fuel FORD F650/750 2023 Service Manual

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As the diesel exhaust fluid level
nears empty, the warning
symbol displays and a series of
tones and messages starting at 500 mi
(800 km) remaining before diesel exhaust
fluid is depleted. The warning symbol and
messages continue until you refill the
diesel exhaust fluid tank.
Continued driving without refilling results
in the following actions as required by the
California Air Resources Board (CARB) and
the U.S. Environmental Protection Agency
(EPA):
• Within a preset distance to empty,
speed is limited upon vehicle restart.
Prior to this occurring a message
appears in the information display.
• Further vehicle operation without
refilling the diesel exhaust fluid tank
causes the engine to enter an idle-only
condition. This only occurs upon vehicle
refueling or at an extended idle. A
message indicates the required actions
to resume normal operation. It is
required to add a minimum of 1.0 gal
(3.8 L) of diesel exhaust fluid to the
tank to exit the idle-only condition, but
your vehicle is still in the speed-limiting
mode until you refill the tank
completely.
Note:For either vehicle speed limiting or
idle-only condition, normal vehicle operation
resumes when you refill the diesel exhaust
fluid tank.
Note:When filling the diesel exhaust fluid
tank from empty, there may be a short delay
before detecting the increased level of fluid.
The increased level detection must occur
before your vehicle returns to full power.Diesel Exhaust Fluid Guidelines
and Information
• Use only diesel exhaust fluid that
carries the American Petroleum
Institute (API) certified diesel exhaust
fluid trademark or ISO 22241.
• Do not put diesel exhaust fluid in the
diesel fuel tank. If this happens, do not
switch the ignition on. Drain the fuel
tank as soon as possible.
• Do not overfill the diesel exhaust fluid
tank.
• Diesel exhaust fluid is corrosive.
• Do not reuse the diesel exhaust fluid
container once it is emptied.
• Avoid spilling diesel exhaust fluid on
painted surfaces, carpeting or plastic
components. Immediately wipe away
any diesel exhaust fluid that has spilled
with a damp cloth and water. If it has
already crystallized, use warm water
and a sponge.
• Store diesel exhaust fluid out of direct
sunlight and in temperatures between
23°F (-5°C) and 68°F (20°C).
• Diesel exhaust fluid freezes below 12°F
(-11°C).
• Do not store the diesel exhaust fluid
bottle in your vehicle. If it leaks it could
damage interior components or release
an ammonia odor inside your vehicle.
• Diesel exhaust fluid is a
non-flammable, non-toxic, colorless
and water-soluble liquid.
• The system has a diesel exhaust fluid
quality sensor. Dilution of diesel
exhaust fluid or use of any other liquid
in the selective catalytic reduction
system leads to a diesel exhaust fluid
system fault, eventually leading to the
vehicle only operating in idle-only
mode.
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Engine Emission Control

• Do not dilute diesel exhaust fluid with
water or any other liquid.
• An ammonia odor may be smelled
when the cap is removed or during
refill. Refill diesel exhaust fluid in a well
ventilated area.
Typical Diesel Exhaust Fluid Usage
When Using the Power Take Off (PTO)
Continuous PTO use—Minimal PTO use
0–7,800 mi (0–12,550 km)
Contaminated Diesel Exhaust
Fluid or Inoperative Selective
Catalytic Reduction System
Selective catalytic reduction systems are
sensitive to contamination of the diesel
exhaust fluid. Maintaining the purity of the
fluid is important to avoid system
malfunctions. Do not add fuel or any
additive to the diesel exhaust fluid tank. If
you remove or drain the diesel exhaust fluid
tank, do not use the same fluid to refill the
tank. The system has a sensor to monitor
fluid quality.
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A warning lamp illuminates and
a message appears in the
information display if the system
becomes contaminated or inoperative.Continued driving without replacing diesel
exhaust fluid or having the selective
catalytic reduction system repaired results
in the following actions as required by the
California Air Resources Board (CARB) and
U.S. Environmental Protection Agency
(EPA):
€ Within a preset distance to empty,
speed is limited upon vehicle restart.
Prior to this occurring a message
appears in the information display.
€ Further vehicle operation without
replacing contaminated diesel exhaust
fluid causes the engine to enter an
idle-only condition. This only occurs
upon vehicle refueling, vehicle idling in
park for 1 hour, or engine shutdown for
10 minutes or more and is indicated by
a message in the information display
indicating the required actions to
resume normal operation.
Note:For vehicle speed limiting or idle-only
condition, normal vehicle operation resumes
when you repair the contaminated system.
To service a contaminated or inoperative
system, see an authorized dealer.DIESEL PARTICULATE FILTER
(IF EQUIPPED)
Your vehicle has a diesel particulate filter.
The diesel particulate filter is an inline filter
in the exhaust system that reduces carbon
emissions by trapping exhaust particles
before they reach the tailpipe. The diesel
particulate filter looks similar to a
traditional exhaust catalyst, except larger,
and is part of the exhaust system under
your vehicle. The filter couples to a diesel
oxidation catalyst that reduces the amount
of harmful exhaust emitted from the
tailpipe. As soot gathers in the system, it
begins to restrict the filter. Periodically, you
need to clean the soot that gathers inside
the filter. You can clean the soot in two
different ways, passive regeneration and
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Engine Emission Control

