clutch FORD F650 2012 12.G Owners Manual

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 ensure 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 oilUse the dipstick to verify the oil level is in the
proper operating range.
Engine coolantLook through the plastic reservoir or the clear
sight glass on the reservoir (depending upon
vehicle equipment) and verify the coolant level is
within the proper operating range as marked on
the reservoir.Do not remove pressure cap
until the coolant has cooled.
Power steering
fluidVerify that the fluid level is in the proper
operating range. Refer toPower steering fluidin
theMaintenance and Specificationschapter.
Brake fluidRemove the master cylinder caps and inspect the
fluid level. The full mark is at the bottom of the
opening of the fluid ports.
Hydraulic clutch
fluidRemove the cap and inspect the fluid level. The
full mark is at the step of the reservoir.
Belts (fan,
alternator, water
pump and A/C
compressor)Inspect for glazing, fraying or cracking. There
should be no more than 5-7 cracks per rib, per
inch (2.5 cm).
Fluid leaksInspect for signs of fluid puddles, dripping fluid
on the ground under the engine or the underside
of the engine.
HVAC air inletInspect for debris that may have collected on the
HVAC air inlet grille or inside the exterior module
as this may cause reduced system performance.
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WARNING: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 starts at this 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
equipmentBefore 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 verify 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. Inspect door
latches for positive closing, latching and locking.
Starting the
engineSet the parking brake, press 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) or P (Park) (if equipped with a park
position).
Diesel engine:Turn the key to the on position;
when the
light in the instrument cluster
turns off, turn the key to start.
Gas engine:Turn the key to start, then release
it as soon as the engine starts.
Oil pressureVerify engine oil pressure builds to normal
operating range.
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Starting a diesel engine with the vehicle on a steep grade
When starting a diesel engine when the loaded vehicle is on a grade, the
engine RPM starts 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 recovers as the vehicle begins moving.
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.
For best engine operation in temperatures of 32°F (0°C) or lower:
•Make sure the batteries are the correct type and are fully charged.
Check other electrical components to make sure they’re in optimum
condition.
•Use a permanent-type engine coolant 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.
•Use the proper engine oil and maintain it 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.
Note:Idling in cold weather does 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.
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.
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Hot weather operation
•Use a permanent-type engine coolant to protect the engine 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 into
the next lower gear.
Restarting after running out of fuel
The fuel system may need to be purged of air, refer toRunning out of
fuelin theMaintenance and Specificationschapter.
Engine shutdown (diesel engine only)
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.
GENERAL OPERATING INSTRUCTIONS
•Start the vehicle in motion by using the highest gear speed in the
transmission that lets 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, press 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 overspeeding of
the engine; normally, choose the same gear to descend the hill that
you use to ascend the hill. The engine governor has no control over
engine speed when it is being pushed by a loaded vehicle.
•Operate in a gear that permits an engine speed not in excess of the
maximum governed speed or high-idle RPM (no load).
•
Always shift to a lower gear at high altitudes to prevent engine smoking.
•Diesel engines: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.
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POWER PARK (PARKING BRAKE) OPTION (IF EQUIPPED)
This feature uses a brake chamber mounted on the chassis to power a
spring-applied, hydraulically-released driveline parking brake. It is
controlled by a yellow, dash-mounted parking brake knob.
The Power Park Brake is controlled by the park brake dash-mounted,
yellow knob-type switch. The switch has three positions: apply (out),
neutral (central), and release (in). The switch is spring-loaded to return
to the neutral (central) position after being pushed or pulled.
There is no visual indication at the knob that the park brake is applied or
released; check the instrument cluster. If the
light is illuminated,
the parking brake is applied.
Applying the parking brake
To apply the parking brake, pull the yellow, dash-mounted parking brake
knob. A red light (
) in the instrument cluster should illuminate
indicating that the parking brake has been successfully set.
Note:If the
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 toParking 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 does not disengage unless sufficient system air
pressure is available.
Automatic transmissions - dash-mounted push button (Allison
3000 Series) and steering column-mounted (Allison 2200 and 2500)
gear selection:
1. With the engine running, press 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
light turns off, then release.
Manual transmissions - (TTC 7–speed, Eaton/Fuller 5–speed and
6–speed):
1. With the engine running, press and hold the service brake pedal.
2. Press and hold the clutch pedal.
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EXHAUST BRAKE (IF EQUIPPED)
An exhaust brake is an auxiliary braking system that assists, but does
not replace, the primary service brake system. It is intended to help
control vehicle speed; it is not a vehicle stopping device.
