2003 FORD F650 headlamp

Replacing visor/cab marker bulbs
To change the cab marker bulbs:
1. Make sure the headlamp switch is
in the OFF position and then
remove the screw and lens from the
lamp assembly.
2. Carefully pull the bulb straight
out of the socket and push in the
new bulb.
3. Install lens on lamp assembly with
screw.
Replacing visor marker bulbs (SuperCrewzer only)
For visor bulb replacement see a dealer or qualified technician.
Replacing brake/tail/backup lamp bulbs – Except F650
SuperCrewzer
The brake/tail/backup lamp bulbs
are located in the same portion of
the tail lamp assembly. Follow the
same steps to replace either bulb:
1. Make sure the headlamp switch is
in the OFF position and then
remove the four screws and the
lamp lens from lamp assembly.
2. Carefully pull the bulb straight
out of the socket and push in the
new bulb.
3. Install the lens on the lamp
assembly with the four screws.
Lights
66

Replacing tail lamp/turn/backup lamp bulbs—F650 SuperCrewzer
only
The tail lamp/backup lamp bulbs are
located in the same portion of the
tail lamp assembly, one just below
the other. Follow the same steps to
replace either bulb:
1. Make sure the headlamp switch is
in the OFF position and then
remove the two screws holding the
light cover to the light housing.
2. Carefully pull away the lamp
cover.
3. Twist the bulb 1/8 of a turn
counter clockwise and remove it from the socket.
4. Pull the bulb straight out and push the new bulb in.
5. Turn the bulb clockwise to secure in place.
6. Replace the tail lamp cover and secure with the two screws.
Replacing foglamp bulbs (if equipped)
1. Make sure the headlamp switch is
in the OFF position and then
remove the bulb socket from the
foglamp by turning
counterclockwise.
2. Disconnect the electrical connector from the foglamp bulb.
3. Connect the new foglamp bulb to the electrical connector.
4. Install the bulb socket in the foglamp by turning clockwise.
Lights
67

The BeltMinder feature can be deactivated/activated by performing the
following procedure:
Before following the procedure, make sure that:
•The parking brake is set.
•The gearshift is in P (Park) (automatic transmission) or the neutral
position (manual transmission).
•The ignition switch is in the OFF position.
•All vehicle doors are closed.
•The driver’s safety belt is unbuckled.
•The parklamps/headlamps are in OFF position (If vehicle is equipped
with Autolamps, this will not affect the procedure).
To reduce the risk of injury, do not deactivate/activate the Belt
Minder feature while driving the vehicle.
BeltMinder activation and deactivation procedure
1. Turn the ignition switch to the RUN (or ON) position. (DO NOT
START THE ENGINE.)
2. Wait until the safety belt warning light turns off. (Approximately 1–2
minutes.)
•Steps 3–5 must be completed within 60 seconds or the procedure will
have to be repeated.
3. Buckle then unbuckle the safety belt three times, ending with the
safety belt unbuckled. This can be done before or during BeltMinder
warning activation.
4. Turn on the parklamps/headlamps, turn off the parklamps/headlamps.
5. Buckle then unbuckle the safety belt three times, ending with the
safety belt unbuckled.
•After step 5 the safety belt warning light will be turned on for three
seconds.
6. Within seven seconds of the safety belt warning light turning off,
buckle then unbuckle the safety belt.
•This will disable BeltMinder if it is currently enabled, or enable
BeltMinder if it is currently disabled.
7. Confirmation of disabling BeltMinder is provided by the safety belt
warning light flashing four times per second for three seconds.
Seating and Safety Restraints
99

STARTING PROCEDURES
Operating precautions
•Always shift to a lower gear at high altitudes to prevent engine
smoking.
•Avoid extended and unnecessary idling.
Diesel engine vapors are combustible. Do not operate the engine
in an enclosed area. These vapors can be sucked through the air
intake system and cause engine acceleration and overspeeding, which
may result in bodily injury and extensive property damage. The
equipment owner and operator are responsible for safe operation in a
hostile environment.
Starting the engine
1. Ensure headlamps and all accessories are turned off, the parking
brake is applied and the transmission is in the neutral position (or P
[Park] for Allison 2400 transmissions).
If your vehicle is equipped with an
air intake heater, the heater will
activate in cooler weather. If the
Wait to startlight illuminates,do
notcrank the engine until the light
goes off.
If equipped with an air intake heater, DO NOT use ether or any
other starting fluids. The use of starting fluids (ether) in an
engine equipped with an air intake heater could cause an explosion
and result in vehicle damage, property damage and/or personal injury.
2. Do not depress the accelerator during starting the engine.
3. Start the engine.
If the engine does not start after 30 seconds of cranking, allow two
minutes for the starter to cool before trying again. Excessive cranking
may damage the starter.
After the engine starts:
WAIT
TO
START
Driving
109

The fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
1 20A Horn
2 15A Turn/Hazard lamps
3 20A Cigar lighter
4 10A Diagnostic connectors
5 15A Back-up lamps, Daytime Running
Lamps (DRL) relays, Blend door
actuator, Heated seat module
(SuperCrewzer only), On/Off fan
clutch (SuperCrewzer only),
Warning chime module
(SuperCrewzer and Ambulance)
6—Not used
7—Not used
8 5A Radio, GEM
9 5A Switch Illumination (headlamp,
power windows, power door
locks), Power window relay,
Trailer hook-up lamps
(SuperCrewzer only)
10—Not used
11 30A Wiper motor, Washer pump relay
12 10A Stoplamp switch (hydraulic brake
vehicles only)
13 20A Radio, Cluster, 7.3L Power Stroke
Powertrain Control Module
(PCM), Keep Alive Memory
14 10A Interior lamps, Running board
lamps (SuperCrewzer only)
Roadside Emergencies
153

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
15 10A GEM, Interior lamp relay, Map
lamps, Glove box lamps
(SuperCrewzer only), Power
mirrors (SuperCrewzer only),
Warning chime module
(SuperCrewzer only)
16 15A Highbeams
17—Not used
18 5A Headlamp switch, GEM
19 15A Engine, Cluster, Cummins PCM,
CAT PCM, 7.3L Power Stroke
PCM (idle valid switch input),
Alternator (Ambulance only)
20 15A Starter relay, GEM
21 10A DRL
22 15A Exhaust brake (SuperCrewzer
only), Heated mirrors
(SuperCrewzer only), Rear air
suspension (SuperCrewzer and
Ambulance)
23 10A Electronic flasher
24 15A Vacuum pump, Air dryer, ABS,
Fuel heater relay
25 10A Blower motor relay
26 10A Right-hand low beam headlamp
27—Not used
28 10A Left-hand low beam headlamp
Roadside Emergencies
154

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
11 20A* Allison MD transmission, Allison
2000/2400 transmission
12 10A* Keyless entry module
(SuperCrewzer only)
13 10A* Park brake adjustment module
(SuperCrewzer only)
14—Not used
15 7.5A* Body builder prep (hydraulic
brake vehicles only)
16 10A* Allison 2000/2400 transmission
(except F650 SuperCrewzer)
17 5A* Radio (SuperCrewzer only)
18—Not used
19—Not used
20—Not used
21 10A* GEM (hydraulic brake vehicles
only)
22—Not used
23—Not used
24—Not used
101 40A** Anti-lock Brake System (ABS)
(air brake vehicles only)
102 20A** Body builder prep run feed
103 50A** Ignition switch (Junction box
fuses 8, 9, 11, 19, 20, 22, 23, 24,
25, 29, 30, 31)
104 20A** Power point
105 20A** Power door locks
106 30A** Headlamps
107 50A** Junction box battery feed (fuses
1, 2, 3, 4, 12, 13, 14, 15)
108 40A** Cummins fuel heater
Roadside Emergencies
157

If fuses burn out
Burned-out or“blown-out”fuses or circuit breaker tripping (if equipped)
usually indicate an electrical short circuit, although a fuse may
occasionally fail from vibration. Insert a second fuse or reset the breaker
(if equipped). If this fuse immediately burns out or the breaker (if
equipped) trips and you cannot locate the fuse, return your vehicle to
your dealer for a circuit check.
If lamp bulbs burn out
Repeated lamp burn-out usually indicates a loose connection, either at
the lamp socket, the system ground or a malfunctioning voltage
regulator. If examination does not indicate the cause of the trouble,
return your vehicle to your dealer for inspection.
If headlamps flash on and off
If headlamps flash on and off at regular intervals, the system circuit
breaker (if equipped) is operating, indicating a short circuit or overload.
Take your vehicle to your dealer for a circuit check.
ENGINE COOLANT AND OIL REFILL CAPACITIES
Engine Engine coolant
(approximate
capacity)Engine oil
(approximate
capacity)
Caterpillar 3126 B 23.7L (25.0 quarts)
1
Cummins B 5.9L 23.1L (24.4 quarts)1
Power Stroke 7.3L 18.0L (19.0 quarts) 18.0L (19.0 quarts)2
1
Refer to the engine operator’s manual for engine oil refill capacities.
2Engine oil and filter change.
POWER STEERING FLUID CAPACITIES
GVWR Axle application System capacity
11 794/13 608 kg
(26 000/30 000 lb.)3 856/4 082 kg
(8 000/9 000 lb.)4.3L (4.5 quarts)
14 969 kg (33 000 lb.) 5 443 kg (12 000 lb.) 4.5L (4.7 quarts)
Maintenance and Specifications
215