engine FORD F650/750 2024 Workshop Manual

When the engine control module detectsthat the diesel particulate filter is nearlyfull of particulates and you are notoperating your vehicle in a manner to alloweffective automatic regeneration,messages appear in the informationdisplay as a reminder for you to drive yourvehicle in order to clean the dieselparticulate filter. If you drive your vehiclein a manner to allow effective automaticregeneration, the information displayshows a cleaning exhaust filter message,which is the normal regeneration process.You can also choose operator commandedregeneration to clean the exhaust systemat this point. See Information Messages(page 75).
If you are not able to drive in a manner thatallows effective automatic activeregeneration or you choose to performregeneration of the diesel particulate filterwhile at idle, then operator commandedregeneration would need to be performed.
Operator Commanded Regeneration(If Equipped)
If your vehicle is operated with significantstationary operation, low speed drivecycles less than 25 mph (40 km/h), shortdrive cycles, a drive time is less than 10 -15 minutes or the vehicle does not fullywarm up, passive and active regenerationmay not sufficiently clean the dieselparticulate filter system. Operatorcommanded regeneration allows you tomanually start regeneration of the dieselparticulate filter at idle to clean the filteronly when the diesel particulate filter is full(100%). If you are not sure whether yourvehicle has this feature, contact anauthorized dealer.
When to Carry Out Operator CommandedRegeneration
You can use the operator commandedregeneration feature when a messageappears in the information display only.When viewing the Exhaust Filter Statusmessage - Exhaust Filter XX% and thediesel particulate filter message indicatesFULL, and you are not able to drive in amanner that allows effective automaticactive regeneration, or if you choose tomanually start the regeneration of thediesel particulate filter manually while thevehicle is idle. See InformationMessages (page 75).
How to Run Multiple Regeneration Cycles
1.Park the vehicle in an outdoor location.
2.Fully raise the vehicle hood. The hoodshould remain up for the entireregeneration process.
3.Start the DPF Service Regenerationprocedure on the vehicle. The DPFregeneration cycle should takeapproximately 30 minutes tocomplete.
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4.After the DPF Service Regenerationprocedure completes:
•If the vehicle’s soot level is at anacceptable level, close the hood.The vehicle is ready to be driven.
•If the vehicle’s soot level remainshigher than desired, let the vehicleidle for a minimum of 30 minutes(hood remains fully open). Afterthe 30 minutes have passed,initiate the second DPFregeneration procedure. It is veryunlikely that more than 2regeneration cycles will be required,but if additional cycles arenecessary, allow for a 30-minutevehicle idle (hood up) to occurbetween regeneration cycles.
5.Once all DPF regeneration cycles arecomplete, close the hood. The vehicleis ready to be driven.
Operator Commanded RegenerationPrecautions and Safe Exhaust Position
WARNING: Do not park or idle yourvehicle over dry leaves, dry grass or othercombustible materials. The regenerationprocess creates very high exhaust gastemperatures and the exhaust willradiate a considerable amount of heatduring and after regeneration and afteryou have switched the engine off. This isa potential fire hazard.
WARNING: Stay clear of theexhaust tailpipe during regeneration. Hotexhaust gases can burn you badly.
Make sure that the louvers located at thetip of the exhaust are clear of anyobstructions as they are used to introducefresh air into the tailpipe to cool theexhaust gases as they leave the exhaustsystem.
Before you start operator commandedregeneration, do the following:
•Shift into park (P) or if you have anRNDM selector shift into neutral (N)and apply the parking and or air brake,on stable, level ground.
•Park your vehicle outside of anystructure.
•Park your vehicle 10–15 ft (3–5 m)away from any obstructions and awayfrom materials that can easily combustor melt, for example paper, leaves,petroleum products, fuels, plastics andother dry organic material.
•Make sure there is a minimum of 1/8tank of fuel.
•Make sure all fluids are at proper levels.
