Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
101 30A Bendix Air ABS relay (Air brake vehicles
only)
Hydraulic brakes module (hydraulic brake
vehicles only)
102 20A Ignition switch
103 20A Ignition switch, Passenger compartment fuse
box fuses 19, 29 and 30
104 20A Power point
105 20A Power door lock switches
106 30A Main light switch, Multi-function switch
107 50A Passenger compartment fuse box fuses 1, 2,
3, 4, 12, 13, 14 and 15
108 40A Fuel heater (diesel engine only)
20A Fuel pump module (gasoline engine only)
109 40A Power window
110 30A Windshield wiper
111 30A Body builder relay, Parking lamps
112 40A Blower motor
113 30A Heated seats, Air-Ride seat
114 20A Aftertreatment DCU
115 20A Ignition switch, Passenger compartment fuse
box fuses 8, 9, 10 and 11
116 30A Left/Right turn relays, Back up lamp relay
117 20A Stop lamps
118 60A Hydraulic brake vehicles (trailer tow package
only)
601 60A Trailer socket
602 60A Air brake trailer tow fuse block
30A Hydraulic brakes pump motor 2
201 — Windshield washer relay
202 — Wiper high/low relay
203 — Wiper run/park relay
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
204 — Windshield wiper relay
205 — Body builder relay, right turn
206 — Body builder relay, left turn
207 — ABS event relay (hydraulic brake vehicles
only)
208 — Body builder relay, back up lamps relay
209 — Auxiliary stop lamp relay
301 — Fuel heater/Fuel transfer pump relay (diesel
engine only)
— Fuel pump module (gasoline engine only)
302 — Body builder relay, parking lamps relay
303 — Blower motor relay
304 — DEF (Urea) line heaters relay (diesel engine
only)
— Powertrain control module power VPWR1
(gasoline engine only)
Individual Maxi Fuse Holder in Engine Compartment
Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
9925 30A Hydraulic brakes pump motor 1
198Fuses
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USA(fus)
Passenger Compartment Fuse Panel
The fuse box is located behind the passenger airbag cover and can be
accessed through the glove box.
Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
1 20A Horn
2 15A Flasher relay
3 20A Power point
4 10A Data Link Connector (DLC), Engine
diagnostic connector, Parking brake warning
5 15A Run relay
6 — Not used
7 — Not used
8 5A Radio, GEM
9 5A Power window relay
10 15A Heated mirrors
11 5A Wiper and washer systems
12 10A Transmission shift selector
13 20A Radio/SYNC®, Power mirrors
14 10A Interior lamp relay
15 10A Interior lamp relay
Relay #2
Relay #3
Horn
Relay #4
Relay #5#1
#12#22
#2
#13#23
#3
#14#24
#4
#15#25
#6
#17#27 #5
#16#26
#7
#18#28
#8
#19#29
#9 #30
#10
#20
#11
#21#31 Relay #1
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GENERAL INFORMATION
WARNING:Making modifications to various parts, components
and systems of the vehicle, such as brake and steering systems,
can adversely affect the quality, reliability and operation of your vehicle
and could result in property damage, personal injury or death. Such
modifications must be avoided.
WARNING:Failure to properly perform maintenance and
servicing procedures could result in vehicle damage, personal
injury or death.
WARNING:Take care when performing any maintenance,
system check or service on your vehicle. Some of the materials
may also be hazardous if used, serviced or handled improperly and
could result in property damage, personal injury or death.
Always use care when performing vehicle maintenance, repairs or system
checks. Improper or incomplete service could result in the vehicle not
working properly which may result in personal injury or damage to the
vehicle or equipment. It is the operator’s responsibility to see that the
vehicle receives proper care and maintenance. If you have any questions
about performing service, have the service done by a qualified technician.
Servicing Guidelines
When servicing your vehicle:
•always wear safety glasses for eye protection.
•always set the parking brake or chock the wheels.
•always use support stands, not a jack, when working under a raised
vehicle.
•always turn off the ignition unless a procedure requires the engine to
be running.
•always avoid contact with hot metal parts. Allow the components to
cool before working with, or around, them.
•always operate the engine in a well-ventilated area.
•do not wear loose-fitting clothing, hanging jewelry, watches or rings.
•do not smoke.
•do not work on the brakes or the clutch unless the proper
precautions are taken to avoid inhaling friction material dust.
Quality service parts are available through your dealer. If dealer parts are
not used, make sure the replacement parts are of equivalent quality.
204Maintenance
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USA(fus)
Air Brakes
WARNING:Do not manually adjust the automatic slack adjusters
to correct excessive push rod stroke as it may result in reduced
brake effectiveness and a vehicle crash. Excessive push rod stroke
indicates that a problem exists with the automatic adjuster, with the
installation of the adjuster, or with foundation brake components that
manual adjustment does not remedy. Seek service from a qualified
facility for excessive push rod stroke.
Inspection and adjustment:Establish a regular schedule for periodic
cleaning, lubrication and adjustment inspection based on vehicle use.
Exact maintenance intervals are difficult to predetermine since vehicles
are used in a wide variety of applications and conditions. If you are
uncertain of the proper schedule for your vehicle, contact your dealer.
