torque FORD F650 2012 12.G Owners Manual

Seating and Safety Restraints 69
Seating 69
Rear seats 78
Safety restraints 80
Child restraints 89
Driving 103
Starting 103
Brakes 110
Air suspension 129
Transmission operation 132
Vehicle loading 146
Roadside Emergencies 152
Hazard flasher switch 153
Fuses and relays 153
Jump starting 162
Wrecker towing 166
Customer Assistance 170
Getting assistance outside the U.S. and Canada 172
Reporting safety defects (U.S. only) 174
Reporting safety defects (Canada only) 174
Cleaning 175
Underbody preservation 179
Maintenance and Specifications 181
Hood 189
Engine oil 192
Battery 195
Engine coolant 197
Fuel information 204
Diesel Exhaust Fluid (DEF) 210
Wheel lug nut torque 237
Tire information 238
Lubricant specifications 245
Refill capacities 259
Engine data 262
Table of Contents
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Releasing spring brake manually
WARNING:Do not attempt to disassemble the parking brake
chamber under any circumstances. The high spring load may
cause serious injury if the chamber clamps are removed.
If air pressure is released from the spring brake chamber the power spring
applies the brake and, unless air pressure can be re-established, the spring
brake must be released as follows in order to move the vehicle.
WARNING:Block the wheels to help prevent the vehicle from
moving.
WARNING:Unexpected and possibly sudden vehicle movement
may occur if these precautions are not taken.
Impact wrenches should not be used as they may damage the piston and
prevent proper caging of the spring. Do not apply more than 50 ft-lb
(68 N•m) torque to the release bolt nut.
1. Remove the stud tool and nut
from the carrying pocket on the
brake chamber assembly.
2. Remove the access plug from the
end of the spring chamber.
3. Insert the release stud through
the opening in the chamber and into
the spring pressure plate.
4. Turn the release stud one-quarter
turn to engage the stud tangs with
the slot in the pressure plate. Keep
the stud engaged and install the nut
on the release stud.
5. Tighten the nut until the spring is
fully caged and the brakes are
released. Do not loosen or remove
the release stud and nut unless the brake chamber is completely
assembled and is securely clamped.
6. When the air pressure is restored, unscrew and remove the release
stud and install in the carrying pocket. Install the access plug.
Driving
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Allison 2500
This transmission is available with a column-mounted gearshift lever. The
gear positions are displayed on the RNDL in the instrument cluster.
WARNING: 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.
Transmission fluid operating temperatures - 2200/2500 models
Allison 2200 and 2500 models:The sump/fluid reservoir temperatures
should not exceed 250°F (120°C). The converter temperature should not
exceed 300°F (144°C). he sump/fluid reservoir temperature should not
exceed 250 F (120 C).
TorqShift6-Speed models:The sump/fluid reservoir temperatures
should not exceed 250°F (120°C).
Allison 3000 series
The Allison 3000 Series offers two shift modes: Performance and
Economy. Performance Mode gives the best all-around transmission
operation; Economy Mode provides operation at lower engine RPM while
maintaining adequate performance. The transmission defaults to
Performance Mode when you start the engine. Pressing MODE on the
shifter activates Economy Mode and illuminates the Mode ON lamp.
If the engine speed is above idle when a gear is selected using the
shifter, the vehicle won’t move; 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 separateAllison 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 parking pawl, making it 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.
Driving
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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. After the
PTO is engaged, move the range selector to N (Neutral). Increase the engine
speed until the desired PTO 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.
WARNING: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, always maintains direct relation to vehicle speed. PTO speed
decreases 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 manual transmission
Transmission-mounted PTO units are available for local installation on
your vehicle. See yourBody Builder’s Layout Bookfor restrictions on
use and installation of PTO units.
To engage the PTO unit, stop the vehicle and place the transmission in N
(Neutral). Press the clutch and allow the gears to stop rotating, then
engage the PTO unit. The PTO can also be selected with the
transmission in gear as long as the clutch is pressed.
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).
Driving
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To shift the axle from LOW to HIGH with the vehicle moving, accelerate
to approximately 35 mph (56 km/h), press the lower part of the switch
while the transmission is in N (Neutral), then release and apply the
accelerator.
To shift the axle from HIGH to LOW with the vehicle stopped, place the
transmission in N (Neutral), then press the upper part of the switch.
Note:Do not shift the axle to LOW with the vehicle in motion.