How to Start Operator CommandedRegeneration
WARNING: Stay clear of theexhaust tailpipe during regeneration. Hotexhaust gases can burn you badly.
Note:You cannot use the operatorcommanded regeneration until the dieselparticulate filter load percentage hasreached 100%. The diesel particulate filterload percentage fluctuates up and downwhen driving your vehicle due to active andpassive regenerations.
Note:During the use of operatorcommanded regeneration, you may observea light amount of white smoke. This isnormal.
You may not be able to useoperator commandedregeneration if the service enginesoon warning lamp appears in theinformation display
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2024 F-650/750 (TBC) , enUSA, Edition date: 202210, First-PrintingEngine Emission ControlE67028

Information Display Procedure
Start your vehicle engine and when it hasreached the normal operating temperature,arrow through the display to get to theDiesel Particulate Filter Status on theTruck Info tab. Exhaust Filter XX%/FULLdisplays. Operator commandedregeneration can only be initiated whenFULL See Information Display Control(page 53). If a message advising that theexhaust filter is full appears in theinformation display, press and hold the OKbutton to initiate Exhaust Cleaning. Ifsuccessful, a second prompt appearsregarding exhaust position required toinitiate operator commanded regeneration.Be sure to understand each prompt. If youare not sure what is being asked by eachprompt, contact an authorized dealer. Ifthe exhaust system meets the positionrequirements then press and hold the OKbutton to fully activate the OperatorCommanded Regeneration. The displayconfirms the operation has started andwhen it has finished.
You can also drive to clean the filter.
When the system is at the pointof oversaturation, the serviceengine warning lamp illuminatesand a message appears in the informationdisplay. You cannot initiate filter cleaning.You must have your vehicle checked assoon as possible.
Once operator commanded regenerationstarts, engine speed increases toapproximately 1200 rpm and the coolingfan speed may increase. You will hear achange in audible sound due to enginespeed and cooling fan speed increases.
It is not necessary to open the hood on theengine compartment. Once operatorcommanded regeneration completes, theengine speed returns to normal idling. Theexhaust system remains very hot forseveral minutes even after regeneration is
complete. Do not reposition the vehicleover materials that could burn until theexhaust system has had sufficient time tocool. Depending on the amount of sootcollected by the diesel particulate filter,ambient temperature and altitude,operator commanded regeneration lastsapproximately 30 minutes.
Operator Commanded Regenerationwith Automatic Regeneration Control(If Equipped)
If your vehicle is operated with significantstationary operation, low speed drivecycles less than 25 mph (40 km/h), shortdrive cycles, drive time less than 15 minutesor the vehicle does not fully warm up,passive and active regeneration may notsufficiently clean the diesel particulatefilter system. You can switch off automaticregeneration until better driving conditionsare available, for example steady highspeed driving. You can then switchautomatic regeneration back on to cleanthe diesel particulate filter.
Switching Automatic RegenerationControl On and Off
To switch operator commandedregeneration on and off, use theinformation display control on the steeringwheel. See Information Display Control(page 53). Scroll through the Settings tabto ensure there is a check in the box nextto Auto Regeneration, this means it isactive. To deactivate Auto Regeneration,uncheck the box. A message appears “AutoExhaust Cleaning Off” along with an iconindicating that Auto Exhaust Cleaning isdisabled. The icon stays illuminated untilyou switch Auto Exhaust Cleaning back onby checking the box.
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2024 F-650/750 (TBC) , enUSA, Edition date: 202210, First-PrintingEngine Emission ControlE67028

How to Interrupt or Cancel OperatorCommanded Regeneration
If you need to cancel the operatorcommanded regeneration, pressing thebrake, accelerator or switching the engineoff stops the procedure. Depending on theamount of time you allowed the operatorcommanded regeneration to operate, sootmay not have had sufficient time to be fullyeliminated, but the exhaust system andexhaust gas may still be hot. If you shutyour vehicle off during operatorcommanded regeneration, you may noticeturbo flutter. This is a normal consequencecaused by shutting off a diesel engineduring boosted operation and is considerednormal.
