light FORD F650 2012 12.G Workshop Manual

WARNING:Do not coast the vehicle with the clutch pedal
pressed or with the transmission in neutral. This practice could
result in loss of vehicle control.
To go forward
With the engine idling, press the clutch pedal in 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
Put the gearshift lever in R (Reverse) and engaging the clutch while
pressing lightly on the accelerator.
Shifting with a synchronized transmission
With the clutch pedal pressed in, use the 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 helps 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 toClutch brakeandDouble clutch proceduresin theClutch
section of this chapter.
Operating the Eaton FS-5205A 5–speed transmission
This transmission is equipped with
five forward gears and one reverse;
gears 2–5 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.
R 2 4
3 5 1
Driving
139
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Operating the Eaton FS–5406A, FS–5406N, FS–6406A and
FSO–6406A 6-speed transmissions
These transmissions are equipped
with six forward gears and one
reverse; all 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.
Operating the Spicer ES56-7B and ES066-7B 7-speed transmissions
These transmissions are equipped
with seven forward gears and one
reverse; gears 2–7 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.
POWER TAKE-OFF (PTO) OPERATION (IF EQUIPPED)
Vehicles equipped with an Allison automatic transmission (except
Allison 3000 Series applications )
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 which could result in further
damage to the transmission and PTO.
R 1 3 5
4
6 2
2 4 6
3 5 71 R
Driving
140
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Care should be taken to avoid sudden accelerations when both drive
wheels are on a slippery surface.
WARNING:Sudden accelerations on slippery surfaces could
cause the wheels to spin, the vehicle to turn sideways on a
crowned road surface or in a turn, possibly resulting in loss of vehicle
control and personal injury.
Some drive axles have a driver-controlled differential lock. The
differential lock can lock or unlock the differential when the vehicle is
moving or stopped. When extra traction is required, the differential lock
provides full power to both axles.
When the differential is locked, the vehicle’s turning radius increases
(vehicle “under-steers”).
The differential can be locked or unlocked when the vehicle is moving at
a constant speed of under 25 mph (40 km/h) and while the wheels are
not slipping. The differential must not be locked when the vehicle is
traveling down steep grades and traction is minimal.
Note:Never use the differential lock at vehicle speeds above 25 mph
(40 km/h).
The differential lock and differential lock light automatically disengage at
speeds above 25 mph (40 km/h). The differential lock remains off until
either the vehicle is restarted or the differential lock switch is turned off
then back on.
Axle conversions
It is not recommended, or approved, for axle conversions to be
performed. However, it is understood that, on occasion, aftermarket
add-on axles are installed by others on the truck chassis which allow
operator control for weight transfer from other axles (i.e., air lift axles).
WARNING: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.
Driving
143
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

