2005 FORD F650 air suspension

Locks and security 64
Keys 64
Locks 64
Seating and safety restraints 65
Seating 65
Safety restraints 70
Child restraints 79
Driving 87
Starting 87
Brakes 93
Air suspension 115
Transmission operation 118
Vehicle loading 134
Roadside emergencies 139
Hazard flasher switch 140
Fuses and relays 140
Jump starting 147
Wrecker towing 150
Customer assistance 154
Getting assistance outside the U.S. and Canada 156
Ordering additional owner’s literature 157
Reporting safety defects (U.S. only) 157
Cleaning 158
Cleaning your vehicle 158
Repairing paint chips 159
Underbody preservation 161
Table of Contents
2
2005 F650/750(f67)
Supplement
USA English(fus)

Rear wheels
Spacers:Make sure dual wheels are evenly separated
and that tires are not touching one another.
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.
TRAILER
If you are pulling a trailer, an inspection of the trailer similar to that of
the tractor should be done. Such an inspection should follow trailer
manufacturer recommendation and should include at a minimum: general
condition, landing gear, doors, sides, lights, reflectors, suspension,
brakes, tires, wheels, cargo placement, stability and tie-downs.
TRANSMISSION
If your vehicle is equipped with an automatic transmission, regularly
check the transmission’s neutral start switch. The engine should only
start in the N (Neutral) or P (Park) positions.
If the unit starts in gear and/or the neutral start switch is not
functioning correctly, the vehicle may inadvertently move which
could result in property damage, personal injury or death.
Check the transmission fluid level and shift linkage for proper operation.
Vehicle inspection guide
20

WARNING LIGHTS AND CHIMES
Warning lights and gauges can alert you to a vehicle condition that may
become serious enough to cause expensive repairs. A warning light may
illuminate when a problem exists with one of your vehicle’s functions.
Many lights will illuminate when you start your vehicle to make sure the
bulb works. If any light remains on after starting the vehicle, have the
respective system inspected immediately.
Service engine soon:If this light
illuminates while driving, it is a
possible indication that one of the
engine’s emission control systems
has failed.
Check suspension (if equipped):
Illuminates when there is a fault in
the electronic subsystem of the air
suspension.
Stop engine (if equipped):This
light is used in conjunction with the
electronic engine control.
Refer to the Engine Operator’s Manual for specific information regarding
this feature.
If the engine shuts down, it can be restarted and operated for 30
seconds at a time or until the problem is corrected. Refer toEngine
shutdown systemin theDrivingchapter.
Drivers of electronically controlled engines should know the
extent of warning engine shutdown system before operating the
vehicle. This information can be obtained from your dealer.
SERVICE
ENGINE
SOON
STOP
ENGINE
Instrumentation
Instrumentation
21

Fuel gauge:Indicates
approximately how much fuel is left
in the fuel tank (when the ignition
is in the on position). If your vehicle
is equipped with dual fuel tanks, the
engine will draw fuel from the
passenger-side fuel tank only. With
dual fuel tanks, the vehicle will be
equipped with a fuel transfer pump system that will draw fuel from the
driver-side fuel tank and send fuel to the passenger-side fuel tank. The
passenger-side fuel tank must have fuel in it at all times otherwise the
vehicle may stall and may be difficult to re-start. The fuel gauge reads
the fuel level only from the passenger-side fuel tank.
Air pressure gauge (if equipped):
All vehicles equipped with air brakes
have a dual-pointer air gauge to
indicate the pressure in each brake
circuit. The green pointer indicates
the air pressure in the primary
system and the red pointer indicates
the air pressure in the secondary
system. When the pressure is too low
for normal brake operation (less than
60 psi [414 kPa]) and the ignition is
on:
•a warning buzzer will sound and
•a warning light will illuminate in the instrument cluster
Vehicles equipped with hydraulic brakes and an air compressor have a
single-pointer air gauge.
Note:This system doesnothave a low air pressure warning buzzer or a
low air pressure warning light.
Do not drive the vehicle when the low air pressure buzzer is
sounding or the warning light is lit. These warnings indicate
there is not enough air pressure for the brake or suspension system to
operate properly.
0 30120 90 60
150AIR
PRESSURE
PSI
Instrumentation
29

When the Traction Controlswitch, located on the instrument panel, is
in the off position, the traction control light will be illuminated.
If you should become stuck in snow or ice or on a very slippery road
surface, try switching the Traction Controlsystem off. This may allow
excess wheel spin to“dig”the vehicle out and enable a successful
“rocking”maneuver.
Aggressive driving in any road conditions can cause you to lose
control of your vehicle increasing the risk of severe personal
injury or property damage. The occurrence of a Traction Control
event is an indication that at least some of the tires have exceeded
their ability to grip the road; this may lead to an increased risk of loss
of vehicle control, vehicle rollover, personal injury and death. If you
experience a severe road event, SLOW DOWN.
AIR SUSPENSION (IF EQUIPPED)
Note:The vehicle must not be operated without air in the suspension
springs. Operating the vehicle without air in the air suspension springs
will damage the suspension, degrade ride performance and may cause
property damage.
The suspension system automatically adjusts to different loads to
maintain a constant frame height. The system allows for ease of vehicle
loading and provides improved vehicle ride and increased driver comfort.
Air suspension dump switch (if equipped)
The system is controlled by a switch
located on the instrument panel.
The switch will operate only when
the ignition is in the ACC
(Accessory) or IGNITION positions
and the air tanks have sufficient
pressure to fill the air springs. When
the ignition is turned off, the
suspension will remain in whatever
state it was last set.
Note:The suspension will dump air when the ignition is in the ACC or
IGNITION position, but will only fill when the ignition is in the IGNITION
position.
When the upper portion of the switch is pressed and the vehicle speed is
below 5 mph (8 km/h), air supplied to the air spring is exhausted,
Driving
115

lowering the frame for loading. Pressing the lower portion of the switch
causes air to fill the air springs so the vehicle will remain normal ride
height.
Tractor-trailer connections
To reduce the risk of personal injury, use extreme caution when
making brake and light connections. Inclement weather and
accumulated road contamination deposits on handhold and stepping
surfaces require extra care to avoid slip and falls. Provide adequate
lighting of working areas.
Do not climb on the back of the tractor unless it has been
provided with a deck plate and handholds. Use a three-point
stance when climbing up and down from a deck plate. Do not jump
from the vehicle. Whenever possible, make all connections while
standing on the ground.
Connecting and disconnecting a trailer with air suspension
When connecting to a trailer:
•Press the lower portion of the switch and air will exhaust from the air
suspension system.
•After making the connection to the trailer, press the upper portion of
the switch, then raise the landing gear.
When disconnecting the trailer:
•Lower the landing gear, then press the lower portion of the switch.
•Disconnect the brake hoses, trailer-side and rear light connectors,
then pull the release lever on the fifth wheel.
The upper portion of the switch must be pressed before operating with a
trailer or operating in the bobtail mode.
Suspension conversions
It is not recommended, or approved, that suspension conversions be
performed. However, it is understood that, on occasion, aftermarket
add-on suspensions are installed by others on the truck chassis which
allow operator control for weight transfer from other axles (i.e., air lift
axles).
Driving
116

Fuse/Relay
LocationFuse Amp
RatingFuse Description
13 20A Radio, Cluster
14 10A Interior lamps
15 10A GEM, Interior lamp relay, Map lamps
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
2005 F650/750(f67)
Supplement
USA English(fus)
Roadside emergencies
142

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
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 assure 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.
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 assure a“like
new”condition when re-torquing.
Note:See theU-Bolt Nut Torquechart later in this section.
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
201