Filter Service and Maintenance
Over time, a slight amount of ash buildsup in the diesel particulate filter, which isnot removed during the regenerationprocess. The filter may need to be replacedwith a new or remanufactured part atapproximately 250,000 mi (400,000 km).Actual mileage varies depending on engineand vehicle operating conditions.
If filter service is required, theengine control system warninglamp illuminates in theinformation display.
If there are any issues with thediesel particulate filter system,the engine control systemwarning lamp and a serviceengine soon warning lampilluminate to inform you thatyour vehicle requires service. Have yourvehicle checked as soon as possible.
Resonator and Tailpipe AssemblyMaintenance
Aftermarket devices or modifications tothe exhaust system may reduce theeffectiveness of the exhaust system aswell as cause damage to the exhaustsystem or engine. This may also degradevehicle performance and could lead toengine damage that may not be coveredby the vehicle Warranty.
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To return to normal drive (D) position,move the shift lever back from manual (M)to drive (D).
The transmission operates in gears onethrough six.
Second (2)
The transmission operates in second (2)gear only. Use second (2) gear to just starton slippery roads.
First (1)
•The transmission operates in first (1)gear only.
•Provides maximum engine braking.
•Allows upshifts by moving gearshiftlever.
•Does not downshift into first (1) gearat high speeds; allows for first (1) gearwhen vehicle reaches slower speeds.
Forced downshifts
•Allowed in drive (D) with the tow/haulfeature on or off.
•Press the accelerator to the floor.
•Allows transmission to select anappropriate gear.
Tow/Haul Mode
To activate tow/haul, press thebutton on the gearshift leveronce. The TOW HAUL indicatorilluminates in the instrument cluster.
The tow/haul feature:
•Delays upshifts to reduce the frequencyof transmission shifting.
•Provides engine braking in all forwardgears, which slows your vehicle andassists you in controlling your vehiclewhen descending a grade.
•Depending on driving and loadconditions, could downshift thetransmission to slow your vehicle andhelp control your vehicle speed whendescending a hill, without pressing theaccelerator pedal. Tapping the brakepedal downshifts the transmission toprovide additional braking, only if thedownshift does not cause an engineoverspeed condition.
The tow/haul feature improvestransmission operation when towing atrailer or a heavy load. All transmissiongear ranges are available when usingtow/haul.
Note:Under certain conditions, theautomatic tow/haul feature engages, andthe TOW HAUL indicator illuminateswithout pressing the tow/haul button.
To deactivate the tow/haul feature andreturn to normal driving mode, press thebutton on the gearshift lever twice. TheTOW HAUL indicator turns off. Tow/haulalso deactivates when you power downyour vehicle.
WARNING: Do not use tow/haulwhen the road surface is slippery. Failureto follow this instruction could result inthe loss of control of your vehicle.
WARNING: Do not use dieselengine exhaust braking when the roadsurface is slippery. Failure to follow thisinstruction could result in the loss ofcontrol of your vehicle.
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Understanding Your SelectShift™Automatic Transmission
Your vehicle has a SelectShift automatictransmission gearshift lever. SelectShiftautomatic transmission gives you theability to change gears up or down, withouta clutch.
Use the buttons on the shifter to lock orunlock gears and manually select gears.Press the (+) button to upshift or the (–)button to downshift.
6- Speed Transmissions
10-Speed Transmissions
With the gearshift lever in drive (D), pressthe (–) button to activate SelectShift. Theinstrument cluster indicates the availableand selected gears.
All available gears display with the currentgear indicated. Press the (–) button againto lock out gears beginning with the highestgear. For example, press the (–) buttontwice to lock out 6th and 5th gears. Onlythe available gears display, and thetransmission shifts between the availablegears. 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 gearyou prefer. Only the current gear displays.Press the (+) button or the (–) button toupshift or downshift. If you press the (–)button at a vehicle speed that would causean engine overspeed, the requested gearflashes, then disappears, and thetransmission remains in the current gear.