Regular inspections should include:
•periodic checking (every service interval) of push rod travel or brake
adjustment. This is essential for effective braking. Brake chamber
push rods on original equipment chambers now incorporate an orange
paint marker near the base of the push rod as a stroke indicator to
aid in adjustment checks. If the push rod is clean and the brakes are
out of adjustment, the orange marker can be seen protruding from
the chamber when the brakes are applied.
•checking the brake lining (every service interval). When brake lining
or blocks are worn to within 1/16th inch (1.6 millimeters) of rivets,
replace the brake linings. This inspection or adjustment should only
be performed by a qualified technician and must be in accordance
with instructions provided by the service manual.
Do not back off or disconnect the front brakes so that they are less
effective, letting the rear brakes do all the stopping of the vehicle. Do
not overlook the brakes on the trailer either. Brake condition on the
trailer is just as important as the tractor. Proper brake balance on trucks
and tractor-trailers is essential for effective braking.
Once a year, the entire brake system must be inspected:
•Rubber components for deterioration. These components should be
inspected by a qualified technician and replaced as necessary.
Replacement intervals vary according to the severity and length of
vehicle service.
•Condition of brake drums, brake chambers and slack adjusters.
•System for air leaks.
•Hose or pipes for rust, damage and deterioration.
•Operation of service and parking brakes.
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Hydraulic Brakes
Establish a regular schedule for periodic cleaning, lubrication and
adjustment inspection based on vehicle use. Exact maintenance intervals
are difficult to predetermine since vehicles are used in a wide variety of
applications and conditions. If you are uncertain of the proper schedule
for your vehicle, contact your dealer.
Regular inspections should include:
•checking the brake lining (every service interval). Establish
inspection intervals that provide for lining replacement before damage
to the disc occurs. Excessive lining wear may expose the backing
plate to the disc causing scoring of the disc faces. This inspection
should be performed by a qualified technician and must be in
accordance with instructions provided by the service manual.
Hydraulic brake systems are power-assisted. Braking capabilities are
greatly reduced without engine assist.
•proper fluid level. The level should be at the bottom edge of the ring
on each reservoir fill port. Do not fill the master cylinder to the top of
the reservoir. If fluid level requires attention to maintain a proper
master cylinder level, this is an indication of either severe operation
(pad wear) or fluid leakage. A more frequent and thorough brake
inspection is required.
•brake lines, hoses and fittings. Repair or replace brake line tubes,
hoses or fittings as required. Inspect these components every
4000 miles (6000 kilometers):
•Lines for kinks, dents, corrosion or rupture.
•Hoses for abrasions, kinks, soft spots or rupture, collapse, cracks,
twists or loose frame supports. When replacing a hose, be sure
there is adequate clearance to the hose to avoid an abrasion to the
new hose.
•All connections for leaks.
Driveline Parking Brake
WARNING:Use wheel chocks and exercise caution when
inspecting under the vehicle. A vehicle roll-away could result in
property damage, personal injury or death.
Parking brake adjustment should only be performed by a qualified
technician, and in accordance with the instructions in the service
manual.
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Supporting Your Vehicle for Service
WARNING:Do not use a jack when working under a vehicle. It
may give way, causing the vehicle to fall and result in property
damage, personal injury or death. Always use floor stands to support
the vehicle.
Prepare the vehicle for service repairs by doing the following:
1. Park the vehicle on a level, concrete floor.
2. Set the parking brake and block the wheels to prevent the vehicle
from moving.
3. Select a jack with a rated capacity sufficient to lift and hold up the
vehicle.
4. Raise the vehicle with the jack applied to the axle(s). DO NOT use
the bumper as a lifting point.
5. Support the vehicle with floor stands under the axle(s). If the axle or
the suspension is being serviced, support the vehicle with floor
stands under the frame side-members, preferably between the axles.
Frame and Tow Hooks
Your vehicle’s chassis is manufactured with frame rails of either HSLA
steel or heat-treated steel. Each must be handled in a specific manner to
make sure maximum service life. Consult the service manual or your
dealer before attempting frame repair or modification.
It is important, particularly on vehicles where the tow hooks are used
frequently, to inspect the front and rear tow hooks for damage or a loose
mounting.
OPENING AND CLOSING THE HOOD
WARNING:The parking brake must be fully set before opening
the hood or possible personal injury may occur.
WARNING:To reduce the risk of the possibility of personal
injury, never stand beneath the hood when it is being raised or
lowered.
WARNING:If you must leave the engine running while checking
under the hood, do not allow any loose clothing, jewelry, hair or
other items to get near moving engine components or possible personal
injury may occur.
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The hood and fenders are held in position by a latch located on each
fender.
Before opening the hood, set the parking brake, shift into positionN
(automatic transmission) or first (manual transmission) and turn the
engine off.
To open the hood:
1. Lift up on the bottom of each latch.
2. Pull the bottom of each latch away from the fender.
216Maintenance
2013 F-650/750(f67)
Owners Guide gf, 2nd Printing, March 2013
USA(fus)