Before you start operator commanded
regeneration, do the following:
• Shift into park (P) or if you have an
RNDM selector shift into neutral (N)
and apply the parking and or air brake,
on stable, level ground.
• Park your vehicle outside of any
structure.
• Park your vehicle 10–15 ft (3–5 m)
away from any obstructions and away
from materials that can easily combust
or melt, for example paper, leaves,
petroleum products, fuels, plastics and
other dry organic material.
• Make sure there is a minimum of 1/8
tank of fuel.
• Make sure all fluids are at proper levels.
How to Start Operator Commanded
Regeneration
WARNING: Stay clear of the
exhaust tailpipe during regeneration. Hot
exhaust gases can burn you badly.
Note:You cannot use the operator
commanded regeneration until the diesel
particulate filter load percentage has
reached 100%. The diesel particulate filter
load percentage fluctuates up and down
when driving your vehicle due to active and
passive regenerations.
Note:During the use of operator
commanded regeneration, you may observe
a light amount of white smoke. This is
normal.
You may not be able to use
operator commanded
regeneration if the service engine
soon warning lamp appears in the
information displayInformation Display Procedure
Start your vehicle engine and when it has
reached the normal operating temperature,
arrow through the display to get to the
Diesel Particulate Filter Status on the
Truck Info tab. Exhaust Filter XX%/FULL
displays. Operator commanded
regeneration can only be initiated when
FULL See Information Display Control
(page 52). If a message advising that the
exhaust filter is full appears in the
information display, press and hold the OK
button to initiate Exhaust Cleaning. If
successful, a second prompt appears
regarding exhaust position required to
initiate operator commanded regeneration.
Be sure to understand each prompt. If you
are not sure what is being asked by each
prompt, contact an authorized dealer. If
the exhaust system meets the position
requirements then press and hold the OK
button to fully activate the Operator
Commanded Regeneration. The display
confirms the operation has started and
when it has finished.
You can also drive to clean the filter.
When the system is at the point
of oversaturation, the service
engine warning lamp illuminates
and a message appears in the information
display. You cannot initiate filter cleaning.
You must have your vehicle checked as
soon as possible.
Once operator commanded regeneration
starts, engine speed increases to
approximately 1600 rpm and the cooling
fan speed increases. You will hear a
change in audible sound due to engine
speed and cooling fan speed increases.
It is not necessary to open the hood on the
engine compartment. Once operator
commanded regeneration completes, the
engine speed returns to normal idling. The
exhaust system remains very hot for
several minutes even after regeneration is
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Engine Emission Control

AUTOMATIC TRANSMISSION
WARNING: Apply the parking
brake, shift into park (P), switch the
ignition off and remove the key before
you leave your vehicle. Failure to follow
this instruction could result in personal
injury or death.
WARNING: Do not apply the brake
pedal and accelerator pedal
simultaneously. Applying both pedals
simultaneously for more than a few
seconds will limit engine performance,
which may result in difficulty maintaining
speed in traffic and could lead to serious
injury.
Understanding the Shift Positions
of a 6–Speed Automatic
Transmission
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PRNDM21
Putting your vehicle in or out of gear:
1. Fully press the brake pedal.2. Move the gearshift lever into the
preferred gear.
3. When you finish driving, come to a
complete stop.
4. Move the gearshift lever and securely
latch it in park (P) or neutral (N).
The instrument cluster displays the current
gear.
Park (P)
If your transmission has a park (P) position,
this position locks the transmission and
prevents the rear wheels from turning.
Reverse (R)
With the gearshift lever in reverse (R), your
vehicle moves backward. Always come to
a complete stop before shifting into and
out of reverse (R).
Neutral (N)
With the gearshift lever in neutral (N), you
can start your vehicle and it is free to roll.
Hold the brake pedal down when in this
position.
Drive (D)
Drive (D) is the normal driving position for
the best fuel economy. The overdrive
function allows automatic upshifts and
downshifts through gears one through six.
Manual (M)
With the gearshift lever in manual (M), the
driver can change gears up or down as
preferred. By moving the gearshift lever
from drive (D) to manual (M), you now
have control of selecting the gear you
prefer using the buttons on the shift lever.
See Understanding Your SelectShift
Automatic™ Transmission later in this
section.
128
Transmission

