2012 FORD F650 engine

Instrument cluster lamp(s)
illuminate and/or flash when
operator assistance is required. In
addition, engine performance
becomes increasingly limited above
Level 1.
At Levels 1 and 2, two courses of
action may be taken by the operator
to facilitate filter regeneration:
1. The vehicle may be driven on the highway at highway speeds,
2. The operator may perform a parked regeneration by following the
steps inParked regeneration procedure.
At Level 3, performing a parked regeneration is the only available course
of action (short of professional servicing) available to the operator for
regenerating the filter. At Level 4, professional servicing is the only way
to regenerate the filter.
Parked regeneration procedure
WARNING:When performing the parked regeneration
procedure, make certain the vehicle is safely off roadway, and
the exhaust system is away from people, or any flammable materials,
vapors, or structures. Engine speed may increase during parked
regeneration.
Note:Parked regeneration is only available when the DPF lamp on the
instrument cluster is illuminated (solid or flashing).
1. Bring the vehicle to a complete stop on level ground and safely off the
road with the exhaust system away from people, flammable materials,
vapors or structures. Ford recommends that you perform a walk-around
to check before commencing parked regeneration.
2. If your vehicle is equipped with an automatic transmission and a
steering column shift lever, place transmission in P (Park). Otherwise,
place the transmission in N (Neutral).
3. Remove feet from the accelerator pedal and clutch pedal (if
equipped).
4. Set the parking brake.
5.Within 5 seconds of setting the parking brake,remove foot from
the service brake pedal.
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The engine speed may increase slightly. To allow parked regeneration to
continue uninterrupted:
1. The vehicle must remain parked
2. The transmission must remain in P (Park) or N (Neutral) (as
previously described in Step 2).
3. The accelerator pedal, service brake pedal, and clutch pedal (if
equipped) must not be pressed
4. The parking brake must remain set
On average (depending on filter level and other factors), the process takes
20–30 minutes to complete. The DPF lamp turns off when the process is
complete. Repeat Steps 1–5, if parked regeneration is interrupted.
To discontinue parked regeneration
Press any of the floor pedals to discontinue parked regeneration.
Diesel particulate filter maintenance and service
The DPF is designed to retain a relatively large amount of residual ash
and provide many miles and hours of maintenance-free operation. At
some point, generally beyond 150,000 miles (240,000 km) or 5,000 hours
of operation (whichever comes first), the DPF requires professional
cleaning to remove the accumulated ash.
The exact number of miles or hours of operation varies greatly depending
upon vehicle/engine loading and operating conditions, ash content of the
engine oil, and quality of the diesel fuel used in your truck. Adhering to
your engine manufacturer’s recommended oil and fuel specifications
maximizes the miles and hours of operation before a DPF professional
cleaning is required. Refer to your engine manufacturer’s owner’s manual for
more details regarding recommended maintenance and service of your DPF.
Exhaust outlet assembly
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Failure to follow these
instructions may result in serious personal injury.
The exhaust outlet assembly on your vehicle is a uniquely functioning
device that accompanies the DPF assembly. It is designed to help control
the temperature of the exhaust during the DPF regeneration process.Do
not modify or remove this device. Modification of the system
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and/or additions of aftermarket devices can reduce the
effectiveness of the system, as well as cause damage to the
exhaust system and/or engine. Any modifications may also
invalidate the vehicle and/or engine warranties. See the vehicle
and engine warranty guides for more information.
The inlet holes in the side of the assembly are functional. These holes
allow outside air to be drawn into the outlet assembly. The holes need to
be kept clear of mud and other foreign material to maintain proper
functionality of the system. One way to keep the holes clear is to spray
the outlet assembly with a hose when washing the vehicle. Failure to
keep the functional holes clear of foreign material may result in the holes
becoming blocked or plugged.Blocked/plugged holes or
modification/removal of the outlet assembly could result in
elevated exhaust temperatures which may result in
vehicle/property damage and/or personal injury.
