warning FORD SUPER DUTY 2012 3.G Diesel Supplement Manual

Low DEF Warnings and Actions — Instrument Cluster Messages
(Optional message center messages shown, base message center messages similar)
Cluster MessageDistance/Exhaust Fluid
Level or ActionCustomer
Requested
ActionsVehicle Actions
Exhaust Fluid Level OK Full exhaust fluid tank Drive normally None
Exhaust Fluid Under
12FullExhaust fluid tank below
12fullDrive normally None
Exhaust Fluid Range
500 miles (805 km)Approximately 500 miles
(805 km) left before
exhaust fluid tank is emptyRefill exhaust fluid None
In 99 Miles (159 km) Speed
Limited to 50 MPH
(80 km/h) Exhaust Fluid
EmptyApproximately 99 Miles
(159 km) left before
exhaust fluid tank is emptyRefill exhaust fluid None
Speed Limited to 50 MPH
(80 km/h) Upon Restart
Exhaust Fluid Empty0 Miles (0 km) – exhaust
fluid tank is emptyRefill exhaust fluid None
Speed Limited To 50 MPH
(80 km/h) Exhaust Fluid
EmptyVehicle restarted with
exhaust fluid tank emptyRefill exhaust fluidSpeed is limited
to 50 MPH.
(80 km/h)
Engine Idled Soon Exhaust
Fluid EmptyThis occurs 200 Miles
(322 km) after the vehicle
reaches the 0 mile (0 km)
exhaust fluid rangeRefill exhaust fluid —
Maintenance and Specifications
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2012 Diesel(67l)
Supplement(supplement), 1st Printing
Arabic_(LHD)(gc_lhd)

Low DEF Warnings and Actions — Instrument Cluster Messages (Optional message
center messages shown, base message center messages similar)
Cluster MessageDistance/Exhaust Fluid
Level or ActionCustomer
Requested
ActionsVehicle Actions
Engine Idled-See Owner’s
Manual Exhaust Fluid EmptyThis occurs when the
exhaust fluid is empty and:
•The vehicle’s diesel fuel
tank is refueled or,
•the engine is shut off for
10 minutes or,
•the engine is idling with
the parking brake engaged
for 60 minutes.Refill exhaust fluidEngine is limited
to idle ONLY
Maintenance and Specifications
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Filling the DEF tank
Your vehicle is equipped with a DEF tank with a blue-capped filler port
located next to the diesel fuel fill inlet. The tank can be filled using a
nozzle at a DEF filling station (similar to fuel fill) or using a DEF bottle
with a spout. MotorcraftDEF bottles are recommended as they are
designed to be spill proof and will stop the flow of DEF when the tank is
full. Other aftermarket bottles can be used, but they should have a seal
on the spout and an internal vent tube to achieve best fill performance
and prevent overfilling. Overfilling your DEF tank can cause damage to
the tank. For DEF capacity, seeMaintenance product specifications
and capacitiesin this chapter.
Note:Do not put DEF in the fuel tank. This can cause engine damage
not covered by your vehicle’s warranty.
Note:Immediately wipe away any DEF that has spilled on painted
surfaces with water and a damp cloth to prevent damage to the paint.
You can purchase DEF at your authorized dealer, most highway truck stops
or you can contact roadside assistance for help in finding a retailer that
sells DEF. See theCustomer Assistancechapter in theOwner’s Guidefor
more information. In addition, there is a government website locator for
DEF at the following web address that can be used to find the nearest
location to purchase DEF: http://www.afdc.energy.gov/afdc/locator/def.
Use only DEF certified by the
American Petroleum Institute (API)
such as MotorcraftDEF or
equivalent meeting Ford specification
WSS-M99C130-A and/or ISO 22241.
Look for API certification trademark
shown here. Repairs resulting from
the use of non-certified DEF
products may not be covered by your vehicle’s warranty.
Maintaining the purity of DEF is important to avoid malfunctions in the
SCR system.
If DEF is removed from the tank for repair work, etc., the same DEF
must not be used to refill the tank as its purity is no longer guaranteed.
WARNING:Make sure that DEF does not come into contact
with eyes, skin or clothing. Should DEF contact your eyes, flush
them with plenty of water and contact a physician. Clean affected skin
with soap and water. If DEF is swallowed, drink plenty of water and
contact a physician immediately.
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WARNING:Refill DEF in a well-ventilated area. When opening
the cap on the DEF tank or bottle containing DEF, ammonia
vapors may escape. The vapors can be irritating to skin, eyes and
mucous membranes. Inhaling ammonia vapors can cause burning to the
eyes, throat and nose and cause coughing and watery eyes.