Split-shifting (combined axle and transmission shift - manual
transmissions only)
Split-shift sequence
Ratio combination1234567891011
Transmission gear 1st 1st 2nd 2nd 3rd 3rd 4th 4th 5th 6th 6th
Axle range LO HI LO HI LO HI LO HI LO LO HI
To downshiftthe axle to a slower ratio and shift the transmission, shift
the transmission and move the switch to the lower ratio before the
clutch is re-engaged.
To upshiftthe axle and shift the transmission, move the switch to a
faster ratio and make the transmission shift in the usual manner.
Ratio extender use
Low end:A two-speed axle can be used as a ratio-extender when
split-shifting is not necessary. For low end use, just shift the axle into
LOW to start out, and shift to HIGH when the extra torque is no longer
needed.
Transmission (5-speed) 1st 1st 2nd 3rd 4th 5th 6th
Two-speed axle Axle low Axle high
High end:To use the two-speed axle as a high end ratio-extender, stay
in the LOW range for normal upshifts and only shift the axle to HIGH on
the freeway for greater road speed.
Transmission (5-speed) 1st 2nd 3rd 4th 5th 6th
Two-speed axle Low for gradeability Axle high
Driving
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4. If tapered dowels are required, install them at each stud and into the
flange of the axle shaft. Use a punch or drift and hammer, if needed.
5. Install the fasteners and tighten to correct torque value. Refer to the
Service Manual.
Towing the vehicle with the rear wheels suspended
Note:To avoid damage to the cab roof or air deflector when towing the
vehicle backward (rear wheels suspended) the air deflector must be
removed.
Whenever possible, it is preferable to tow a disabled vehicle from the
rear by raising the rear of the chassis. When towing a vehicle with the
rear of the chassis suspended, the front wheels must be locked in the
straight-ahead position.
Vehicles equipped with a manual transmission must have at least 1.0 pint
(0.5L) of transmission fluid drained from the case. This prevents the
transmission fluid from entering the clutch housing and fluid saturating
the clutch discs. Make sure that the transmission fluid is replaced before
the vehicle is returned to service.
Roadside Emergencies
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At regular intervals, or during other scheduled maintenance (tire
rotation/service, wheel bearing service, alignment, etc.), the kingpins
should be checked for excessive wear. Refer to the service manual for
proper procedures.
Toe-in setting - general inspection
Inspecting steer axle tires in the first 3,000–10,000 service miles
(5,000–16,000 service km) generally shows if tires are wearing normally.
Rapid outside shoulder wear on both tires indicates too much toe-in.
Rapid inside shoulder wear on both tires indicates too much toe-out. In
P&D-type service, left-to-right steer tire tread life differentials up to 40%
can be observed depending on routes and other variables.
Follow the tire manufacturer’s recommended cold inflation pressure for
the tire size, load range (ply rating) and steer axle loading typical for
their operation (each steer axle tire equals
12steer axle loading).
Special applications may warrant a setting based on experience with the
type of tire operating loads and conditions. Radial tires are more
sensitive to toe-in setting than bias ply tires. While not insensitive to
vehicle alignment, fine tuning school bus alignment to line-haul truck
standards does not drastically improve tire tread life.
It is essential that correct toe-in and tire pressure be maintained for
optimum tire wear.
Rear axle - general inspection
Make sure that the axle mounting U-bolts, attaching or mounting bolts
and nuts are securely tightened. Refer toU-bolt nut torquein this
chapter. Regularly check the rear axle for damaged, binding or worn
parts.
NoSpin Detroit Locker positive locking differential
Vehicles equipped with this type differential have the operator’s manual
supplied with the vehicle. Refer to this manual for maintenance checks.
Maintenance and Specifications
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DEF Low Level Warning and Vehicle Consequence
DEF Tank LevelIndicator
LampsConsequence Remedy
Below initial warning
threshold (10% full)DEF solid
None
Add minimum of
1 gallon (3.8L)
DEF to 5 gallon
(19.0L) tank or
2 gallons (7.6L)
DEF to 9 gallon
(34.0L) tank Below critical
warning threshold
(5% full)DEF
blinking
None
Below initial derate
level (2.5% full)DEF
blinking
/
Amber warning
solid40% torque
reduction
Empty + engine
intentionally shut
down or in extended
idleDEF
blinking
/
Amber warning
solid
/
Red engine
solid
40% torque
reduction +
5 mph
(8 km/h)
vehicle speed
limit
Filling the DEF tank
Your vehicle is equipped with a DEF tank with a blue-capped filler port
The 5 gallon (19.0L) DEF tank is located on the left side of the vehicle
under the cab and the 9 gallon (34.0L) DEF tank is located on the right
side of the vehicle behind the Regular Cab and Super Cabs and under the
Crew Cab. The tank can be filled using a nozzle at a DEF filling station
(similar to fuel fill) or using a DEF bottle with a spout. Motorcraftbrand
DEF bottles are recommended. Other aftermarket bottles can be used but
it should have a seal on the spout and an internal vent tube to achieve best
fill performance and prevent overfilling.