NOISE EMISSIONS – EXTERIOR
In order to comply with the federal exterior noise regulations, your
vehicle may be equipped with noise emission items. Depending on the
vehicle configuration, it may have all or some of the following items:
Air Intake System:Inspect air cleaner; do not alter its location. Do not
alter inlet and outlet piping.
Body:Inspect wheel well splash shields, cab shields and underhood
insulation for deterioration, dislocation and orientation.
Cooling System:
•Inspect fan for damage to blades; if damaged, replace with the
recommended parts. Inspect for fan-to-shroud interference and any
damage to shroud such as cracks and holes.
•Do not change fan ratio or alter fan spacer dimensions and positions.
•Inspect fan clutch for proper operation; make sure the fan is
disengaged when cooling of the engine is not required.
•Inspect radiator shutters (if equipped) for proper operation; the
shutters should be open during normal operating temperatures.
Engine:Valve covers and block covers are made to damp-out engine
mechanical noise and, if needed, should be replaced with recommended
parts. Check for mechanical isolations.
Transmission Enclosure:Inspect for cracks, holes and tears. Clean any
deposits such as oil, dirt and stones.
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Exhaust System:
•Inspect for leaks at various joint connections and loose clamps.
•Perform a visual inspection for cracks or holes in the muffler and tail
pipe.
•Always use the recommended parts when items need to be replaced.
•Do not change the tail pipe elbow or offset tail pipe orientation from
the standard position as originally received.
•To avoid abnormal changes in vehicle sound levels, it is necessary for
the owner to perform inspections and necessary maintenance at the
intervals shown in theScheduled Maintenance Guidechapter.
POWER STEERING FLUID
Check the power steering fluid level using the following procedure:
1. Set the parking brake, shift into N (Neutral) (automatic transmission)
or 1 (First) (manual transmission) and turn the engine off.
2. Open the hood.
3. Clean the top of the power steering fluid reservoir.
4. Remove the dipstick from the reservoir and wipe the dipstick clean.
5. Reinstall the dipstick. Remove it again and check the fluid level.
•Check the COLD side of the
dipstick if the fluid is cool or
warm to the touch
(approximately 68°-120°F
[20°-49°C]); the fluid level should
be within the FULL range. If
necessary, add fluid in small
amounts, continuously checking
the level, until it reaches the proper level.
•Check the HOT side of the
dipstick if the fluid is too hot to
touch (approximately 176°–230°F
[80°-110°C]); the fluid level
should be within the FULL range.
If necessary, add fluid in small
amounts, continuously checking
the level, until it reaches the
proper level.
Whenever the dipstick is installed, make sure it is properly seated and
tightened securely.
ADD MAX. COLDFULL
ADD MAX. HOTFULL
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CLUTCH FLUID/LINKAGE ADJUSTMENTS
Clutch fluid (if equipped)
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, fill to step in the reservoir.
1. Set the parking brake, shift into 1
(First) and turn the engine off.
2. Open the hood.
3. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
4. Remove cap and rubber
diaphragm from reservoir.
5. Add fluid, if necessary, until it
reaches the step in the reservoir.
6. Reinstall rubber diaphragm and cap onto reservoir.
Use only a DOT 3 brake fluid designed to meet manufacturer
specifications. Refer toLubricant specificationsin this chapter.
WARNING:Carefully read cautionary information on product
label. For MEDICAL EMERGENCY INFORMATION, contact a
physician or Poison Control Center immediately; on Ford-Motorcraft
products call: 1-800-959-3673 (FORD). Failure to follow these
instructions may result in personal injury.
Refer to theScheduled Maintenance Guidechapter for service interval
schedules.
Clutch linkage (if equipped)
Lubricate the clutch linkage using the following procedure. Use a grease
which meets manufacturer specifications. Refer toLubricant
specificationsin this chapter.
