2015 FORD F650 service

Regeneration
Unlike a normal filter that requires periodic replacement, the DPF can
regenerate, or clean itself, to maintain operating efficiency. The
regeneration process takes place automatically. A small increase in
engine or turbo sound level is normal during filter regeneration.
However, some driving conditions mean that you may need to support
the regeneration process:
•Operating in stop-and-go traffic or maintaining low speeds as in city
or delivery driving
•Frequent engine starting and stopping
•Relatively light vehicle payload
•Regular operation in cold ambient temperatures, such as below 0°F
(-18°C).
Diesel particulate filter four–level loading chart
Level and lamp
statusFilter status Requested action
Level 1
solidRegeneration required.Drive on the highway
at highway speedsOR
start parked
regeneration to
prevent loss of engine
performance. Level 2
flashing
(once per second)Nearly full. Engine
performance is limited.
Level 3
flashing +solidFull. Engine
performance is
increasingly limited.Perform parked
regeneration to
prevent loss of engine
performance.
Level 4
solidOver full. Engine
performance is highly
limited. Continued
operation may result
in irreparable damage
to the filter.Pull vehicle safely off
roadway, turn on
hazard flashers and
shut down engine as
soon as possible. Seek
service immediately.
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Instrument cluster lamp(s) illuminates or flashes when operator
assistance is required. In addition, engine performance becomes
increasingly limited above Level 1.
At Levels 1 and 2, the operator can take two courses of action to
facilitate filter regeneration:
1. Drive your vehicle on the highway at highway speeds.
2. Perform a parked regeneration by following the steps inParked
regeneration.
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
WARNING:When performing the parked regeneration
procedure, make certain the vehicle is safely off the 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 your 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 before beginning a parked regeneration.
2. If your vehicle is equipped with an automatic transmission and a
steering column shift lever, place the transmission in positionP.
Otherwise, place the transmission in positionN.
3. Remove your feet from the accelerator pedal and clutch pedal
(manual transmission).
4. Set the parking brake.
5. Within five seconds of setting the parking brake, remove your foot
from the service brake pedal.
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 positionPorNas previously
described in Step 2.
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3. Do not press the accelerator pedal, service brake pedal, or clutch
pedal (manual transmission).
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.
Maintenance and Service
The DPF can retain a relatively large amount of residual ash and provide
many miles and hours of maintenance-free operation. At some point,
generally beyond 150000 miles (240000 kilometers) or 5000 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 vary greatly depending
upon vehicle and 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. See your engine manufacturer’s owner’s manual for
more details about 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.
Note:Do not modify or remove this device. Modification of the system
or additions of aftermarket devices can reduce the effectiveness of the
system, as well as cause damage to the exhaust system or engine. Any
modifications may also invalidate the vehicle or engine warranty. See
your warranty information.
Note:Blocked or plugged holes or modification to, or removal of, the
outlet assembly could result in elevated exhaust temperatures that may
result in vehicle or property damage or personal injury.
The exhaust outlet assembly on your vehicle is a uniquely functioning
device that accompanies the DPF assembly. It can help control the
temperature of the exhaust during the DPF regeneration process.
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Diesel Engine
WARNING:Using low sulfur (16-500 ppm) or high sulfur
(greater than 500 ppm) diesel fuel in a diesel engine designed to
use only Ultra Low Sulfur Diesel fuel causes certain emission
components to malfunction which may also cause the Service Engine
Soon light to illuminate indicating an emissions-related concern. It may
also increase the likelihood of engine oil dilution with fuel which may
lead to major engine damage
WARNING:Do not mix diesel fuel with gasoline, gasohol or
alcohol. This could cause an explosion resulting in personal
injury.
WARNING:Do not add gasoline, gasohol or alcohol to diesel
fuel. This practice creates a serious fire hazard resulting in
personal injury and engine performance problems.
WARNING:Do not use starting fluid such as ether or gasoline.
Such fluids can cause immediate explosive damage to the engine
and possible personal injury.
WARNING:Do not use home heating oil or any diesel fuel not
intended for highway use. Red dye is used to identify fuels
intended for agricultural and non-highway use. Damage to the fuel
injection system, engine and exhaust catalyst can occur if an improper
fuel is used.
Note:Use of any fuel other than those recommended may cause
powertrain damage, a loss of vehicle performance, and repairs may not
be covered under warranty.
Use only Ultra Low Sulfur (15 ppm Sulfur Maximum) No. 1-D or 2-D
diesel fuel in your diesel engine. Diesel fuel No. 1-D or winter diesel fuel
blend of No. 2-D is recommended at ambient temperatures below 20°F
(-7°C). Diesel fuel that is blended with 20% biodiesel maximum may be
used.
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Biodiesel fuel is a product converted from renewable fuel sources,
including vegetable oil, animal fat and cooking oil. You should not use
raw, refined, and recycled vegetable/plant oils, greases, and animal fats.
Biodiesel fuel blends must meet requirements of ASTM D7467 standard
specification. See your engine operator’s manual for more information
and restrictions about the use of biodiesel fuel.
