engine FORD F750 2006 11.G Workshop Manual

Operating the Eaton 9210B 10–speed transmissions
These transmission have five
forward speeds in both the LO and
HI ranges, and two reverse speeds.
Study the instruction plate on the
sun visor and learn the shift pattern
of your transmission.
To go forward
With the engine idling, depress the
clutch pedal and push the range
control button to the LO range
position. Shift into the LO gear
position and engage the clutch while
pressing on the accelerator to start
forward. Operate the clutch and
upshift through the pattern as
required by driving conditions. To
shift into the HI range from 5th gear
(LO range), place the range control
in the HI range position, then shift into 6th gear. When downshifting
from HI to LO, place the range control into the LO range, then downshift
from 6th gear to 5th gear (below 1,500 engine RPM).
To go backward
Reverse is obtained by putting the
gearshift lever in R (Reverse) and
the range control button in LO or
HI.
7
29
4
8
3 6
1
10
5
R
Neutral
7
29
4
8
3 6
1
10
5
R
Neutral
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
130

POWER TAKE-OFF (PTO) OPERATION
Vehicles equipped with an Allison automatic transmission (except
3000 Series applications and vehicles equipped with a Caterpillar
engine)
The PTO can be operated while the vehicle is standing or moving. To
engage the PTO, apply the brakes and shift to any gear other than N
(Neutral), then engage the PTO.
If engagement is prevented by the gear teeth not meshing properly,
release the brakes and allow the vehicle to creep slightly or shift the
selector to N (Neutral) and then back into gear. The PTO should never
be engaged by clashing the gear teeth as this may damage the PTO unit
and the transmission PTO drive gear teeth. This could result in further
damage to the transmission and PTO.
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 power take-off 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.
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 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, will always maintain direct relation to vehicle speed.
PTO speed will decrease 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.
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
131

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 Caterpillar engine
The PTO will only operate if the transmission is in N (Neutral). This
feature can be overridden by a special service tool; see your dealer or
service representative for more information.
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). Depress 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 depressed.
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).
REAR AXLE INFORMATION
Axle operating temperature normally will not exceed 100°F (38°C). If
the operating temperature exceeds 230°F (110°C), the rate of axle
lubrication oxidation will increase and shorten 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).
Gross axle weight
Your truck has gross axle weight, gross vehicle weight and gross
combination weight ratings. Do not exceed these ratings.
Exceeding these ratings by overloading can cause component
failure resulting in property damage, personal injury or death.
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
132

Rear axles with locking or limited-slip differentials
If your vehicle is equipped with a locking or limited-slip differential, note
the following:
•Power will be transmitted to the opposite wheel should one of the
wheels begin to slip.
•Both wheels must be raised off the ground should it be necessary to
operate one wheel with the vehicle stationary.
If both wheels are not raised off the ground, the one wheel that
is not raised may pull the vehicle off its support, possibly
resulting in personal injury
Driver-controlled differential lock
To prevent the vehicle from moving when servicing the wheels, tires or
brakes, turn the engine off and raise all drive wheels of the locker
differential axle. Axles equipped with NoSPIN Detroit Locker differentials
deliver power to both wheels even when only one wheel is on the
ground.
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.
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.
Some Dana/Spicer drive axles have a driver-controlled differential lock.
The differential lock can lock or unlock the differential when the vehicle
is moving or stopped. When extra traction is required, the differential
lock will provide full power to both axles.
When the differential is locked, the vehicle’s turning radius will increase
(vehicle will “under-steer”)
The differential can be locked or unlocked when the vehicle is moving at
a constant speed of less than 25 mph (40 km/h) and while the wheels
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
133

When operating empty or lightly loaded, sudden or hard braking
may induce wheel lockup with loss of vehicle control and the
possibility of accident and serious injury, especially on wet or slippery
road surfaces.
TRAILER TOWING
Towing a trailer places an additional load on your vehicle’s engine,
transmission, axle, brakes, tires and suspension. Inspect these
components carefully prior to and after any towing operation.
Your vehicle’s load capacity is designated by weight, not by volume, so
you cannot necessarily use all available space when loading a vehicle.
2nd unit bodies are not included in maximum trailer weight ratings. The
weight of the additional “body” must be subtracted from the maximum
trailer weight.
Note:Do not exceed the GVWR or the GAWR specified on the
certification label.
Towing trailers beyond the maximum recommended gross trailer
weight exceeds the limit of the vehicle and could result in
engine damage, transmission damage, structural damage, loss of vehicle
control, vehicle rollover and personal injury.
Model Maximum
GVWR - lb.
(kg)Maximum
GCWR - lb.
(kg)*
F-650 Regular/Super/Crew Cab 26000 (11793) 40000 (18143)
F-750 Regular/Super/Crew Cab 30000 (13608) 45000 (20412)
F-750 Regular/Super/Crew Cab 33000 (14969) 60000 (27216)
* Figures shown are the maximum available for each model. Actual
ratings may be less, depending on your transmission. Check with your
sales consultant for the exact rating on your vehicle.
Preparing to tow
Use the proper equipment for towing a trailer and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use hitches that clamp onto the vehicle’s bumper or attach to the
axle. You must distribute the load in your trailer so that 10–15% of the
total weight of the trailer is on the tongue.
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
138