To fill the DEF tank, see your authorized dealer or do the following
(before filling the DEF tank in cold climates, seeFilling the DEF tank
in cold climateslater in this section):
•DEF bottle fill with spout:
The following procedure applies to MotorcraftDEF or similar DEF
bottles; for other brands or bottle types, refer to the instructions on the
bottle label.
1. Remove the cap from the DEF
container. Remove the spout from
the bottle and insert the straw end
into the bottle. Ensure that the
arrow above the nut is aligned with
the bottle handle and the small tube
end extends into the far corner of
the bottle. Twist the spout nut on
the container until it is tight.
2. Open the DEF filler port on the
vehicle by turning the blue cap
counterclockwise.
Maintenance and Specifications
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FUEL FILTER/WATER SEPARATOR
Diesel Fuel Conditioner Module (DFCM)
The vehicle is equipped with a diesel fuel conditioning module (DFCM)
located on the frame-rail under the driver-side floorboard near the
transmission
Water should be drained from the
module assembly whenever the
warning light comes on and the
message center directs you to drain
the water separator. This will occur when approximately 0.32 pints (150
ml) of water accumulates in the module. If water level is allowed to
exceed this level, the water may be passed through to the engine and
may cause fuel injection equipment damage.
Draining the DFCM
1. Stop the vehicle andshut offthe engine.
WARNING:The vehicle must be stopped with the engine off
when draining the DFCM. Fuel may ignite if the separator is
drained while the engine is running or vehicle is moving.
Note:Air will enter into the fuel system if the DFCM is drained while
the system is running. The engine will not operate properly if air enters
the system.
2. Locate the DFCM and place an appropriate container under the drain
port (see illustration).
3. Rotate the drain counterclockwise
until the O-ring is visible. Allow the
DFCM to drain for approximately
25 seconds or until clean fuel is
observed. Rotate the drain clockwise
to tighten it. If no liquid drains, the
drain may be clogged. Have the
DFCM serviced by your authorized
dealer.
Maintenance and Specifications
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Supplement(supplement), 1st Printing
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To change the engine oil and oil filter:
1. Unscrew the oil filter and oil pan drain plug and wait for the oil to drain.
Note:The oil pan drain plug only requires 1/4 turn to removal/install. A
3/8 inch socket drive may be used to assist with removal/installation, but be
careful not to over-tighten the plug during installation.
2. Replace the filter.
3. Reinstall the oil pan drain plug.
4. Refill the engine with new oil. For the proper capacity, see
Maintenance product specifications and capacitiesin this chapter.
5. Reset the Intelligent Oil Life Monitor™. SeeMessage centerin the
Instrument Clusterchapter for more information.
WARNING:Do not handle a hot oil filter with bare hands.
WARNING:Continuous contact with used motor oil has caused
cancer in laboratory mice. Protect your skin by washing with
soap and water.
Engine lubrication for severe service operation
The following conditions define severe operation for which engine
operation with SAE 5W-40 API CJ-4 is recommended. Oil and oil filter
change intervals will be determined by the Intelligent Oil Life Monitor™
as noted previously.
•
frequent or extended idling (over 10 minutes per hour of normal driving)
•low-speed operation/stationary use
•if vehicle is operated in sustained ambient temperatures below -10°F
(-23°C) or above 100°F (38°C)
•frequent low-speed operation, consistent heavy traffic less than
25 mph (40 km/h)
•operating in severe dust conditions
•operating the vehicle off road
•towing a trailer over 1,000 miles (1,600 km)
•sustained, high-speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation)
•
use of fuels with sulfur content other than ultra-low sulfur diesel (ULSD)
•use of high-sulfur diesel fuel
Maintenance and Specifications
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Adding coolant
When adding coolant, make sure it is a 50/50 mixture of coolant and
distilled water. Add the mixture to the coolant reservoir(s),when the
engine is cool, until the appropriate fill level is obtained.
If you have to add more than 1.0 quart (1.0 liter) of coolant per month,
have your dealer check the cooling system. Your cooling system may
have a leak. Operating an engine with a low level of coolant can result in
engine overheating and possible engine damage.
Note:If coolant is added to bring the level within the COLD FILL
RANGE when the engine is not cold, the system will remain underfilled.
WARNING:Do not add coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
WARNING:Do not put coolant in the windshield washer fluid
container. If sprayed on the windshield, coolant could make it
difficult to see through the windshield.
•DO NOT MIX different colors or types of coolant in your
vehicle. Make sure the correct coolant is used.Refer to
Maintenance product specifications and capacitiesin this chapter
for the proper coolant type.
•The use of an improper coolant may harm engine and cooling
system components and may void the warranty.Refer to
Maintenance product specifications and capacitiesin this chapter
for the proper coolant type.
Note:Do not use stop leak pellets or cooling system sealants/additives
as they can cause damage to the engine cooling and/or heating systems.