Understanding Your SelectShift™
Automatic Transmission
Your vehicle has a SelectShift automatic
transmission gearshift lever. SelectShift
automatic transmission gives you the
ability to change gears up or down, without
a clutch.
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Use the buttons on the shifter to lock or
unlock gears and manually select gears.
Press the (+) button to upshift or the (…)
button to downshift.
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With the gearshift lever in drive (D), press
the (–) button to activate SelectShift. The
instrument cluster indicates the available
and selected gears.
All available gears display with the current
gear indicated. Press the (–) button again
to lock out gears beginning with the highest
gear. For example, press the (–) button
twice to lock out 6th and 5th gears. Only
the available gears display, and the
transmission shifts between the available
gears. Press the (+) button to unlock gears.
By moving the gearshift lever from the drive
(D) position to the manual (M) position,
you could now manually select the gear
you prefer. Only the current gear displays.
Press the (+) button or the (–) button to
upshift or downshift. If you press the (–)
button at a vehicle speed that would cause
an engine overspeed, the requested gear
flashes, then disappears, and the
transmission remains in the current gear.
Recommended shift speeds
Upshift according to the following chart:
Upshifts when accelerating (recommended for best fuel economy)
Diesel engines Gasoline engines Shift from:
12 mph (20 km/h) 15 mph (24 km/h) 1 – 2
19 mph (31 km/h) 25 mph (40 km/h) 2 – 3
26 mph (42 km/h) 40 mph (64 km/h) 3 – 4
34 mph (55 km/h) 45 mph (72 km/h) 4 – 5
46 mph (74 km/h) 50 mph (80 km/h) 5 – 6
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Transmission

To prevent the engine from running at too
low an RPM, which could cause it to stall,
SelectShift still makes some downshifts
if it has determined that you have not
downshifted in time. Although SelectShift
makes some downshifts for you, it still
allows you to downshift at any time if the
SelectShift determines that there is no
damage to the engine from over-revving.
SelectShift does not automatically upshift,
even if the engine is approaching the RPM
limit. Shift manually by pressing the (+)
button.
Note:Engine damage could occur if you rev
the engine excessively and hold it without
shifting.
Progressive Range Selection (If
Equipped)
Progressive range selection gives you the
ability to lockout gears from the automatic
shifting range. This could provide you with
an improved driving experience, for
example, in slippery conditions or when
experiencing a steep slope.
With the gearshift lever in drive (D), press
the (–) button to activate progressive
range selection. The instrument cluster
indicates the available and selected gears.
All available gears display with the current
gear indicated. Press the (–) button again
to lock out gears beginning with the highest
gear. For example, press the (–) button
twice to lock out 6th and 5th gears. Only
the available gears display, and the
transmission shifts between the available
gears. Press the (+) button to unlock gears
to allow the transmission to shift to higher
gears. The transmission shifts within the
gear range you select.
Automatic Transmission at a Stop
(If Equipped)
Your transmission could reduce the load
on the engine when the vehicle stops, and
the gear selector is in drive (D) to reduce
fuel consumption and emissions. The
transmission resumes operation when you
release the brake. This feature activates
when the transmission is sufficiently
warmed, and the vehicle is on a level slope.
Automatic Transmission Adaptive
Learning
This feature could increase durability and
provide consistent shift feel over the life
of your vehicle. A new vehicle or
transmission may have firm shifts, soft
shifts, or both. This is normal and does not
affect the function or durability of the
transmission. Over time, the adaptive
learning process fully updates transmission
operation.
Brake-Shift Interlock
WARNING: Do not drive your
vehicle until you verify that the
stoplamps are working.
WARNING: When doing this
procedure, you need to take the
transmission out of park (P) which
means your vehicle can roll freely. To
avoid unwanted vehicle movement,
always fully apply the parking brake prior
to doing this procedure. Use wheel
chocks if appropriate.
WARNING: If the parking brake is
fully released, but the brake warning
lamp remains illuminated, the brakes
may not be working properly. Have your
vehicle checked as soon as possible.
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Transmission

