damage from overheating.
•Fill the fuel tank at the end of daily operation to prevent condensation
in the fuel system.
•Keep external surfaces of the engine, radiator, charge air cooler, A/C
condenser and accessories clean to avoid dirt build-up.
Above normal coolant temperatures could be experienced while driving
in a transmission gear ratio which lugs the engine. To correct this
problem, engine speed should be increased by downshifting in to the
next lower gear to increase engine RPM.
Starting a turbocharged engine with the vehicle on a steep grade
When starting a diesel engine when the loaded vehicle is on a grade, the
engine RPM will start to fall slightly when the clutch is engaged; do not
disengage the clutch and try to increase engine RPM as this may damage
driveline components. The engine will recover as the vehicle begins
moving.
Engine shutdown
Allow the engine to idle for three to five minutes before shutting it
down. The larger the engine, the greater the need for this idling period.
However, do not let the engine idle for more than 10 minutes.
Restarting after running out of fuel
The fuel system may need to be purged of air, refer toRunning out of
fuelin theMaintenance and Specificationschapter.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
95

GENERAL OPERATING INSTRUCTIONS
•Avoid extended (more than 10 minutes) and unnecessary idling.
•Start the vehicle in motion by using the highest gear speed in the
transmission that will let the engine easily start the load without
slipping the clutch.
•Accelerate smoothly and evenly; rapid acceleration increases fuel
consumption without increasing engine performance.
•When approaching a hill, depress the accelerator smoothly to start the
incline at full power, then shift down as needed to maintain vehicle
speed.
•When going down a hill, or long steep grades, prevent over-speeding
of the engine. The engine governor has no control over engine speed
when it is being pushed by a loaded vehicle.
•Always shift to a lower gear at high altitudes to prevent engine
smoking.
•Operate in a gear that will permit an engine speed not in excess of the
maximum governed speed or high-idle RPM (no load).
•Normally, choose the same gear to descend the hill that you would use
to ascend the hill.
WARNING:All vehicles have blind spots. To reduce the risk of
severe injury or property damage, never move your vehicle to
the side or rear or change lanes without being sure your way is clear
on both sides and to your rear.
Backing up
WARNING:To reduce the risk of the possibility of personal
injury while backing the vehicle, always be sure your vehicle’s
path is clear.
Before backing your vehicle, be sure you can do so safely. If anything
behind the cab limits your view, do not rely on mirrors alone to ensure
that your intended path is clear. If other people are in the vicinity, have
someone standing well behind your vehicle and outside of your intended
path (visible through an exterior mirror) guide you as you back up.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
96

Although OSHA or some governmental regulations may require the use
of an electrical or mechanical back-up alarm to warn bystanders, such an
alarm does not ensure that the intended path is clear. When in doubt,
get out of the vehicle and visually check the intended path is clear;
back-up slowly as to allow others time to move, if necessary.
If an electrical back-up alarm is installed, it should be connected to the
back-up lamp circuit.
Parking your vehicle
Always use the parking brake. When parking on a grade, block the
wheels and turn the front wheels to one side so that if the vehicle rolls,
the front tires will act against the curb to stop the vehicle. The front
wheels will be more effective at stopping a rolling vehicle than the rear
wheels.
WARNING:When parking your vehicle, do not leave the
transmission in gear; if the key is in the ON position and the
vehicle rolls, the engine could start. Failure to follow these instructions
could result in an unattended vehicle moving, possibly causing personal
injury or property damage.
Driving through water
If driving through deep or standing water is unavoidable, proceed very
slowly especially if the depth is not known. Never drive through water
that is higher than the bottom of the hubs. Traction or brake capability
may be limited and your vehicle may stall. Water may also enter your
engine’s air intake and severely damage your engine, drive axles or the
transmission (through the breather ports).
Once through the water, always dry the brakes by moving your vehicle
slowly while applying light pressure on the brake pedal. Wet brakes do
not stop the vehicle as quickly as dry brakes.
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). During the engine idle shutdown
process:
•TheService Engine Soonlight will flash, once per second, for the
final 30 seconds just prior to shutdown.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
97