Note:Do not put DEF in the fuel tank or any other tank on the vehicle.
This can cause damage to components not covered by your vehicle’s
warranty.
Maintenance and Specifications
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Contaminated DEF
SCR systems are sensitive to
contamination of the DEF. USE
ONLY CERTIFIED DIESEL
EXHAUST FLUID. If the system
becomes contaminated and the
vehicle continues to be driven with
contaminated DEF, the following warnings result:
Reducing Agent and Vehicle Consequence
Condition Indicator Lamps Consequence
Correct reducing agent None None
Incorrect reducing agent, at
detectionAmber warning
None
Incorrect reducing agent, at
detection + 10 hoursAmber warning
40% torque
reduction
Incorrect reducing agent, at
detection + 20 hours and
engine intentionally shut
down or in extended idleAmber warning
Red engine
40% torque
reduction+5mph
(8 km/h) vehicle
speed limit
If any of these warnings appear, the contaminated DEF must be purged
and replaced with approved DEF; refer to an authorized dealer or the
workshop manual.
Upon filling the DEF tank after a DEF contaminated warning, normal
operation resumes when the vehicle is restarted.
DEF guidelines and information
•DEF is non-flammable, non-toxic, colorless and water-soluble liquid.
•Use only DEF that carries the trademark: AMERICAN PETROLEUM
INSTITUTE CERTIFIED DIESEL EXHAUST FLUID.
•Ammonia odor may be smelled when cap is removed or during refill.
Refill DEF in a well ventilated area.
•Prior to filling, make sure surrounding area is clean of debris to
prevent contamination.
•Do not dilute DEF with water or any other liquid.
•Do not put DEF in the fuel tank or any other tank on the vehicle.
•Do not re-use the DEF container or nozzle once it is emptied.
•Do not overfill the DEF tank.
Maintenance and Specifications
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ELECTRICAL SYSTEM INSPECTIONS
Periodically inspect electrical connectors on the outside of the cab, and
on the engine and frame for corrosion and tightness. Exposed terminals
such as the fuel sender, cranking motor, alternator and feed-through
studs should be cleaned and re-coated with a lubricant sealing grease
such as MotorcraftSilicone Brake Caliper Grease and Dielectic
Compound XG-3, or equivalent. This should include the ground cable
connector for batteries, engine and cab as well as the jump starting stud.
Accessory feed connections
Vehicle electrical systems are complex and often include powertrain
components such as engine and transmission controls, instrument panels,
ABS, etc. While most systems operate on battery voltage (12 volts),
some systems can be as high as 90 volts or as low as 5 volts. Refer to the
Electrical Circuit Diagram Manuals, available from your vehicle’s
manufacturer, to ensure that any additional body lights and accessories
are connected to circuits that are both appropriate and not overloaded.
No modification should be made to any vehicle control system without
first contacting your dealer.
SUSPENSION INSPECTION
Note:Do not adjust air suspension height to any setting other than the
specified setting. Altering the height setting changes the driveline angle
and may result in unwarrantable component damage, such as
transmission component damage.
Verify drive axle air suspension height and height control valve
performance at engine oil change intervals.
Periodically check:
•
Condition of spring leaves for evidence of fatigue, bending or breakage.
•Condition of suspension mounting brackets and bushings.
•Torque rod mounting fasteners for tightness.
•For proper suspension alignment; this must be maintained at all times.
•U-bolts after the chassis has been operating under load for 1,000 miles
(1,600 km) or six months (whichever comes first), the U-bolt nuts
must be re-torqued. The U-bolt nuts must be re-torqued every
36,000 miles (58,000 km) thereafter. The U-bolt and nut threads and
seats should be cleaned and lubricated to ensure a “like new”
condition when re-torquing.
Note:See theU-bolt nut torquechart later in this section.
Maintenance and Specifications
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