GENERAL INFORMATION
WARNING: Exceeding these ratings
by overloading can cause component
failure resulting in property damage,
personal injury or death.
Fluid Temperature
If the operating temperature exceeds
250°F (121°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. Do not
consistently run extreme pressure (EP)
lubricants above 250°F (121°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.
We do not recommend, or approve,
performing axle conversions. However, we
understand that, on occasion, others install
aftermarket add-on axles on the truck
chassis that allow operator control for
weight transfer from other axles (such as
air lift axles).
2-SPEED REAR AXLE (IF EQUIPPED)
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.
Note:Do not shift between ranges when
the speed control is on.
A two-speed rear axle allows the driver to
select a low range for greater pulling power
and a high range for greater road speed
and fuel economy. You can also use these
ranges to provide extra steps between
transmission shifts when driving on steep
grades or fuel economy may be factors.
Axle Shifting
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Note:Do not shift the axle to LOW when
your vehicle is moving. Use LOW when you
drive a fully loaded vehicle on a severe grade
or in congested traffic. Use HIGH for all
normal driving conditions with a lightly
loaded or partially loaded vehicle.
Note:The axle is set to HIGH by default.
To shift the axle between HIGH and LOW
with the vehicle stopped, place the
transmission in position N, then press and
hold the button for two seconds.
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Rear Axle

Push the palm release lever (A) on the
parking brake handle (B) and push down
as far as possible to release the brake.
Driving with the parking brake on causes
the brakes to wear out quickly and reduces
fuel economy.
We recommend you not use the parking
brake to stop a moving vehicle. However,
if the normal brakes fail, you can use the
parking brake to stop your vehicle in an
emergency. Since the parking brake only
applies retardation to the rear wheels, the
vehicle's stopping distance increases
greatly and the handling of your vehicle is
adversely affected.
Releasing Spring Manually
WARNING: Do not attempt to
disassemble the parking brake air
chamber under any circumstances as
this may cause serious injury.
WARNING: Block the wheels to
help prevent the vehicle from moving.
WARNING: Unexpected and
possibly sudden vehicle movement may
occur if you do not take these
precautions.
If you release hydraulic pressure from the
spring brake chamber, the power spring
applies the brake. If the hydraulic pressure
can be re-established, you must release
the spring brake in order to move your
vehicle.
Air Brakes (If Equipped)
WARNING: This control is for
parking only. Do not leave the vehicle
unattended after setting the parking
brake without placing the transmission
in park (P). We recommend using wheel
chocks for hilly or off-road
circumstances.
If the service brakes fail to operate while
your vehicle is moving, you can make an
emergency stop with the parking brake.
Since the parking brake only applies
stopping power to the rear wheels, your
vehicle’s stopping distance greatly
increases and the handling of your vehicle
is adversely affected. Make repairs
immediately to an inoperative air brake
system circuit.
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Pull the yellow, dash-mounted parking
brake knob to apply the parking brake.
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The parking brake light
illuminates and remains
illuminated (when you switch
the ignition to the on position) until you
release the parking brake.
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Brakes

• Shift to a lower gear when driving down
a long or steep hill. Do not apply the
brakes continuously, as they may
overheat and become less effective.
• If your transmission is equipped with
the Tow/Haul feature, use this feature
when towing. This provides engine
braking and helps eliminate excessive
transmission shifting for optimum fuel
economy and transmission cooling.
• Allow more distance for stopping with
a trailer attached. Anticipate stops and
brake gradually.
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 open.
• The fifth wheel is fully tilted back to
prevent body damage when the tractor
is backed under a trailer.
• You block the trailer wheels and adjust
and apply the trailer spring brakes.
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;
make 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.
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. Make sure the coupler release lever is
in the locked position.
5. Charge the trailer brake system. Set
the trailer brakes, with either the hand
valve or tractor protection valve. Pull
against the trailer for an extra check of
proper hook-up. Do not pull hard
enough to damage or strain the
equipment.
6. Set the tractor parking brakes and fully
raise the trailer landing gear.
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.
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Towing

GENERAL DRIVING POINTS
General Information
• 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, and 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.
• Do not operate in a gear that permits
an engine speed more than the
maximum governed speed or high-idle
RPM (no load).
• Always shift to a lower gear at high
altitudes to prevent engine smoking.
Backing Up
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.
WARNING: To reduce the risk of
the possibility of personal injury while
backing up the vehicle, always be sure
your vehicle’s path is clear.Before backing up your vehicle, be sure you
can do so safely. If anything behind the cab
limits your view, do not rely on mirrors
alone to make sure 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.
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
guarantee that the intended path is clear.
When in doubt, get out of your vehicle and
visually check the intended path is clear.
Back up slowly as to allow others time to
move, if necessary.
If you install an electrical back up alarm,
connect it to the backup lamp circuit.
Parking
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.
Always use the parking brake. When
parking on a grade, block the wheels and
turn the front wheels to one side so that if
your vehicle rolls, the front tires act against
the curb to stop your vehicle. The front
wheels are more effective at stopping a
rolling vehicle than the rear wheels.
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Driving Hints