A switch on the instrument panel, in
combination with the accelerator
and clutch pedal, allows the
operator to make maximum use of
the exhaust brake in the following
conditions:
•off-highway driving
•mountain driving
•heavy traffic
•high speed highway driving
To operate the brake, push the switch up to turn it on. Push the switch
down to turn it off.
Note:Before starting the engine, make sure that the exhaust brake
switch is pushed down to the off position. Do not turn the exhaust brake
on until the engine has reached normal operating temperature.
While approaching a steep grade, make sure that the exhaust brake
switch is in the on position. The exhaust brake actuates as soon as you
remove your foot from the accelerator pedal.
Before descending a hill or steep grade always select the proper gear. If
the transmission is taken out of gear while descending, it is possible that
you can’t select another gear because of maximum RPM being governed.
Make sure the engine speed does not exceed the maximum allowable
engine RPM; exceeding the maximum allowable engine RPM can result in
damage to the engine. Apply the service brakes to reduce the engine
RPM or make a slower descent by using a lower gear.
While going down the grade, use a low enough gear to descend safely
with a minimum application of the service brakes. As a general guideline,
use the same gear as you use to ascend the hill.
Note:Engine speed has a major influence of retarding performance.
When engine speed is maintained at the maximum allowable level, the
exhaust brake operates at peak performance.
Note:Maximum exhaust brake performance is related to the type of
transmission your vehicle is equipped with.
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Note:Manual transmissions should be downshifted to the lowest gear
possible, without exceeding the maximum RPM limit of the engine. This
maximizes the exhaust brake’s retarding effect.
Note:Exhaust brakes operate effectively with automatic transmissions,
but performance varies with engine speed and the gear selected by the
transmission.
Note:Installing an exhaust or auxiliary brake does not necessarily
protect the engine from exceeding maximum governed speed. The
primary brakes should be used to make sure the engine never exceeds
maximum governed speed under any conditions.
WARNING:The exhaust brake is not recommended for use on
slippery or low traction road surfaces. Under these conditions a
loss of vehicle control could occur.
Exhaust brake operating characteristics
When you remove your feet from both the accelerator and clutch pedals
and the exhaust brake switch is in the on position, the exhaust brake is
activated. The following conditions should exist if the brake is operating
properly:
•A slight change in the sound of the engine when the exhaust brake is
activated.
•A smooth braking effect; do not expect a retarding effect similar to
sudden, hard application of the service brakes.
•The retarding force possibly felt acting against your body when the
brake is applied, depending on the grade and vehicle load. The brake’s
retarding force is actually preventing the vehicle from going much
faster.
•Engine temperature remains in the normal operating range.
•During a descent, the tachometer usually shows a drop in engine RPM
depending on the grade and the vehicle load.
•Road speed usually decreases when the exhaust brake is applied
during a descent, except when the vehicle is carrying a heavy load or
the grade is extremely steep. In these instances, you may need to
apply the service brakes occasionally.
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Allison 3000 series push-button shifter
To shift the transmission into R
(Reverse) or D (Drive), press the
brake pedal, press R or D on the
shifter, 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.
Allison 3000 prognostics
Allison 3000 Series transmissions are equipped with the Allison
Prognostics feature that can alert the driver to needed transmission
maintenance and transmission fluid/filter life. Refer to the separate
Allison transmission manual for complete details.
CLUTCH (IF EQUIPPED)
Do not ride or slip the clutch as this causes unnecessary heat and wear.
Maintain the specified clutch adjustment to prolong its life and regularly
inspect the clutch control linkage for tightness. Refer to theScheduled
Maintenance Guidechapter for other maintenance information. When
adjustment of the clutch is necessary, it is very 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.
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.
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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 starts 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 causes 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 the 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 this causes erratic
engagement which can cause engine stalling and potential serious
damage to driveline components.
Clutch brake (non-synchronized transmissions) - Vehicle stationary
A clutch brake is used to stop 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 at idle speed. Clutch
brake application occurs in the last inch (25 mm) of clutch pedal travel.
When using the clutch brake, fully press the clutch pedal and shift the
transmission into 1 (First) or R (Reverse). If the transmission won’t go
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 shortens and
gear selection shift efforts may increase.
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Double-clutch procedures - non-synchronized transmissions
In order to properly upshift or downshift:
1. Press 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. Press the clutch pedal
immediately and shift into the desired gear, then release the clutch
pedal.
MANUAL TRANSMISSION OPERATION (IF EQUIPPED)
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.
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 press 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.
R 1 3 5
4
6 2
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