engine FORD F750 2006 11.G Owners Manual

INSTALLATION
The engine will not run properly if the fuel filter is not installed
in housing.
1. Install new fuel filter into the fuel filter housing.
2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run roughly and smoke until the air
is completely eliminated.
Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
FUEL FILTER REPLACEMENT - CUMMINS B ENGINE
Refer to your engine operator’s manual for service intervals and
procedures.
FUEL FILTER REPLACEMENT - CATERPILLAR ENGINE
The fuel filter/water separator is
located on the left side of the
engine. Replace the fuel filter/water
separator as recommended in the
Scheduled Maintenance Guide
chapter, or sooner if it becomes
plugged. Vehicles operated on fuel
with more than average impurities
may require replacement of the fuel
filter more frequently. The spin-on
filter has a water drain valve built
into the bottom of the filter canister.
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REMOVAL
1. Using an oil filter wrench, remove the filter.
2. Carefully clean the mating surfaces.
INSTALLATION
1. Fill the filter with clean, fresh diesel fuel.
2. Coat the filter seal with clean, fresh diesel fuel.
3. Hand-tighten the filter until it seats firmly against the mount, then
tighten (by hand) an additional
13to12turn.
4. Start the engine and check for fuel leaks.
FUEL INFORMATION
Important safety precautions
Do not overfill the fuel tank. The pressure in an overfilled tank
may cause leakage and lead to fuel spray and fire.
The fuel system may be under pressure. If the fuel cap is venting
vapor or if you hear a hissing sound, wait until it stops before
completely removing the cap.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Observe the following guidelines when handling fuel:
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•Extinguish all smoking materials
and any open flames before
fueling your vehicle.
•Always turn off the vehicle before
fueling.
•Automotive fuels can be harmful
or fatal if swallowed. If fuel is swallowed, call a physician immediately,
even if no symptoms are immediately apparent. The toxic effects of
fuel may not be visible for hours.
•Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind
can lead to eye and respiratory tract irritation. In severe cases,
excessive or prolonged breathing of fuel vapor can cause serious
illness and permanent injury.
•Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes,
remove contact lenses (if worn), flush with water for 15 minutes and
seek medical attention. Failure to seek proper medical attention could
lead to permanent injury.
•Fuels can also be harmful if absorbed through the skin. If fuel is
splashed on the skin and/or clothing, promptly remove contaminated
clothing and wash skin thoroughly with soap and water. Repeated or
prolonged skin contact with fuel liquid or vapor causes skin irritation.
If you must replace the fuel filler cap, replace it with a genuine
Ford or Motorcraft part. The customer warranty may be void for
any damage to the fuel tank or fuel system if a genuine Ford or
Motorcraft fuel filler cap is not used.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Choosing the right fuel
The engine is designed to use low sulfur number 1D or 2D diesel fuel
only. At temperatures below –20°F (–7°C), number 1D or winter blend
number 2D fuel is recommended. (SeeCold weather operationin the
Drivingsection.) Diesel fuel containing no more than 5% of biodiesel
may be used. Biodiesel fuel is a product derived from renewable fuel
sources such as vegetable oil, animal fat and cooking oil.
Do not use home heating oil or any diesel fuel not intended for
highway use. Red dye is used to identify fuels intended for
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agricultural and non-highway use. Damage to the fuel injection
system, engine and exhaust catalyst can occur if an improper fuel
is used. Do not add gasoline, gasohol or alcohol to diesel fuel.
This practice creates a serious fire hazard and engine
performance problems.
Use low sulfur (less than 0.05% by weight) fuel as required by the EPA
for emission compliance.
Do not mix diesel fuel with gasoline, gasohol or alcohol. This
could cause an explosion resulting in personal injury.
Do not use starting fluid such as ether or gasoline. Such fluids
can cause immediate explosive damage to the engine and
possible personal injury.
Fuel quality
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated diesel fuel that meets ASTM D 975
specification. Aftermarket additives can damage the injector system or
engine. Repairs to correct the effects of using an aftermarket product in
your fuel may not be covered by your warranty.
Do not blend used engine oil with diesel fuel under any
circumstances.Blending used oil with the fuel will significantly increase
your vehicle’s exhaust emissions and reduce engine life due to increased
internal wear.
Many of the world’s automakers approved the World-wide Fuel Charter
that recommends diesel fuel specifications to provide improved
performance and emission control system protection for your vehicle.
Diesel fuel that meet the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about fuel that meet the World-Wide
Fuel Charter.