TWO-SPEED REAR AXLE (IF EQUIPPED)
A two-speed rear axle allows the
driver to select a LO range for
greater pulling power and a HI
range for greater road speed and
fuel economy. These ranges can also
be used to provide additional steps
between transmission shifts when
driving on steep grades and/or fuel
economy may be factors.
Note:Do not shift between ranges
when the speed control is on.
WARNING:Never shift a two-speed axle when descending a
steep grade as this may cause loss of vehicle control and result
in personal injury.
Axle shifting
Manual transmissions
•To downshift,select the next lower gear, release and press the
accelerator pedal rapidly, or while holding the accelerator pedal down,
release and engage the clutch rapidly.Note:The clutch method is
recommended when driving at slower speeds.
•To upshift,keep the accelerator pedal down, select the next higher
gear, release the accelerator and pause until the axle upshifts.Note:
De-clutch for smoother axle upshifts when driving at slower speeds.
Automatic transmissions
•Use LOW when you drive a fully-loaded vehicle on a severe grade or
in congested traffic. To activate LOW, press the upper portion of the
switch.
•Use HIGH for all normal driving conditions with a lightly-loaded or
partially-loaded vehicle. To activate HIGH, press the lower portion of
the switch.
Note:You can’t split-shift with an automatic transmission. Also,
downshifting above 40 mph (64 km/h) may result in transmission or axle
damage.
To shift the axle from LOW to HIGH with the vehicle stopped, place the
transmission in N (Neutral), then press the lower part of the switch.
2SPD
LOW
HIGH
Driving
144
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Unloaded or lightly loaded vehicles
The braking system has been designed to safely stop your vehicle when
fully loaded to its GVWR.
WARNING:When operating empty or lightly loaded, sudden or
hard braking may induce wheel lockup with loss of vehicle
control and the possibility of accident and serious injury, especially on
wet or slippery road surfaces.
TRAILER TOWING
Towing a trailer places an additional load on your vehicle’s engine,
transmission, axle, brakes, tires and suspension. Inspect these
components carefully prior to and after any towing operation.
Consult your local motor vehicle speed regulations for towing a trailer.
Your vehicle’s load capacity is designated by weight, not by volume, so you
cannot necessarily use all available space when loading a vehicle. 2nd unit
bodies are not included in maximum trailer weight ratings. The weight of the
additional “body” must be subtracted from the maximum trailer weight.
Note:Do not exceed the GVWR or the GAWR specified on the
certification label.
Note:Do not exceed the GCWR rating or transmission damage may occur.
WARNING:Towing trailers beyond the maximum recommended
gross trailer weight exceeds the limit of the vehicle and could
result in engine damage, transmission damage, structural damage, loss
of vehicle control, vehicle rollover and personal injury.
Model Maximum
GVWR - lb (kg)Maximum
GCWR
F-650 Pro-Loader (Kick-Up
Frame)20500–26000
(9299–11792)*
F-650 Pro-Loader (Straight
Frame)/F-650 Straight Frame20500–29000
(9299–13154)*
F-750 25999–37000
(11793–16783)*
* Specific GCWR and maximum trailer weight applicable to a given
F–650/750 model is dependent on many variables including
transmission capability. Check with your sales consultant for the exact
rating on your vehicle.
Driving
147
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Preparing to tow
Use the proper equipment for towing a trailer and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use hitches that clamp onto the vehicle’s bumper or attach to the
axle. You must distribute the load in your trailer so that 10–15% of the
total weight of the trailer is on the tongue.
Safety chains
Always connect the trailer’s safety chains to the frame or hook retainers
of the vehicle hitch. To connect the trailer’s safety chains, cross the
chains under the trailer tongue and allow slack for turning corners.
If you use a rental trailer, follow the instructions that the rental agency
gives to you.
Do not attach safety chains to the bumper.
Trailer brakes
Electric brakes and manual, automatic or surge-type trailer brakes are safe
if installed properly and adjusted to the manufacturer’s specifications. The
trailer brakes must meet local and Federal regulations.
WARNING:Do not connect a trailer’s hydraulic brake system
directly to your vehicle’s brake system. Your vehicle may not
have enough braking power and your chances of having a collision
greatly increase.
Trailer lamps
Trailer lamps are required on most towed vehicles. Your vehicle may be
equipped with one of two possible trailer wiring designs. Make sure all
running lights, brake lights, turn signals and hazard lights are working.
See your dealer or trailer rental agency for proper instructions and
equipment for hooking up trailer lamps.
Driving while you tow
When towing a trailer:
•Do not drive faster than 70 mph (113 km/h) during the first 500 miles
(800 km) of trailer towing and don’t make full-throttle starts.
Driving
148
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

