2005 FORD F650 Owners Manual

Power Windows
Front/RearPower Window Lockout
Child Safety Door
Lock/UnlockInterior Luggage
Compartment Release
Symbol
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Emission SystemEngine Air Filter
Passenger Compartment
Air FilterJack
Check fuel capLow tire warning
Introduction
9

FEDERAL HIGHWAY ADMINISTRATION REGULATION
Regulations such as those issued by the Federal Highway Administration
or issued pursuant to the Occupational Safety and Health Act (OSHA),
and/or state and local laws and regulations may require additional
equipment for the way you intend to use the vehicle. It is the
responsibility of the registered owner to determine the applicability of
such laws and regulations to your intended use for the vehicle, and to
arrange for the installation of required equipment. Your dealer has
information about the availability of equipment which may be ordered for
your vehicle.
ENTERING, EXITING AND/OR CLIMBING ON THIS VEHICLE
You must be careful and deliberate to minimize the possibility of personal
injury from a slip and fall when entering, exiting and/or climbing on this
vehicle. Always use the steps and assist handles before climbing. Do not
skip any steps or assist handles. Use three point contact at all times with
at least two feet and one hand or two hands and one foot firmly placed
during all phases of entering, exiting and/or climbing. Always keep your
shoe soles and hands clean. Keep the steps and assist handles free of
snow, ice, oil, grease, substances or debris. Be sure to use extra care in
bad weather. Avoid wearing thick gloves. Always perform trailer hook-up
while standing on the ground.
Do not carry items while entering, exiting, and/or climbing. Make
sure you keep a firm grip. Always FACE the VEHICLE STEP and
HANDLE SYSTEM while climbing up and down. Do not climb behind
the cab unless you have three point contact with a step and handle
system at all times.
Introduction
10

To be sure your vehicle is ready to operate, conduct a pre-trip inspection
at the beginning of each work period. Follow the steps listed in this
section to assure a proper vehicle inspection procedure. The pages in
this section may be produced locally and used on a regular basis.
VEHICLE INSPECTION INFORMATION
Note:Always make sure the parking brake is applied before starting the
engine.
Engine compartment (with engine stopped)
Engine oil level:Use the engine oil dipstick to verify that the
engine oil level is between the FULL and ADD
marks.
Engine coolant
level:Look through the plastic reservoir or the clear
sight glass on the reservoir, depending upon
vehicle equipment, and make sure the fluid is
within the minimum and maximum fluid level
range as marked on the reservoir.Do not
remove pressure cap until the coolant has
cooled.
Power steering fluid:Verify that the fluid level is between the full
and refill marks.
Brake fluid (master
cylinder):Remove the master cylinder caps and inspect
the fluid level. The full mark is at the bottom
of the opening of the port ring.
Hydraulic clutch
fluid:Check for adequate amount of hydraulic clutch
fluid. Fluid level should be at the step of the
reservoir; refer toClutch fluid/linkage
adjustmentsin theMaintenance and
specificationschapter.
Belts (Fan,
alternator, water
pump and A/C
compressor):Check for glazing, fraying or cracking. There
should be no more than five - seven cracks per
rib per inch.
Any leaks:Check for signs of fluid puddles, dripping fluid
on the ground under the engine or the
underside of the engine.
Vehicle inspection guide
Vehicle inspection guide
11

Engine compartment (with engine stopped)
HVAC air inlet:Check for debris, leaves, etc. that may have
collected on the HVAC air inlet grille or inside
the exterior module as this may cause reduced
system performance.
HVAC fresh air filter
(if equipped):Periodically check the HVAC fresh air filter for
cleanliness.
Exercise great caution when working on vehicle equipped with
an automatic fan clutch. The fan starts in motion only after the
engine coolant reaches a predetermined temperature or the refrigerant
pressure (if equipped with air conditioning) reaches a predetermined
setting. The fan will start at these point with no advance warning.
Never reach near, or permit objects to protrude into, the fan blade
radius while the engine is running as this could result in vehicle
damage, personal injury or death.
Engine starting (parking brake applied)
Safety/Emergency
equipment:Prior to entering the cab, verify that the
vehicle is equipped with spare electrical fuses
(if used), three red reflective triangles, a
properly charged and rated fire extinguisher
and wheel chocks. Walk around the vehicle
and check that all steps and grab handles,
inside and out as well as behind, are tight and
clean. Use extreme caution and a three-point
stance at all times. Check door latches for
positive closing, latching and locking.
Starting the engine:Verify the parking brake is set. Depress the
clutch (if equipped with a manual
transmission) and verify the transmission is in
neutral. Vehicles equipped with an automatic
transmission should be in N (Neutral).
When the WAIT TO START indicator light in
the instrument cluster turns off, turn the key
to START.
Vehicle inspection guide
12