Octane Recommendations - Gasoline Engines
Regular unleaded gasoline with a
pump (R+M)/2 octane rating of 87
is recommended. Some stations
offer fuels posted as Regular with
an octane rating below 87,
particularly in high altitude areas. Do not use fuels with a posted octane
rating below 87.
Do not be concerned if your engine sometimes knocks lightly. However, if
it knocks heavily under most driving conditions while you are using fuel
with the recommended octane rating, see an authorized dealer to
prevent any engine damage.
RUNNING OUT OF FUEL
Gasoline Engine
Avoid running out of fuel because this situation may have an adverse
effect on powertrain components.
If you have run out of fuel:
•You may need to cycle the ignition from off to on several times after
refueling to allow the fuel system to pump the fuel from the tank to
the engine. On restarting, cranking time takes a few seconds longer
than normal.
•If your vehicle is equipped with dual fuel tanks, adding four–five
gallons (15–19 liters) of fuel is enough to restart the engine. If your
vehicle is out of fuel and on a steep grade, more than four–five
gallons (15–19 liters) may be required.
•The service engine soon indicator may come on. For more
information on the service engine soon indicator, see theInstrument
Clusterchapter.
SeeGeneral informationin theInformation Displayschapter for
information on Miles to Empty.
Diesel Engine
Avoid running out of fuel as this allows air to enter the fuel system,
which makes restarting your vehicle difficult.
87(R+M)/2 METHOD
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Anti-lock Brake System (ABS)
This system helps you maintain steering control during emergency stops
by keeping the brakes from locking.
The ABS lamp momentarily illuminates when you switch on the
ignition. If the light does not illuminate during start-up, if it
remains on or flashes, the ABS may not be working and
requires servicing.
If the ABS is disabled, normal braking is still effective. If the
brake warning lamp illuminates, have your brake system
serviced immediately.
If you connect a PLC trailer with the ignition on, the trailer
ABS light also illuminates. If the light fails to illuminate, if it
remains on after you start the vehicle or continues to flash,
have the system serviced immediately.
FULL POWER BRAKE SYSTEM
WARNING:If the red BRAKE warning lamp in the instrument
cluster remains illuminated after engine start up, this indicates a
system failure in the Full Power Brake System. Stop the vehicle safely
as soon as possible and seek service immediately.
This system incorporates standard braking, an anti-lock braking system
(ABS) and optional Power Park Brake into one fully integrated hydraulic
brake system. With the Full Power Brake System, braking energy is
stored, similar to an air brake system, resulting in faster response times
and shorter stopping distances. This is accomplished using motor and
pump assemblies that pressurize the system by pumping brake fluid into
accumulators. This is similar to the air compressor of an air brake system
pressurizing the air tanks. The system includes a master cylinder that
provides the normal pedal feel and transfers the pedal force, via brake
fluid, to the main components of the system.
Note:The motor and pumps run momentarily with the ignition switch in
the on or run position, or in the off position with the brake pedal
pressed.
Note:During normal driving, you may hear the pump and motors
replenishing the accumulators. This is a normal function of the system.
AIR BRAKES
After starting the engine, give the air compressor time to build up the air
pressure to 60 psi (414 kPa) before moving your vehicle.
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WARNING:Do not drive or continue to drive if the low air
pressure buzzer is sounding or the brake warning light is lit.
These warnings indicate that air pressure is not to normal operating
level. Continued use of the vehicle could result in loss of braking ability.
WARNING:Avoid repeated light application of the brake pedal.
This depletes air pressure faster and could result in loss of
braking capability.
Periodically check the air pressure
gauge while driving. Pressure should
range between approximately
100–125 psi (690–862 kPa). The air
compressor governor cut-in and
cutout pressure settings are set at
the factory and are not adjustable.
When air pressure is insufficient (below 60 psi [414 kPa]), a
warning light illuminates and a buzzer sounds when the ignition
is in the on position.
This may happen because excessive brake applications are depleting the
system air pressure. If this condition occurs, stop driving your vehicle
until the compressor has fully recharged the air system.
WARNING:Do not move the vehicle when the air pressure is
insufficient because the brake system may be inoperative.
Select a gear ratio to help slow your vehicle before descending grades.
Supplementing with brakes, as required, help to safely slow the vehicle
and avoids overspeeding the engine.
Air Chamber Stroke Indication
Air chamber push rods have orange stroke indicator markers that warn
when the braking system requires adjustment or repair. The painted
orange indicator is on the air chamber push rod at the slack adjuster
stroke dimension that requires service when visible during brake
application.
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A qualified service technician should perform air brake inspection and
adjustment or repairs keeping to the instructions in the service manual.
Cam Brakes - Automatic Slack Adjusters
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.
Standard air brakes (cam) are
equipped with automatic brake
adjusters. Automatic adjustment
occurs during brake applications.
Inspect brakes for proper
adjustment at the intervals listed in
theScheduled Maintenance
chapter.
Emergency Air Brake
WARNING:Do not continue to operate the vehicle with a failure
of one of the brake systems. Take the vehicle to your dealer for
service immediately.
All vehicles are equipped with a dual brake system. In the unlikely event
of a failure of one system, the second system functions for emergency
stopping. The brake pedal controls all these systems in the same manner
as for normal stops.
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