2019 FORD F650/750 brake

High Fluid Level
Do not add fluid further than the maximum
mark. Fluid levels above the maximum
mark may cause shift or engagement
concerns and possible damage.
Note:
High fluid levels can be caused by an
overheating condition.
Adding Transmission Fluid
Do not use supplemental transmission
fluid additives, treatments or cleaning
agents. The use of these materials may
affect transmission operation and result
in damage to internal transmission
components and could lead to
transmission damage that may not be
covered by the vehicle Warranty.
Use only recommended transmission fluid
that meets our specifications. See
Capacities and Specifications (page
261).
Note: Use of a non-approved automatic
transmission fluid may cause internal
transmission component damage.
If necessary, add fluid in
8 fl oz (250 ml)
increments through the filler tube until the
level is correct.
If an overfill occurs, excess fluid should be
removed, have your vehicle checked as
soon as possible. BRAKE FLUID CHECK WARNING:
Do not use any fluid
other than the recommended brake fluid
as this will reduce brake efficiency. Use
of incorrect fluid could result in the loss
of vehicle control, serious personal injury
or death. WARNING:
Only use brake fluid
from a sealed container. Contamination
with dirt, water, petroleum products or
other materials may result in brake
system damage or failure. Failure to
adhere to this warning could result in the
loss of vehicle control, serious personal
injury or death. WARNING:
Do not allow the fluid
to touch your skin or eyes. If this
happens, rinse the affected areas
immediately with plenty of water and
contact your physician. WARNING:
A fluid level between
the MAX and MIN lines is within the
normal operating range and there is no
need to add fluid. A fluid level not in the
normal operating range could
compromise the performance of the
system. Have your vehicle checked
immediately.
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CHANGING THE 12V BATTERY
WARNING: This vehicle may be
equipped with more than one battery,
removal of cable from only one battery
does not disconnect the vehicle
electrical system. Be sure to disconnect
cables from all batteries when
disconnecting power. Failure to do so
may cause serious personal injury or
property damage. WARNING:
Batteries normally
produce explosive gases which can
cause personal injury. Therefore, do not
allow flames, sparks or lighted
substances to come near the battery.
When working near the battery, always
shield your face and protect your eyes.
Always provide proper ventilation. WARNING:
When lifting a
plastic-cased battery, excessive pressure
on the end walls could cause acid to flow
through the vent caps, resulting in
personal injury and damage to the
vehicle or battery. Lift the battery with a
battery carrier or with your hands on
opposite corners. WARNING:
Keep batteries out of
reach of children. Batteries contain
sulfuric acid. Avoid contact with skin,
eyes or clothing. Shield your eyes when
working near the battery to protect
against possible splashing of acid
solution. In case of acid contact with skin
or eyes, flush immediately with water for
a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed,
call a physician immediately.
Note: If your battery has a cover/shield,
make sure it is reinstalled after the battery
has been cleaned or replaced. Note:
Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash hands after handling.
Note: Electrical or electronic accessories
or components added to the vehicle by the
dealer or the owner may adversely affect
battery performance and durability.
Your vehicle is equipped with a Motorcraft
maintenance-free battery which normally
does not require additional water during
its life of service.
For longer, trouble-free operation, keep the
top of the battery clean and dry. Also,
make certain the battery cables are always
tightly fastened to the battery terminals.
If you see any corrosion on the battery or
terminals, remove the cables from the
terminals and clean with a wire brush. You
can neutralize the acid with a solution of
baking soda and water.
It is recommended that the negative
battery cable terminal be disconnected
from the battery if you plan to store your
vehicle for an extended period of time.
Because your vehicle ’s engine is
electronically controlled by a computer,
some control conditions are maintained
by power from the battery. When the
battery is disconnected or a new battery
is installed, the engine must relearn its idle
and fuel trim strategy for optimum
driveability and performance. To begin this
process
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in park (P) or neutral (N) and turn off all accessories.
3. Start the engine. Run the engine until it reaches normal operating
temperature.
4. Allow the engine to idle for at least one
minute.
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5. Turn the air conditioning (if equipped)
on and allow the engine to idle for at
least one minute.
6. Release the parking brake. With your foot on the brake pedal and with the
air conditioning on, put the vehicle in
drive (D) and allow the engine to idle
for at least one minute.
•If you do not allow the engine to
relearn its idle trim, the idle quality
of your vehicle may be adversely
affected until the idle trim is
eventually relearned.
7. Drive the vehicle to complete the relearning process
•The vehicle may need to be driven
10 mi (16 km) or more to relearn the
idle and fuel trim strategy along
with the ethanol content for flexible
fuel vehicles.
If the battery has been disconnected or a
new battery has been installed, the clock
and radio settings must be reset once the
battery is reconnected.
Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized standards
for disposal. Call your local authorized
recycling center to find out more about
recycling automotive batteries.
