engine FORD F650 2013 12.G Repair Manual

Position 1
•Provides maximum engine braking.
•Allows upshifts by moving gearshift lever.
•The transmission does not downshift into position1at high speeds; it
downshifts to a lower gear and then shifts into position1when the
vehicle reaches slower speeds.
Forced Downshifts
•Allowed in positionD.
•Press the accelerator to the floor.
•Allows transmission to select an appropriate gear.
Allison 2200 with Parking Pawl Feature
Note:Also see the separateAllison Transmission Operator’s Manual.
WARNING:Always set the parking brake fully. Do not use the
gearshift in place of the parking brake.
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 positionP.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.
A parking pawl effectively grounds the transmission’s output shaft
preventing rotation of the driveline. If the vehicle is stationary, selecting
positionPplaces the transmission in neutral and engages the parking
pawl. Always use the parking brake when parking the vehicle.
Note:If positionPis selected when the vehicle is in motion, the parking
pawl mechanism ratchets andDOES NOThold the truck.
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Allison 2500
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 positionN.
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.
This transmission is available with a column-mounted gearshift lever. The
gear positions are displayed on the RNDL in the instrument cluster.
Allison 3000
Note:For more information regarding this transmission, see the separate
Allison 3000 Series Operator’s Manual.
The Allison 3000 series offers two shift modes: Performance and
Economy.
Performance mode gives the best all-around transmission operation. The
transmission defaults to this mode when you start the engine. Pressing
MODE on the shifter switches to Economy mode and illuminates the
Mode ON lamp.
Economy mode provides operation at lower engine RPM while
maintaining adequate performance.
If the engine speed is above idle when a gear is selected using the
shifter, the vehicle does not move; the shifter must be moved to re-select
a gear after the engine speed returns to idle.
Torque Lock
If your vehicle is parked on an incline and positionPis not properly
engaged (the parking brake is not applied before the transmission is
shifted into positionP),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 positionP.Hold the brake pedal down while
shifting out of positionP,then release the parking brake.
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selector to positionNand then back into gear. The PTO should never be
engaged by clashing the gear teeth. This may damage the PTO unit and
the transmission PTO drive gear teeth, resulting in further damage to the
transmission and PTO.
PTO Operation with Vehicle Stationary
WARNING:When the PTO is operated with the vehicle
stationary, the transmission must be placed in positionNwith the
parking brake set. If the transmission is not in positionNand 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.
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 positionN.
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.
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.
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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.
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.
Turn the engine off and raise all drive wheels of the locker differential
axle in order to prevent the vehicle from moving when servicing the
wheels, tires or brakes. Axles equipped with a NoSPIN Detroit Locker
differential deliver power to both wheels even when only one wheel is on
the ground.
WARNING:Failure to raise all drive wheels with this type of
differential could cause the vehicle to move unexpectedly,
resulting in property damage, personal injury or death.
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.
Fluid Temperature
Axle operating temperatures normally do not exceed 100°F (38°C).
If the operating temperature exceeds 230°F (110°C), the rate of axle
lubrication oxidation increases and shortens 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).
Axle Conversions
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.
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GENERAL 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.
Note:Occasional brake noise is normal. If a metal-to-metal, continuous
grinding or continuous squeal sound is present, the brake linings may be
worn out and should be inspected by an authorized dealer. If the vehicle
has continuous vibration or shudder in the steering wheel while braking,
the vehicle should be inspected by an authorized dealer.
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 results 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 use to ascend the hill.
WARNING:Continuous application of the brakes causes the
brakes to overheat, resulting in a temporary loss of braking.
See theInstrument Clusterchapter for information on the
brake system warning light.
Wet brakes result in reduced braking efficiency. Gently press the brake
pedal a few times when driving from a car wash or standing water to dry
the brakes.
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 on vehicles equipped with air brakes.
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Anti-lock Brake System (ABS)
This system helps you maintain steering control during emergency stops
by keeping the brakes from locking.
The ABS lamp momentarily illuminates when the ignition is
turned on. If the light does not illuminate during start-up,
remains on or flashes, the ABS may be disabled and may need
to be serviced.
If the ABS is disabled, normal braking is still effective. If the
brake warning lamp illuminates, have your brake system
serviced immediately.
If a PLC trailer is connected when the ignition is switched on,
the trailer ABS light also illuminates. If the light fails to
illuminate, remains on after the vehicle is started or continues
to flash, have the system serviced immediately.
FULL POWER BRAKE SYSTEM
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.
This system incorporates standard braking, an anti-lock braking system
(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 and
pump assemblies that pressurize 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 system.
Note:The motor and pumps run momentarily with the ignition switch in
the on or run position, or in the off position with the brake pedal
pressed.
Note:During normal driving, the pump and motors may be heard
replenishing the accumulators. This is a normal function of the system.
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AIR BRAKES
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 depletes air pressure faster and could result in loss of
braking capability.
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 set 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.
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HINTS ON DRIVING WITH ANTI-LOCK BRAKES
When the system is operating, the brake pedal pulses and may travel
further. Maintain pressure on the brake pedal. You may also hear a noise
from the system. This is normal.
The ABS does not eliminate the dangers inherent when:
•You drive too closely to the vehicle in front of you.
•Your vehicle is hydroplaning.
•You take corners too fast.
•The road surface is poor.
EXHAUST BRAKE (IF EQUIPPED)
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.
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.
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.
Note:Maximum exhaust brake performance is related to the type of
transmission your vehicle is equipped with.
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: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.
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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.
While approaching a steep grade, make sure that the exhaust brake
switch is in the on position. The exhaust brake begins working 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 cannot 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.
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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 exist if the brake is operating properly:
•A slight change in engine sound 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). This force
is actually preventing the vehicle from going much faster.
•Engine temperature remaining in the normal operating range.
•The tachometer showing a drop in engine RPM (depending on grade
and vehicle load) during a descent.
•A decrease in road speed 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.
TRAILER BRAKES
Trailer Brake Hand Control (If Equipped)
WARNING:The hand control should never be used to apply
the brakes when the tractor and trailer are parked unattended.
Air may leak from the system and the vehicle could possibly move,
resulting in possible property damage, personal injury or death.
The hand control is located on the
right-hand side of the instrument
panel. It is used to apply the
trailer service brakes which are
independent of the truck or tractor
service brakes.
It operates a valve that provides gradual control of air pressure applied.
When the valve is only partially applied, the trailer brakes can be
overridden by pressing fully on the brake pedal.
To apply the trailer brakes using the hand control, move the lever
downward. The further the lever is pushed down, the greater the air
pressure is applied to the brakes. The lever remains in place until
manually moved.
To release the trailer brakes, move the lever up completely.
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