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Recommended shift speeds
Upshifts when accelerating (recommended for best fuel economy) 6-Speed
Gasoline enginesShift from:
15 mph (24 km/h)1 – 2
25 mph (40 km/h)2 – 3
40 mph (64 km/h)3 – 4
45 mph (72 km/h)4 – 5
50 mph (80 km/h)5 – 6
Upshifts when Accelerating(Recommended for Best FuelEconomy) 10-Speed
Diesel enginesShift from:
10 mph (16 km/h)1 - 2
15 mph (24 km/h)2 - 3
19 mph (31 km/h)3 - 4
22 mph (35 km/h)4 - 5
25 mph (40 km/h)5 - 6
31 mph (50 km/h)6 - 7
36 mph (58 km/h)7 - 8
45 mph (72 km/h)8 - 9
49 mph (79 km/h)9 - 10
To prevent the engine from running at toolow an RPM, which could cause it to stall,SelectShift still makes some downshiftsif it has determined that you have notdownshifted in time. Although SelectShiftmakes some downshifts for you, it stillallows you to downshift at any time if theSelectShift determines that there is nodamage to the engine from over-revving.
SelectShift does not automatically upshift,even if the engine is approaching the RPMlimit. Shift manually by pressing the (+)button.
Note:Engine damage could occur if you revthe engine excessively and hold it withoutshifting.
Progressive Range Selection (If
Equipped)
Progressive range selection gives you theability to lockout gears from the automaticshifting range. This could provide you withan improved driving experience, forexample, in slippery conditions or whenexperiencing a steep slope.
With the gearshift lever in drive (D), pressthe (–) button to activate progressiverange selection. The instrument clusterindicates the available and selected gears.
All available gears display with the currentgear indicated. Press the (–) button againto lock out gears beginning with the highestgear. For example, press the (–) buttontwice to lock out 6th and 5th gears. Onlythe available gears display, and thetransmission shifts between the availablegears. Press the (+) button to unlock gearsto allow the transmission to shift to highergears. The transmission shifts within thegear range you select.
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9.Start your vehicle.
Perform Steps 4 through 8 in reverse order,making sure to engage the hinge pivotsbetween the upper and lower halves of theshroud. Keep slight pressure in the forwarddirection as you rotate the halves together.
If Your Vehicle Gets Stuck in Mudor Snow
Note:Do not rock your vehicle if the engineis not at normal operating temperature ordamage to the transmission could occur.
Note:Do not rock your vehicle for morethan a minute or damage to thetransmission and tires could occur, or theengine could overheat.
If your vehicle is stuck in mud or snow, youcould rock it out by shifting betweenforward and reverse gears, stoppingbetween shifts in a steady pattern. Presslightly on the accelerator in each gear.
POWER TAKE-OFF (IF EQUIPPED)
Auxiliary equipment called power take-off,or PTO, is often added to the engine ortransmission to operate utility equipment.Examples include a wheel-lift for towtrucks, cranes, tools for construction or tireservice and pumping fluids. PTOapplications draw auxiliary horsepowerfrom the powertrain, often while the
vehicle is stationary or mobile. In thestationary condition, there is limitedcooling air flow through the radiator andaround the vehicle that normally occurswhen a vehicle is moving. The aftermarketPTO system installer, having the mostknowledge of the final application, isresponsible for determining whetheradditional chassis heat protection orpowertrain cooling is required and alertingthe user to the safe and proper operation.
Your vehicle is approved for use as aStationary Mode, SplitShaft Mode orMobile Mode power source within the limitsand operating guidelines detailed in theFord Truck Body Builders Layout Book,found at https://fordbbas.com/home andthrough the Ford Truck Body BuildersAdvisory Service. The transmission powersource modes are engine specific.