Battery Management System (If
Equipped)
The battery management system (BMS)
monitors battery conditions and takes
actions to extend battery life. If excessive
battery drain is detected, the system may
temporarily disable certain electrical
features to protect the battery. Those
electrical accessories affected include the
rear defrost, heated/cooled seats, climate
control fan, heated steering wheel, audio
and navigation system. A message may be
shown in the information displays to alert the driver that battery protection actions
are active. These messages are only for
notification that an action is taking place,
and not intended to indicate an electrical
problem or that the battery requires
replacement.
Electrical accessory installation
To ensure proper operation of the BMS,
any electrical devices that are added to
the vehicle should not have their ground
connection made directly at the negative
battery post. A connection at the negative
battery post can cause inaccurate
measurements of the battery condition
and potential incorrect system operation.
Note:
Electrical or electronic accessories
added to the vehicle by the dealer or the
owner may adversely affect battery
performance and durability, and may also
affect the performance of other electrical
systems in the vehicle.
When a battery replacement is required,
the battery should only be replaced with
a Ford recommended replacement battery
which matches the electrical requirements
of the vehicle. After battery replacement,
or in some cases after charging the battery
with the external charger, the BMS requires
eight hours of vehicle sleep time (key off
with doors closed) to relearn the new
battery state of charge. Prior to relearning
the state of charge, the BMS may disable
electrical features (to protect the battery)
earlier than normal.
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Brake Lamp, Rear Lamp, Rear
Direction Indicator, License Plate
Lamp and Reverse Lamp
1.
Switch all of the lamps and the ignition
off.
2. Remove the four screws and the lamp lens from lamp assembly.
3. Remove the bulb by pulling it straight out.
CHANGING THE ENGINE AIR
FILTER - 6.7L DIESEL
Air Filter Restriction Gauge WARNING: To reduce the risk of
vehicle damage and personal burn
injuries, do not start your engine with the
air cleaner removed and do not remove
it while the engine is running.
Note: Operating your vehicle in heavy
snowfall or extreme rain conditions may
allow excessive amounts of snow or water
into the air intake system. This could plug
or soak the air filter that could cause the
engine to lose power or shut down. The restriction gauge, located on the upper
housing of the air filter assembly, measures
the vacuum inside the air filter. The more
the air filter is restricted (dirty, clogged),
the higher the vacuum reading.
Check the air filter restriction gauge
whenever you open the hood to perform
general engine maintenance or at least
every 7,500 mi (12,000 km). If you operate
your vehicle in extremely dusty conditions,
check and reset the gauge at least every
500 mi (800 km), or two weeks, whichever
comes first. Change the air filter when the
restriction gauge reads near the change
filter line and the gauge is yellow. If you
allow the restriction gauge to reach
maximum restriction you can affect your
engine performance and fuel economy.
Note:
Do not blow out the air filter element
with compressed air since the compressed
air could damage the filter paper.
Note: Do not rely on filter appearance
alone. A filter which appears to be dirty may
actually have several thousand miles
(kilometers) of life remaining.
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2.
Rotate the filter fully counterclockwise
until the peg is at the far end of the slot.
3. Pull the filter straight up from the bracket and discard the filter.
Installation
1. Install the new filter into the filter bracket. Turn the filter clockwise to
lock it in place.
2. Reconnect the fuel lines.
3. Switch the ignition on for 30 seconds and then switch the ignition off.
Repeat this operation six times in a row
to purge any trapped air from the fuel
system.
ELECTRICAL SYSTEM
INSPECTION
Periodically inspect electrical connectors
on the outside of the cab and 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 Silicone Brake Caliper
Grease and Dielectric Compound 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 powertrain components,
such as engine and transmission controls,
instrument panels and ABS. While most
systems operate on battery voltage (12
volts), some systems can be as high as 90
volts or as low as five volts. See the
Electrical Circuit Diagram Manuals,
available from your vehicle
’s manufacturer,
to make sure that any extra body lights and
accessory connections to circuits are both
appropriate and not overloaded. Do not
make modifications to any vehicle control
system without first contacting an
authorized dealer.
AIR INDUCTION SYSTEM
INSPECTION WARNING: When performing
maintenance to any turbocharged engine
with engine air inlet piping disconnected,
keep loose clothing, jewelry and long hair
away from the engine air inlet piping. A
turbocharger compressor air inlet
protective shield should be installed over
the turbocharger air inlet to reduce the
risk of personal injury or death.
Perform a complete inspection of the air
induction system annually.
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In areas where road salt is used,
disassemble the joints of each aluminum
component and inspect for salt build-up
and presence of chlorine that can cause
aluminum particles to flake off and enter
the engine combustion chambers. If
evidence of corrosion is found (usually at
the pipe connections), use a wire brush to
clean the inside of the pipes and inside the
rubber hoses.
If pitting is evident at the joint ends of the
intake pipes, use Motorcraft Silicone
Gasket and Sealant TA-30 to seal the
joints. Make sure no excess material, which
can pull into the engine, is on the inside of
the pipes. If the service condition of the
pipes, hoses or clamps is questionable,
replace the defective part(s).