1. Set the parking brake, shift into 1 (First) and turn the engine off.
2. Remove the inspection cover from the clutch housing.
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Transmission and clutch
removed for clarity
3. Lubricate the clutch release bearing (at one location) and the clutch
release shaft (at two locations), using the grease fittings provided, with a
grease gun.
4. Lubricate clutch release wear pads at the two locations where they
contact the clutch release bearing with a brush or similar tool.
5. Install the inspection cover onto the clutch housing.
Refer to theScheduled Maintenance Guidechapter for the service
interval schedules.
TRANSMISSION FLUID
Automatic transmission fluid
Refer to yourAllison Automatic Transmission Operator’s Manualfor
scheduled transmission fluid check/change intervals. Your transmission
does not consume fluid. However, the fluid level should be checked if the
transmission is not working properly, i.e., if the transmission slips or
shifts slowly or if you notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is warmed up
(approximately 20 miles [30 km]). If your vehicle has been operated for
an extended period at high speeds, in city traffic or during hot weather,
the vehicle should be turned off for about 30 minutes to allow fluid to
cool before checking.
1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
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4. Place the gearshift lever in N (Neutral) or P (Park) and leave the
engine running.
5. Remove the dipstick, wiping it clean with a clean, dry, lint-free rag.
6. Install the dipstick, making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level.
If you must add transmission fluid, refer to yourAllison Automatic
Transmission Operator’s Manualfor the correct fluid type.Use of a
non-approved automatic transmission fluid may cause internal
transmission component damage.
Fluid levels above the safe range may result in transmission failure; an
overfill condition of transmission fluid may cause shift and/or
engagement concerns and/or possible damage.
Eaton UltraShift (if equipped)
The Eaton UltraShift transmission is filled with synthetic fluid from the
factory with no scheduled fluid change intervals as this fluid is intended
to last the life of the transmission. However, the system should be
checked regularly to ensure that proper transmission fluid levels remain
constant. Refer to theEaton Driver Instructions Manualfor details.
Manual transmission fluid
Refer to theScheduled Maintenance Guidechapter for transmission
fluid level check/change intervals.
Your manual transmission may be filled with an optional synthetic fluid
which allows the use of extended service intervals. A tag on the filler
plug identifies the use of the synthetic fluid.
Only use fluid that meets manufacturer specifications; refer toLubricant
specificationsin this chapter.Use of a non-approved transmission
fluid may cause internal transmission component damage.
Check your transmission fluid level using the following procedure:
1. Park the vehicle on level ground.
2. Set the parking brake and shift into 1 (First) and turn the engine off.
3. Clean any dirt from around the filler plug.
4. Remove the filler plug and inspect the fluid level; the fluid level should
be at the bottom of the filler plug opening.
5. Add fluid, if necessary, through the filler plug opening.
6. Clean and install the filler plug securely.
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Drain and refill your transmission fluid, while it is warm, using the
following procedure:
1. Park the vehicle on level ground.
2. Set the parking brake and shift into 1 (First) and turn the engine off.
3. Clean any dirt from around the filler and drain plugs.
4. Remove the filler and drain plugs and drain the fluid into a suitable
container. Dispose all used automotive fluids in a responsible manner
following your local authorized standards.
5. Clean and install the drain plug securely.
6. Add fluid through the filler plug opening.
7. Clean and install the filler plug securely.
CHASSIS-MOUNTED CHARGE AIR COOLER
Inspect charge air cooler daily
Visually inspect the core assembly for debris and clogging of external fins
with the engine off. Prior to engine operation, remove any debris
blocking the core.
•Turbocharger-to-charge air cooler
•Charge air cooler-to-intake manifold pipe
•Mounting bracket
•Chassis-mounted charge air cooler core
Inspect air intake piping
•Check for accumulation of salt deposits (where applicable). If present,
disassemble and clean the complete air intake piping system. If the
intake piping is pitted, use MotorcraftSilicone Gasket and Sealant
TA-30 to seal joints against leakage.
•Check for loose hoses and clamps.
•Check for ruptured or collapsed hoses.
•Check air cleaner housing for cracks.
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