FIFTH-WHEEL OPERATION
WARNING:Failure to follow the fifth-wheel manufacturer’s
instructions for hooking and unhooking as well as sliding the
fifth-wheel could result in an accident, personal injury or death.
WARNING:When the tractor and trailer are parked unattended,
the trailer brake hand control should never be used to apply the
brake, since air may leak from the system, allowing vehicle movement,
resulting in possible property damage, personal injury or death.
Before hook-up, make sure:
•The fifth-wheel jaws are fully opened.
•The fifth-wheel is fully tilted back to prevent body damage when the
tractor is backed under a trailer.
•The trailer wheels are blocked and the trailer spring brakes are
adjusted and applied. Never chase a trailer.
•The brake hoses and light cords are clear of the fifth-wheel.
Hook-up
1. Back the tractor squarely under the trailer, engaging the fifth-wheel
jaws on the kingpin. Always back-up slowly, making sure the trailer is
neither too high nor too low. Avoid backing under the trailer from an
angle.
2. Connect the service and emergency brake hoses and trailer light
connector. Refer toTractor-trailer connectionsin theAir suspension
section of this chapter, adhering to the warning and using the three-point
stance while connecting and disconnecting the trailer.
3. Inspect the jaws of the fifth-wheel to be sure they have fully closed on
the trailer kingpin and the trailer plate is resting securely on the
fifth-wheel.
4. Be sure the coupler release lever is in the locked position.
5. Charge the trailer brake system. Set the trailer brakes, either with the
hand valve or tractor protection valve. Pull against the trailer for an
additional check of proper hook-up. Do not pull hard enough to damage
or strain the equipment.
Driving
150
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

6. Set the tractor parking brakes and fully raise the trailer landing gear.
Refer toBrakesin this chapter for proper operation of the parking brake
and trailer brakes.
7. Check the operation of all trailer lights and correct any lights that may
be faulty.
Un-hook
1. Try to keep the tractor and trailer in a straight line.
2. Apply the parking brakes.
3. Lower the trailer landing gear, making sure it is on solid, level ground.
The weight of the trailer is to be on the landing gear.
4. Block the trailer wheels.
5. Disconnect the brake hoses and light cords. Be sure hoses and cords
are clear.
6. Pull coupler release lever to disengage the fifth-wheel jaws.
7. Release the tractor parking brakes.
8. Pull out from the trailer slowly, allowing the landing gear to take the
load gradually.
Driving
151
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Fuse/Relay
locationFuse amp
ratingFuse description
15 10A Interior lamp relay
16 15A High beams, Indicator
17 — Not used
18 5A Dimmer switch, Interior lighting
19 15A Engine control (diesel engine only)
20 5A Starting system
21 10A DRL resistor
22 15A Air horn, Air suspension dump, Two-speed
axle, Driver-controlled locking differential
23 10A Flasher relay
24 15A Hydraulic brakes relay, Fuel heater relay
(diesel engine only), Air dryer
25 10A Blower motor relay coil
26 10A Right-hand low beam headlight
27 — Not used
28 10A Left-hand low beam headlight
29 10A Cluster, GEM
30 15A Allison electronic transmission
31 15A Mirror fold relay
Relay 1 — Interior lamps
Relay 2 — Not used
Relay 3 — Horn
Relay 4 — Not used
Relay 5 — Not used
Roadside Emergencies
155
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)

Fuse/Relay
locationFuse amp
ratingFuse description
10 15A Air tank moisture removal valve
11 30A Electric trailer brake
12 20A Passenger compartment fuse box 5 and 21
13 15A Instrument cluster/Gateway module
14 20A Nitrogen oxide sensor (diesel engine only)
15 — Not used
16 5A BendixAir ABS
17 — Not used
18 10A Fuel transfer pump
19 15A Powertrain control module power 1 (gasoline
engine only)
20 10A Powertrain control module power 2 (gasoline
engine only)
21 20A Powertrain control module power 3 (gasoline
engine only)
22 20A Powertrain control module power 4 (gasoline
engine only)
23 — Not used
24 10A Powertrain control module keep-alive power
(gasoline engine only)
101 30A Bendix Air ABS relay (Air brake vehicles
only)
Hydraulic brakes module (Hydraulic brake
vehicles only)
102 20A Ignition switch
103 20A Ignition switch, Passenger compartment fuse
box fuses 19, 29 and 30
104 20A Power point
105 20A Power door lock switches
106 30A Main light switch, Multi-function switch
107 50A Passenger compartment fuse box fuses 1, 2,
3, 4, 12, 13, 14 and 15
Roadside Emergencies
157
2012 F-650/750(f67)
Supplement, 2nd Printing
USA(fus)