Running out of fuel
Avoid running out of fuel as this will allow air to enter the fuel system,
which will make restarting the vehicle difficult.
If you have run out of fuel:
•If your vehicle is equipped with dual fuel tanks,add at least 4–5
gallons (15–19 liters) of fuel to each tank before attempting to restart
the engine.
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•If your vehicle is equipped with a Caterpillar engine,the fuel
system must be primed before attempting to restart the engine. Refer
to the engine operator’s manual for instructions on priming the engine.
•Use caution not to overheat and damage the starterby cranking
the engine for an excessive period of time. You may need to crank the
engine for a longer time than normal. If the engine fails to start in 30
seconds, turn the ignition to the OFF position and wait for two
minutes before cranking the engine again.
•Any remaining trapped air will self-purge from the fuel system once
the engine starts running.
•The engine may run rough and produce white smoke while air is in
the fuel system. This is normal and should stop after a short period of
time.
FUEL CONSUMPTION IMPROVEMENT MEASURES
There are two important factors you can control to improve fuel
economy: the mechanical condition of your vehicle and how you drive it.
A properly maintained vehicle will deliver better performance than a
neglected vehicle. Always follow your maintenance schedule to keep your
vehicle in top operating condition.
Also, your driving habits have a significant influence on use of fuel. By
following these suggestions, you can stretch your fuel use:
•Avoid changes in speed as much as possible.
•Anticipate changing traffic conditions. Sudden stops and fast
acceleration waste fuel.
•Avoid extensive idling.
•Do not drive with your foot resting on the brake pedal.
Essentials of good fuel economy
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
possible. Fuel expense, frequency of fill-ups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1,000 miles (1,600
km) of driving (engine break-in period). You will get a more accurate
measurement after 2,000–3,000 miles (3,000–5,000 km).
The advertised fuel capacity of the fuel tank(s) on your vehicle is equal
to the rated refill capacity of the fuel tank(s) as listed inFuel tanksin
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this chapter. The advertised capacity is the amount of the Indicated
Capacity and the Empty Reserve combined. Indicated Capacity is the
difference in the amount of fuel in a full tank and a tank when the fuel
gauge indicates empty. Empty Reserve is the small amount of usable fuel
remaining in the fuel tank after the fuel gauge indicates empty.
The amount of Empty Reserve varies and should not be relied
upon to increase driving range. When refueling your vehicle after
the fuel gauge indicates empty, you might not be able to refuel
the full amount of the advertised capacity of the fuel tank due to
the empty reserve still present in the tank.
Filling the tank
For consistent results:
•Use the same fill rate setting (low - medium - high) each time during
filling.
•Allow three automatic click-offs when filling.
•Always use fuel of a known quality, preferably a national brand.
•Have the vehicle loading and distribution the same every time.
•When refueling a vehicle equipped with dual fuel tanks, if the two
tanks are not filled equally, the fuel gauge reading may fluctuate
slightly until the fuel level between the two tanks balance out and
become equal.
Your results will be most accurate if your filling method is consistent.
Note:For vehicles equipped with dual fuel tanks, engine performance
may degrade if fuel is not added to both tanks when refueling.
Calculating fuel economy
1. Fill the fuel tank(s) completely and record the initial odometer
reading (in miles or kilometers).
2. Each time you fill the tank(s), record the amount of fuel added (in
gallons or liters).
3. After at least three to five tank fill-ups, fill the fuel tank(s) and record
the current odometer reading.
4. Subtract your initial odometer reading from the current odometer
reading.
5. Follow one of the simple calculations in order to determine fuel
economy:
•Divide total miles traveled by total gallons used.
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Air Intake System
•Air Cleaner:should be inspected and its location should not be
altered. Do not alter inlet and outlet piping.
Body
•Wheel Well:splash shields, cab shields and under-hood insulation
should be inspected for deterioration, dislocation, and orientation.
Cooling System
•Check the fan for damage to blades; replace, if damaged, with the
recommended parts. Inspect for fan to shroud interference, and any
damage to shroud such as cracks and holes.
•The fan ratio should not be changed and the fan spacer dimensions
and positions should not be altered.
•Inspect the fan clutch for proper operation, make sure that the fan is
disengaged when cooling of the engine is not required.
•Check for proper operation of radiator shutters, if equipped. The
shutters should be open during normal operating temperatures.
Engine and Driveline System
•Transmission Enclosure:inspect for cracks, holes, and tears. Clean
any deposits such as oil, dirt, and stones.
•Engine valve covers and block covers are made to damp out engine
mechanical noise and, if needed, should be replaced with
recommended parts. Check for mechanical isolations.