Trailer towing tips
•Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
•Allow more distance for stopping with a trailer attached.
•If you are driving down a long or steep hill, shift to a lower gear. Do
not apply the brakes continuously, as they may overheat and become
less effective.
•The trailer tongue weight should be 10–15% of the loaded trailer
weight.
•If you will be towing a trailer frequently in hot weather, hilly
conditions, at GCW, or any combination of these factors, consider
refilling your rear axle with synthetic gear lube if not already so
equipped. Refer toLubricant Specificationsin theMaintenance
and Specificationschapter for the lubricant specification. Remember
that regardless of the rear axle lube used, do not tow a trailer for the
first 500 miles (800 km) of a new vehicle, and that the first 500 miles
(800 km) of towing be done at no faster than 70 mph (112 km/h) with
no full throttle starts.
•After you have traveled 50 miles (80 km), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•To aid in engine/transmission cooling and A/C efficiency during hot
weather while stopped in traffic, place the gearshift lever in P (Park)
(if available on your automatic transmission) or N (Neutral) (manual
transmissions and automatic transmissions withoutaP[Park]
position).
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
FIFTH WHEEL OPERATION
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.
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.
2006 F-650/750(f67)
Supplement
USA(fus)
Driving
140

Fuse/Relay
LocationFuse Amp
RatingFuse Description
16 15A High beams
17 — Not used
18 5A Headlamp switch, GEM
19 15A Engine ECM (Caterpillar and Cummins engines)
Engine ECM, Accel, Crank (6.0L Power Stroke
engine only)
20 15A Starter relay, GEM
21 10A Daytime Running Lamps (DRL)
22 15A Air solenoid 4–pack (Air horn, Air suspension
dump, Differential lock axle and Two-speed
axle)
23 10A Electronic flasher
24 15A Vacuum pump, Air dryer, ABS, Fuel heater/Fuel
transfer pump relay, Heated drain valve, 6.0L
Power Stroke Water In Fuel (WIF) module
25 10A Blower motor relay
26 10A RH low beam headlamp
27 — Not used
28 10A LH low beam headlamp
29 10A Cluster (Power, Warning lamps), Hydraulic ABS
relay, Air traction control
30 30A Not used
31 15A Allison transmissions
Relay 1 — Interior lamps
Relay 2 — Not used
Relay 3 — Horn
Relay 4 — One-touch down window
Relay 5 — Not used
2006 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
146

Power distribution box
Always disconnect the battery before servicing high current
fuses.
Fuse/Relay
LocationFuse Amp
RatingFuse Description
1 15A* Park lamps, Roof lamps
2 30A* Power seat (driver)
3 30A* Power seat (passenger)
4 15A* Washer pump
5 15A* Exhaust brake (Caterpillar and Cummins
engines only)
6 15A* Air intake heater (Caterpillar engine only)
7 15A* Stoplamps
8 25A* Fuel heater (Caterpillar engine only)
20A* Fuel heater (6.0L Power Stroke engine only)
9 20A* Inhibit relay, Engine ECM, Cluster,
Transmission TCM
10 15A* Heated drain valve
11 — Not used
2006 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
147

Fuse/Relay
LocationFuse Amp
RatingFuse Description
12 20A* Daytime Running Lamps (DRL), Blend door
actuator, Climate mode, Back-up, Heated
seats, Trailer ABS, Exhaust brake
13 — Not used
14 — Not used
15 7.5A* Body builder prep/trailer socket stop (6.0L
Power Stroke engine only)
16 5A* WABCO hydraulic ABS Run feed
17 — Not used
18 10A* Fuel transfer pump (duel fuel tanks only)
19 — Not used
20 10A* Engine ECM power relay (6.0L Power Stroke
engine only)
21 10A* GEM (Hydraulic brake vehicles only)
22 10A* Engine IDM2 logic power (6.0L Power Stroke
engine only)
23 — Not used
24 — Not used
101 30A** Bendix Air ABS relay (Air brake vehicles
only)
WABCO ABS modulator relay (Hydraulic
brake vehicles only)
102 20A** Body builder prep Run feed
103 20A** Ignition switch (Junction box fuses 8, 9, 10,
11, 19, 29, 30)
104 20A** Power point
105 20A** Power door locks
106 30A** Headlamps
107 50A** Junction box battery feed (1, 2, 3, 4, 12, 13,
14, 15)
108 40A** Fuel heater (Cummins engine only)
109 40A** Power windows
2006 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
148

Fuse/Relay
LocationFuse Amp
RatingFuse Description
110 30A** Wiper power relay (Park, Low/High speed)
111 30A** Body builder prep
112 40A** Blower motor
113 30A** Heated seats
114 25A** WABCO ABS battery feed (Hydraulic brake
vehicles only)
115 20A** Ignition switch, Central Junction Box fuses 8,
9, 10, 11, Starter motor relay
116 30A** Body builder prep
117 20A** Body builder prep/trailer socket stop
(Caterpillar and Cummins engines only)
118 60A** Hydraulic brake trailer two fuse block
119/120 60A** Hydraulic brake trailer two fuse block
Air brake trailer two fuse block
121/122 60A** HydroMax motor
Air brake trailer two fuse block
201 — Washer pump relay
202 — Wiper speed relay
203 — Wiper run/park relay
204 — Neutral start relay (6.0L Power Stroke engine
only)
Exhaust brake relay (Caterpillar and
Cummins engines only)
205 — RH stop/turn relay
206 — LH stop/turn relay
207 — Drain valve heater relay
208 — Back-up lamps relay
209 — Stoplamps relay
301 — Fuel heater/Fuel transfer pump relay
302 — Park lamps relay
303 — Blower motor relay
2006 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
149