Make sure to clean all dust and debris out
of the pipes and couplings with a clean,
damp rag before reassembly.
Chassis-mounted Charge Air
Cooler
Visually inspect the core assembly for
debris and clogging of external fins with
the engine off.
Before 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 pitting is
evident on the intake piping, use
Motorcraft Silicone 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.
EXHAUST SYSTEM
INSPECTION
Note: If your vehicle is equipped with a
catalytic converter or muffler, do not blend
waste oil with diesel fuel. Operate only on
ultra-low sulfur (less than 15 parts per
million sulfur) diesel fuel with a cetane
value of 45 or higher.
If your diesel engine is equipped with a
catalytic converter, it is important to review
the maintenance schedule to make sure
proper functioning of the catalytic
converter. Also, take precautions not to
damage the catalytic converter when
servicing your engine or storing your
vehicle.
BRAKE SYSTEM INSPECTION WARNING: Always wear a
respirator approved by the National
Institute of Occupational Studies of
Health (NIOSH) or Mine Safety and
Appliance (MSA) during all brake service
procedures. Wear the respirator from
removal of the wheels through assembly.
Never use compressed air or dry brushing
to clean brake parts or assemblies.
Clean brake parts and assemblies in
open air. During assembly, carefully
place all parts on the floor to avoid
getting dust in the air. Use an industrial
vacuum cleaner with a HEPA filter
system to clean dust from the brake
drums, backing plates and other brake
parts. After using the vacuum, remove
any remaining dust with a rag soaked in
water and wrung until nearly dry.
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Never use compressed air or dry
sweeping to clean the work area. Use an
industrial vacuum cleaner with a HEPA
filter system and rags soaked in water
and wrung until nearly dry. Dispose of
used rags with care to avoid getting dust
in the air. Use an approved respirator
when emptying vacuum cleaners and
handling used rags.
Worker clean-up: Wash your hands
before eating, drinking or smoking.
Vacuum your work clothes after use and
then launder them separately, without
shaking them, to prevent fiber dust
getting into the air.
Your vehicle is equipped with
non-asbestos brake linings. However,
exposure to excessive amounts of brake
material (whether asbestos or
non-asbestos, fiberglass, mineral wool,
aramid or carbon) may be a serious health
hazard.
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 due to vehicle applications
and operating conditions. If you are
uncertain of the proper schedule for your
vehicle, contact an authorized 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, you can see the orange
marker protruding from the chamber
when the brakes are applied.
• Checking the brake lining (every service
interval). When brake linings or blocks
wear within 0.063 in (1.6 mm) they
must be replaced.
• Periodic checking (every service
interval) of the air compressor filter.
Check the filter minder and when the
indicator is near or on the red line
marked
Service, replace the filter and
reset the service filter minder.
Do not back off or disconnect the front
brakes so that they are less effective,
letting the rear brakes do all the stopping
of your 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.
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Once a year, inspect the entire brake
system:
•
Rubber components for deterioration.
A qualified technician should inspect
these components and replace them
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.
Periodically inspect parts such as air brake
chamber diaphragm, air compressor and
air cleaner. Replace any parts if you can
consider them unserviceable.
Air Dryer
Climactic conditions affect performance
of desiccant or after-cooler type air dryers.
You must establish a maintenance
schedule for each specific operation.
The use of an air dryer on a vehicle does
not eliminate the need to drain the air
reservoirs periodically.
Inspect for moisture in the air system by
opening reservoirs, draincocks or valves
and checking for presence of water. The
presence of small amounts of water due
to condensation is normal and is not an
indication that the dryer is not functioning
properly. Replace or rebuild the desiccant cartridge
when you determine that the desiccant is
contaminated and does not have adequate
water absorption capacity. The desiccant
change interval may vary. A general
recommendation is to replace the
desiccant every 12 months (yearly). If
experience has shown that extended or
shortened life has resulted for a particular
installation, then the yearly interval can be
increased or decreased accordingly.
Draining the Air Brake Reservoir
WARNING: Failure to drain air
brake reservoirs can result in a reduction
or loss of braking ability due to fluid
accumulation in the reservoir and/or
possible freeze-up during cold weather.
Completely drain all the air brake reservoirs
daily by opening the draincock at the ends
of the tanks. (Where accessible.
Pull-chains are used when the drains are
undercab or otherwise inaccessible.) Close
the draincock after draining. Manually drain
any air tanks equipped with automatic
moisture ejector valves, as required, to
maintain a dry air system. Contact an
authorized dealer if you are unsure of the
air reservoir locations or the draining
procedure.
Hydraulic Brakes
Establish a regular schedule for periodic
cleaning, lubrication and adjustment
inspection based on vehicle use. Exact
maintenance intervals are difficult to
predetermine due to vehicle applications
and operating conditions. If you are
uncertain of the proper schedule for your
vehicle, contact an authorized dealer.
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