•Within the final 30 seconds, the timer can be reset by:
1. changing the position of the accelerator pedal, or
2. changing the brake pedal, clutch pedal, or park brake from engaged
to disengaged or from disengaged to engaged.
•When the timer reaches zero, the engine will shut down.
•In this event, the key remains in the ON (Run) position, and power
continues to be supplied to the accessories.
Battery power may be drained if the key is left in the ON (Run)
position without the engine running.
Note:The engine idle shutdown 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 system is regenerating the diesel
particulate filter (DPF).
ENGINE AUTOMATIC SHUTDOWN WARNING LIGHT OR CHIME
(IF EQUIPPED)
Your vehicle may be equipped with an automatic shutdown feature that
stops the engine in the event of high coolant temperature, low engine oil
pressure, high diesel particulate filter soot loading or low engine coolant
level. A warning light in the instrument cluster and a warning chime will
indicate high engine coolant temperature, low engine oil pressure or the
need to have the diesel particulate filter cleaned or serviced. If the
engine coolant temperature becomes too high, engine oil pressure too
low or the diesel particulate filter too restricted, the engine will
automatically shut down.
If the engine shuts down, it can be restarted and operated for
30 seconds at a time or until the problem is corrected. Do not attempt to
use this restarting feature to drive the vehicle very far as serious engine
damage could result.
WARNING:In the event of engine shutdown, make sure the
vehicle is safely off the road and the problem is remedied prior
to returning to the road. Failure to remove the vehicle from the road
could result in an accident, causing serious injury or death.
GENERAL BRAKE INFORMATION
All standard equipment brakes are designed to be self-adjusting.
Automatic adjustment, when required, occurs whenever the brakes are
applied and released during forward or reverse operation. Refer to the
Scheduled Maintenance Guidechapter for scheduled maintenance.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
98

Occasional brake noise is normal and often does not indicate a
performance concern with the vehicle’s brake system. In normal
operation, automotive brake systems may emit occasional or intermittent
squeal or groan noises when the brakes are applied. Such noises are
usually heard during the first few brake applications in the morning;
however, they may be heard at any time while braking and can be
aggravated by environmental conditions such as cold, heat, moisture,
road dust, salt or mud. If a “metal-to-metal,” “continuous grinding” or
“continuous squeal” sound is present while braking, the brake linings
may be worn-out and should be inspected by a qualified service
technician.
Know the required stopping distances for all driving conditions that may
be encountered. For longer brake lining life, take full advantage of engine
braking power when coming to a stop.
WARNING:Do not drive with your foot resting on the brake
pedal. This will result in abnormally high brake temperatures,
excessive lining wear and increased stopping distances.
Before descending a long or steep hill, shift to a lower gear and avoid
continuous application of the brakes. Normally, choose the same gear to
descend the hill that you would use to ascend the hill.
WARNING:Continuous application of the brakes will cause the
brakes to overheat, resulting in a temporary loss of braking.
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 brakes only)
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
99

HYDRAULIC BRAKES (IF EQUIPPED)
Full power brake system
The Full Power Brake System incorporates standard braking, Anti-lock
Braking (ABS), and optional Power Park Brake into one fully integrated
hydraulic brake system. With the Full Power Brake System, braking
energy is stored, similar to an air brake system, resulting in faster
response times and shorter stopping distances. This is accomplished
using motor/pump assemblies that pressurized the system by pumping
brake fluid into accumulators. This is similar to the air compressor of an
air brake system pressurizing the air tanks. The system includes a master
cylinder that provides the normal pedal “feel” and transfers the pedal
force, via brake fluid, to the main components of the Full Power Brake
System.
NOTE:The motor/pumps will run momentarily with the ignition switch
in the ON/RUN positions or the switch is in the OFF position and the
brake pedal is depressed.
WARNING:If the red BRAKE warning lamp in the instrument
cluster remains illuminated after engine start up, this indicates a
system failure in the Full Power Brake System. Stop the vehicle safely
as soon as possible and seek service immediately.
NOTE:During normal driving the pump/motors may be heard
replenishing the accumulators. This is a normal function of the Full
Power Brake System.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
100