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GENERAL INFORMATION
Note: Occasional brake noise is normal. Ifa metal-to-metal, continuous grinding orcontinuous squeal sound is present, thebrake linings may be worn-out. Have thesystem checked as soon as possible. If thevehicle has continuous vibration or shudderin the steering wheel while braking, have thesystem checked as soon as possible.
All standard equipment brakes areself-adjusting. Automatic adjustment,when required, occurs whenever you applyand release the brakes during forward orreverse operation.
Know the required stopping distances forall driving conditions you may encounter.For longer brake lining life, take fulladvantage of engine braking power whencoming to a stop.
Wet brakes result in reduced brakingefficiency. Gently press the brake pedal afew times when driving from a car wash orstanding water to dry the brakes.
If the brakes do not grip well:
•Check brake adjustment.
•Check the brake linings for excessivewear.
•Check the system air pressure onvehicles with air brakes.
•Let the brakes cool if you have beenusing them excessively, as in mountaindriving or after several fast, high-speedstops.
•If you have been driving through deepwater, gently apply the brakes severaltimes while your vehicle is movingslowly.
Brake Over Accelerator
In the event the accelerator pedalbecomes stuck or entrapped, apply steadyand firm pressure to the brake pedal toslow the vehicle and reduce engine power.If you experience this condition, apply thebrakes and bring your vehicle to a safestop. Move the transmission to park (P),switch the engine off and apply the parkingbrake. Inspect the accelerator pedal forany interference. If none are found and thecondition persists, have your vehicle towedto the nearest authorized dealer
Anti-lock Brake System
This system helps you maintain steeringcontrol during emergency stops by keepingthe brakes from locking.
If the light does not illuminateduring start up, remains on orflashes, the system may bedisabled. It also momentarily illuminateswhen you switch the ignition on to confirmthe lamp is functional. If it does notilluminate when you switch the ignition on,or begins to flash at any time, have thesystem checked.
If you connect a PLC trailer withthe ignition on, the trailer ABSlight also illuminates. If the lightfails to illuminate, if it remains on after youstart the vehicle or continues to flash, havethe system serviced immediately.
See Warning Lamps and Indicators(page 67).
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Releasing the Parking Brake
WARNING: When your vehicle isstationary, keep the brake pedal fullypressed when shifting gears. Failure tofollow this instruction could result inpersonal injury, death or propertydamage.
Note:Read and understand the followingsteps and perform them whenever youprepare to drive the vehicle.
Note:The parking brake does not disengageunless sufficient system air pressure isavailable.
1.Press and hold the service brake pedalwhile the engine is running.
2.Select the appropriate drive gear.
3.Push and hold the yellowdash-mounted parking brake knob untilthe parking brake light turns off, thenrelease.
Parking Brake Light Illumination Dueto Low Air Pressure
If the air pressure becomes too low at anytime during vehicle operation, the parkingbrake may apply and the parking brakelight turns on.
If the parking brake applies due to low airpressure, immediate service is required tothe parking brake system.
Releasing Spring Brake with AirPressure
The air system in all vehicles withspring-actuated rear wheel parking brakeshas a valve on the governor for connectionto an outside air supply. The valve lets yourecharge the system with air from anoutside source, releasing thespring-actuated parking brakes. Yourvehicle is now ready to tow in anemergency.
You can only use an outside air source ifthe protected system is in operatingcondition. If you cannot restore air pressurein the protected air system, you mustrelease the spring-actuated brakesmanually.
Releasing Spring Manually
Do not use impact wrenches as they maydamage the piston and prevent propercaging of the spring. Do not apply morethan 50 lb.ft (68 Nm) to the release boltnut.
1.Remove the stud tool and nut from thecarrying pocket on the brake chamberassembly.
2.Remove the access plug from the endof the spring chamber.
3.Insert the release stud through theopening in the chamber and into thespring pressure plate.
4.Turn the release stud ¼ turn to engagethe stud tangs with the slot in thepressure plate. Keep the stud engagedand install the nut on the release stud.
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