Engine starting (parking brake applied)
Oil pressure builds:Make sure engine oil pressure is building to
normal operating range.
Air chime sounds (if
equipped with air
compressor):The low air pressure warning chime should
sound immediately after the engine starts but
before the compressor has built up pressure.
The low air pressure warning chime should
stop when the air pressure reaches 70 psi (483
kPa) (or more). Let the air pressure build to
governed cut-out pressure, which should occur
between 115–130 psi (793–896 kPa).
Accelerator:Depress the accelerator and verify that it
operates smoothly without any binding or
irregular feel. Remove your foot from the
pedal and make sure the engine returns to idle
speed immediately.
Ammeter/Voltmeter:Check the gauge to see if the alternator is
charging.
Steering linkage
free play:Check for excessive free play in the steering
linkages. The steering wheel should have less
than 2 inches (5 cm) of free play at rim of
steering wheel.
Hydraulic brake
check:Pump the brake pedal three times, then apply
firm pressure to the pedal and hold it for five
seconds. The pedal should move (due to the
HydroMax pump operation); if it does not,
there may be a leak or another problem. Do
not drive the vehicle until the problem is
fixed.
Vehicle inspection guide
13

Engine starting (parking brake applied)
Air brake check:Check the air brakes in the following manner
(Chock the wheels, if necessary. Push in the
parking brake and on tractors, also push in the
tractor parking brake knob):
1. Check the air compressor or governor cut-out
pressure (approximately 120 psi [827 kPa]).
2. Cut-off the engine and turn the key back to
ON, without starting the engine.
3. Without the brake pedal applied, note the
air pressure drop for one minute. It should be
less than 2 psi (14 kPa) for single vehicle and
3 psi (21 kPa) for combination vehicles.
4. Depress and hold the brake pedal with 90
psi (621 kPa) or more and make sure there is
no more than a 3 psi (21 kPa) per minute
leak. For combination vehicles, no more than 4
psi (28 kPa) per minute.
5. Pump the brake pedal to deplete the system
air pressure. The warning light and chime
should activate 57 psi (393 kPa).
6. Pump the brake pedal and make sure the
parking brake and trailer parking brake knobs
knobs pop out at 20 psi (138 kPa) or higher.
Parking brake:Check that the parking brake will hold the
vehicle by gently trying to pull forward with
the parking brake applied.
Automatic
transmission fluid:With the engine idling (at normal operating
temperature) and the parking brake applied,
check the automatic transmission fluid. If fluid
needs to be added, place the transmission in
the appropriate gear as specified in the
transmission operator’s manual and refer to
Transmission fluidin theMaintenance and
specificationschapter.
Vehicle inspection guide
14

Front of vehicle
Lights:Make sure all lights illuminate and are clean.
Make sure headlights function on both high
and low beams. Make sure reflectors are clean
and unbroken and of proper color (red on
rear, amber elsewhere). Make sure the running
lights are also clean and unbroken.
Steering gear:Look for: missing or loose fasteners, power
steering fluid leaks and damage to power
steering hoses.
Steering linkage:Make sure connecting links, arms and rods are
not worn or cracked; joints, sockets and boot
seals are not worn or loose and that there are
no loose or missing cotter keys, nuts or bolts.
Tow hooks:Front and rear tow hooks should be inspected
for damage or loose mounting. This is
particularly important on vehicles where tow
hooks are frequently used.
Front suspension
Spring:Inspect for missing, broken or shifted leaves or
leaves that are in contact, or nearly contacting
a tire, rim, brake drum, frame or body
components.
Spring mount:Inspect spring hangers, bolts, bushings, axle
mounting bolts and nuts for cracks, breaks,
wear, damage and tightness.
Shock absorber:Inspect for cracks, leaks and missing or broken
bolts or bushings.
Note:Never apply grease to spring pads.
Do not operate the vehicle if any suspension conditions listed in
theFront suspensionchart are evident. Loss of steering or
suspension could result in property damage, personal injury or death.
Vehicle inspection guide
15

Front brakes
Hoses:Checked for cracked, worn or frayed hoses.
Make sure all couplings are secured.
Chambers:Make sure brake chambers are not cracked or
dented and that they are securely mounted.
Slack adjuster:Check for broken, loose or missing parts; the
angle between the push rod and adjuster arm
should be approximately 90 degrees when the
brakes are applied. When pulled by hand, the
push rod should not move more than
approximately one inch (2.5 cm).
Drum:Make sure there are no cracks, dents or holes
and no loose or missing bolts. Make sure brake
linings are not worn or dangerously thin or
contaminated by lubricant.
Front wheels
Rims:Check for damaged or bent rims. Rims should
not have welding repairs and no rust trails that
indicate it is loose on the wheel.
Lug nuts:Make sure all lug nuts are present and not
loose (look for rust trails around the lug nuts).
There should be no cracks radiating from the
lug bolt holes or distortion of the bolt holes.
Hub oil seal:Check wheel hub oil seal for leaks, and if sight
glass if present, check to see that the oil level
is adequate.
Oil-lubricated front
wheel bearing:If the hubcap has a transparent window, check
for proper lubrication level. If the hubcap does
not have a transparent window, remove the
rubber fill-plug and check for proper level.
If a wheel must be changed, obtain expert tire service help.
Mounting and un-mounting of tires should only be performed by a
qualified technician using necessary safety procedures and equipment,
otherwise the result could be property damage, personal injury or death.
Vehicle inspection guide
16