This damage would not be covered under your vehicle’s warranty.
•A large amount of water without engine coolant may be added to the
engine cooling system only, in case of emergency, to reach a vehicle
service location. Avoid this procedure if delivery to the service location
requires heavy engine loads. In this instance, the cooling system(s)
must be drained, chemically cleaned with MotorcraftPremium
Cooling System Flush, and refilled with a 50/50 mixture of coolant and
distilled water as soon as possible. Water alone (without coolant) can
cause damage from corrosion, overheating or freezing.DO NOTuse
this method for the secondary cooling system. The secondary cooling
system operates close to ambient temperature, and is susceptible to
freezing in any subfreezing environment, in the absence of coolant.
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Supplement(supplement), 1st Printing
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•Do not use alcohol, methanol or brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not mix with recycled coolant. We do not recommend the
use of recycled coolant in vehicles equipped with Motorcraft
Speciality Engine Coolant, since a Ford approved recycling
process is not yet available.
WARNING:To reduce the risk of personal injury, make sure the
engine is cool before unscrewing the coolant pressure relief cap.
The cooling system(s) are under pressure; steam and hot liquid can
come out forcefully when the cap is loosened slightly.
Engine and secondary cooling system refill procedure
The following procedure should be used when refilling the engine or
secondary cooling systems after it has been drained or become extremely
low.
1. Before you remove the cap, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the cap. Slowly
turn cap counterclockwise until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
5. Slowly add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
6. Reinstall the pressure relief cap.
7. Start and run the engine at 2,000 rpm for 2 minutes.
8. Shut engine off, and remove the pressure relief cap as previously
outlined.
9. If required, add a 50/50 mixture of coolant and distilled water to the
coolant reservoir until the coolant level is within the COLD FILL RANGE
as listed on the reservoir.
Maintenance and Specifications
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Arabic_(LHD)(gc_lhd)

After installation of the new filter
element, reset the gauge by pressing
the reset button on top of the
gauge.
Note:Vehicle operation in heavy
snowfall or extreme rain conditions
may feed excessive amounts of
snow/water into the air intake
system. This could plug/soak the air
filter with snow and may cause the
engine to lose power and possibly
shut down.
The following actions are recommend after operating the vehicle up to
200 miles (320 km) in heavy snowfall or extreme rain:
•Snow:At the earliest opportunity, open the hood and clear all the
snow and ice from the air filter housing inlet (do NOT remove the
foam filter) and reset the air filter restriction gauge.
•Extreme rain:The air filter will dry after about 15–30 minutes at
highway speeds. At the earliest opportunity, open the hood and reset
the air filter restriction gauge.
Air filter replacement:
When replacing the air filter element, use the Motorcraftair filter
element listed inMotorcraft part numberslater in this chapter.
WARNING:To reduce the risk of vehicle damage and/or
personal burn injuries do not start your engine with the air filter
removed and do not remove it while the engine is running.
Failure to use the correct air filter element may result in severe
engine damage.
Maintenance and Specifications
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OCR precautions and safe exhaust position
WARNING:Failure to comply with the following instructions for
operator commanded regeneration (OCR) may result in fire,
serious injury, death and/or property damage.
Before you start OCR, observe/do the following:
•Place the vehicle in P (Park) with the parking brake set on stable,
level ground.
•The vehicle must not be parked in a structure.
•The vehicle must be 10 – 15 feet (3 – 5 meters) away from any
obstructions,
•and must be away from materials that can easily combust or melt such
as: paper, leaves, petroleum products, fuels, plastics and other dry
organic material, such as grass.
•Make sure there is a minimum of 1/8 tank of fuel.
•Make sure all fluids are at proper levels.
Make sure that the louvers (holes) located at the tip of the exhaust are
also clear of any obstructions as they are used to introduce fresh air into
the tailpipe to cool the exhaust gas as it leaves. SeeExhaustunder the
Cleaningchapter for more information.
How to start operator commanded regeneration (OCR)
WARNING:Stay clear of exhaust tip during regeneration. You or
others can be burned.
Note:OCR will not be allowed until DPF load percentage has reached at
least 80%. The DPF load percentage will fluctuate up and down when
driving your vehicle due to active and passive regenerations.
Note:OCR will not be allowed to operate if the service engine soon
light
is illuminated
Note:During the use of OCR, you may observe a light amount of white
smoke. This is normal.
Note:During stationary PTO operation, OCR will change the engine speed
to 2,000 or 2,400 rpm (depending on vehicle application), therefore it is
recommended you exit PTO mode before starting OCR. During mobile PTO
use, OCR is not necessary; regeneration will function normally.
Maintenance and Specifications
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2012 Diesel(67l)
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Arabic_(LHD)(gc_lhd)