Exhaust System
•Inspect the exhaust system for leaks at various joint connections and
tighten the clamps.
•Do a visual inspection for cracks or holes in the muffler and tail pipe.
•Always use the recommended parts when items need to be replaced.
•The tail pipe elbow or offset tail pipe orientation must not be changed
from the standard position as originally received.
•To avoid abnormal changes in vehicle sound levels, it is necessary for
the owner to perform inspections and necessary maintenance at the
intervals shown in theScheduled Maintenance Guidechapter.
CHASSIS-MOUNTED CHARGE AIR COOLER
Inspect charge air cooler daily
With the engine off, visually inspect the charge air cooler core assembly
for debris and clogging of external fins. Prior to engine operation,
remove any debris blocking the core.
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•Turbocharger-to-charge air cooler
•Charge air cooler-to-intake manifold pipe
•Mounting bracket
•Chassis-mounted charge air cooler core
Inspect air intake piping
•Check for accumulation of salt deposits (where applicable). If present,
disassemble and clean the complete air intake piping system. If the
intake piping is pitted, use Motorcraft Silicone Gasket and Sealant
TA-30 to seal joints against leakage.
•Check for loose hoses and clamps.
•Check for ruptured or collapsed hoses.
•Check air cleaner housing for cracks.
ELECTRICAL SYSTEM INSPECTIONS
Periodically inspect electrical connectors on the outside of the cab, 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 Motorcraft Silicone 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 electronic
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 five 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 will change the driveline
angle and may result in unwarrantable component damage, such as
transmission component damage.
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Verify drive axle air suspension height and height control valve
performance at engine lube oil change intervals.
Periodically:
•Check condition of spring leaves for evidence of fatigue, bending or
breakage.
•Check condition of suspension mounting brackets and bushings.
•Check that torque rod mounting fasteners are tight.
•Check to be sure the suspension alignment is maintained at all time.
•Check 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 thereafter must be
re-torqued every 36,000 miles (58,000 km). 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.
Supporting your vehicle for service
When performing service repairs on your vehicle, first prepare the
vehicle by doing the following:
1. Park the vehicle on a level concrete floor.
2. Set the parking brake and block the wheels to prevent the vehicle
from moving.
3. Select a jack with a rated capacity sufficient to lift and hold up the
vehicle.
4. Raise the vehicle with the jack applied to the axle(s). DO NOT use the
bumper as a lifting point.
5. Support the vehicle with floor stands under the axle(s). If the axle or
the suspension are being serviced, support the vehicle with floor stands
under the frame side-members, preferably between the axles.
Do not use a jack when working under a vehicle. It may give
way, causing the vehicle to fall and result in property damage,
personal injury or death. Always use floor stands to support the
vehicle.
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6. Re-torque the nuts to 425 ft. lb (576 N•m), using a diagonal pattern.
(For vehicles equipped with 14ACC, 14 ADN and 14ADP axles.)
7. Use the same diagonal pattern with each U-bolt nut re-torque.
Spring U-bolt checks
Check U-bolt nuts and re-torque every 36,000 miles (58,000 km) after
initial 1,000 miles (1,600 km) re-torque. The U-bolt and nut threads and
seats should be cleaned and lubricated to ensure peak condition when
re-torqued.
PROPELLER SHAFT
At the regular lubrication interval, check the universal joints for any
evidence of wear or looseness. Should propeller shaft vibrations occur,
stop the vehicle immediately to avoid possible hazardous consequences
or damage to other components.
REAR AXLE LUBRICANT
Refer to theScheduled Maintenance Guidechapter for rear axle
lubricant level checks and lubricant change intervals.
Your rear axle may be filled with an optional synthetic lubricant which
allows the use of extended service intervals. A tag on the filler plug will
identify the use of the synthetic lubricant.
Use only a lubricant that meets manufacturer specifications (refer to
Lubricant specificationsin this chapter).
Use of a non-approved rear axle lubricant may cause internal axle
component damage.
Checking the rear axle lubricant level
1. Park the vehicle on level ground.
2. Set the parking brake and shift into N (Neutral) (automatic
transmission) or 1 (First) (manual transmission) and turn the engine off.
3. Clean any dirt from around the rear axle filler plug.
4. Remove the filler plug and inspect the lubricant level.
5. The lubricant level should be up to the bottom of the filler plug
opening.
6. If necessary, add enough lubricant through the filler plug opening so
that the lubricant level is at the bottom of the opening.
7. Clean and install the filler plug securely.
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