Note:If the park brake indicator light blinks and a warning chime
sounds when the control knob is pulled, the parking brake is not
functioning properly; seek immediate service from your dealer. Refer to
Parking Brake Warning Systemin this section.
Releasing the parking brake
Note:Read and understand the following steps and perform them
whenever you prepare to drive the vehicle.
Note:The parking brake will not disengage unless sufficient system air
pressure is available.
For vehicles with automatic transmissions - dash-mounted push
button (Allison 3000 Series) and steering column-mounted
(Allison 2200 and 2500) gear selection:
1. With the engine running, depress and hold the service brake pedal.
2. Select the appropriate drive gear.
3. Push and hold the yellow, dash-mounted parking brake knob until the
Park Brake indicator goes out, then release.
For vehicles with manual transmissions -
(TTC 7–speed, Eaton/Fuller 5–speed and 6–speed):
1. With the engine running, depress and hold the service brake pedal.
2. Depress and hold the clutch pedal.
3. Select the appropriate drive gear.
4. Push and hold the yellow, dash-mounted parking brake knob until the
Park Brake indicator goes out, then release.
WARNING:Hold the brake pedal down while moving the
gearshift lever from position to position. If the brake pedal is not
held down, the vehicle may move unexpectedly resulting in property
damage, personal injury or death.
Parking brake light illumination due to low air pressure
If at any time during vehicle operation air pressure is too low, the
parking brake may apply and the parking brake light will turn on.
If the parking brake is applied due to low air pressure, immediate service
is required to the parking brake system.
Parking brake warning system
If the parking brake warning light blinks and a chime sounds when
pulling the yellow control knob out, this indicates the parking brake is
not functioning properly; seek service for the parking brake immediately.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
103

Loosen the jam nut (1) and un-thread the adjustment rod (2) from the
chamber to reduce tension on the cable (3). Continue to un-thread the
adjustment rod all the way and remove it from the chamber. The nut and
shaft are metric.
AIR BRAKES (IF EQUIPPED)
General air brake information
After starting the engine, give the air compressor time to build up the air
pressure to 60 psi (414 kPa) before moving the vehicle.
WARNING:Do not drive or continue to drive if the low air
pressure buzzer is sounding or the brake warning light is lit.
These warnings indicate that air pressure is not to normal operating
level. Continued use of the vehicle could result in loss of braking
ability.
WARNING:Avoid repeated light application of the brake pedal.
This will deplete air pressure faster and could result in loss of
braking capability.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
105

Periodically check the air pressure
gauge while driving. Pressure should
range between approximately
100–125 psi (690–862 kPa). The air
compressor governor cut-in and
cut-out pressure settings are preset
at the factory and are not
adjustable.
When air pressure is insufficient
(below 60 psi [414 kPa]), a warning
light illuminates and a buzzer
sounds when the ignition is in the
ON position.
This condition may be caused by excessive brake applications depleting
the system air pressure. If this condition occurs, stop driving the vehicle
until the compressor has fully recharged the air system.
WARNING:Do not move the vehicle when the air pressure is
insufficient because the brake system may be inoperative.
Select a gear ratio to help slow your vehicle before descending grades.
Supplement with brakes as required to safely slow the vehicle and avoid
overspeeding the engine.
Air chamber stroke indication
Air chamber push rods have orange stroke indicator markers that warn
when the braking system requires adjustment or repair. The orange
stripe is painted on the air chamber push rod at the slack adjuster stroke
dimension which requires service when visible during brake application.
Air brake inspection and adjustment or repairs should be performed by a
qualified service technician in accordance with the instructions in the
service manual.
2009 F-650/750(f67)
Supplement
USA(fus)
Driving
106