Ford - Truck - Owners Manua - 1999 - 1999

FORD TRUCKS USER MANUAL /FordTrucksInternational /FordTrucksInternational /FordTrucksInternational /fordtrucksinternational www.fordtrucks.com.tr Sharing the load The illustrations, technical information, data and descriptions contained in this publication, were correct at the time of going to print. We reserve the right to make any changes necessary in line with continuous development and improvement/ This publication may not be duplicated, reprinted, stored in a data processing system or transmitted by electronic, mechanical, photographic or other means, or recorded, translated, edited, abridged or expanded without prior written consent of Ford Otomotiv San A.S. The same also applies for parts of this manual and their use in other applications. Although due care has been taken to make it as complete and accurate as possible, it can stilll be subject to alterations. This publication describes options and trim levels available throughout the Ford model range in every country, and therefore some of the items covered may not apply to your vehicle. Important: Ford genuine parts and accessories have been specifically designed for Ford vehicles. They are dedicated for your Ford vehicle. We would like to point out that other parts and accessories than mentioned above have not been examined and approved by Ford unless explicitly stated by Ford. In spite of continuous market product monitoring, we cannot certify the suitability of such products. Ford is not liable for any damage caused by use of such products. September 2021 Copyright Issued by Ford Otomotiv San. A.S., Ford Customer Service Division Table of Contents INTRODUCTION 1 Accessories and Parts.......................................... 2 Dashboard.................................................................4 SAFETY 6 Seat Belts.................................................................. 7 Park Brake Control.................................................9 Tires and Wheels.................................................. 10 General Safety Warnings ..................................12 CONTROLS AND INDICATORS 15 Instrument Panel ................................................. 16 Trip Computer........................................................ 27 Control Buttons.................................................... 34 Multi-functional Handles..................................37 Tachograph............................................................40 Tachograph Simulator Unit............................. 46 OPERATION 47 Opening and closing of the vehicle ............. 48 Cab Ventilation..................................................... 53 Seats and Beds.................................................... 54 In-cab storage compartments ...................... 64 Steering....................................................................67 Mirrors......................................................................68 Lighting.................................................................... 70 Window Washing and Heating Systems ...75 Circuit Breakers .................................................... 77 A/C and Heater.....................................................79 Driving......................................................................90 Braking..................................................................... 94 Shifting...................................................................103 Power take off....................................................... 113 While driving..........................................................115 ECAS (Electronically Controlled Air Suspension).............................118 Air Suspension Mechanical Level Adjustment........................ 121 Tag Axles................................................................ 122 EBS-ESP................................................................126 Differential Lock..................................................128 Lane Departure Warning System.................. 131 Emergency braking system.............................134 Useful Information.............................................139 MAINTENANCE AND SERVICE 143 Attaching and Detaching a Trailer ..............144 Fuel Quality and Refueling.............................154 Cleaning of Exhaust Filter...............................156 Urea System.........................................................159 Tires and Rims.....................................................162 Driver Cab............................................................... 171 Engine..................................................................... 175 Steering................................................................. 186 Towing the Vehicle............................................. 187 Electrical Systems............................................. 189 Changing Bulbs.................................................. 198 Suspension Systems........................................203 Locations of the Tools in the Vehicle.........205 Questions and Remedies.............................. 206 TECHNICAL SPECIFICATIONS 209 Labels.....................................................................210 Fluid Filling Capacities....................................... 211 Engine Specifications.......................................214 Transmission Specifications..........................216 Installation of Upper structure......................218 About This Manual ABOUT THIS MANUAL Thank you for choosing Ford. We recommend that you take some time to get to know your vehicle by reading this manual. The more that you know about it, the greater the safety and pleasure you will get from driving it. Also some features may be explained although they are not introduced because of the time periods between the dates of issue. Regular servicing of your vehicle helps maintain both its roadworthiness and its resale value. More than 100 Ford Authorized Dealerships around the world will offer you help with their professional service experience. Authorized Dealerships provide you the best expert service with their specifically trained personnel. Moreover, they are supported with a wide range of tools and equipment specially developed for applying service on Ford vehicles. Note: Remember to pass on the Owner’s manual when reselling the vehicle. It is an integral part of the vehicle. All technical information and data included in this manual are valid in the issue date of this manual. However, we reserve the right to make changes without prior information due to our continous product development policy as FORD OTOSAN. Some features described in the user manual may not be present in your vehicle depending on the vehicle model. Regards, FORD OTOMOTİV SANAYİ A. Ş. For Diesel Vehicles CAUTION ! Use only EN590 compliant, high quality fuel (Eurodiesel) with low ratio of sulphur. Fuel-related faults that may occur when EN590 compliant, high quality fuel (Eurodiesel) with low ratio of sulphur is not used shall be considered out of warranty cover. FORD OTOSAN INTRODUCTION -1- 1 1 INTRODUCTION xxxxxxxx Accessories and Parts PARTS AND ACCESSORIES Your Ford has been built to the highest standards using high quality Ford Original Parts. You may enjoy driving your vehicle for years. Ford logo on them. Inspect whether the part has a Ford logo in case of a repair, and make sure that Ford Original Parts are used. Symbols on your vehicle We advise you to use Ford Original Parts only when an unexpected situation occurs and a part should be replaced. The use of Ford Original Parts ensures that your vehicle is repaired to its pre-accident condition and maintains its maximum residual value. Ford Original Parts complies with the strictest safety conditions and highest safety standards of Ford. Thus, they offer the best total repair cost including the costs of parts and labor. SYMBOLS GLOSSARY Symbols in this manual WARNING If you do not follow the instructions marked with the warning symbols, you may expose yourself and others to an accident resulting in death or injury. CAUTION When you see these symbols, refer to the relevant section of this manual before touching any part or attempting an adjustment of any kind. Now it is much more easier to understand if the part offered to you is a Ford Original Part. Ford Original Parts listed below have a Ford logo on them. Inspect whether the part has a Ford logo in case of a repair, and make sure that Ford Original Parts listed below have a -2- You risk damaging your vehicle, if you do not follow the instructions highlighted by the caution symbol. INTRODUCTION ACCESSORIES, SPARE PARTS AND MODIFICATIONS Today, there are many non-original parts and accessories are being sold in the market for FORD TRUCKS vehicles. Using these types of non- original FORD TRUCKS parts and accessories (even these parts are authorized by some institutions in your country) may have an adverse effect on the safety of your vehicle. Therefore, non-original FORD TRUCKS parts and accessories and problems likely to result from the usage of these are not considered under warranty and this does not put FORD TRUCKS under any liability. No modifications should be performed on this vehicle. Any modification on your FORD TRUCKS could effect your vehicle’s performance, safety, and durability, and it might also be against legal regulations. Additionally, any damage and performance problems due to the modification of your vehicle are not considered under warranty cover. FORD OTOMOTİV SANAYİ A. Ş. -3- 1 1 INTRODUCTION xxxxxxxx Dashboard -4- INTRODUCTION Dashboard xxxxxxxxxxxx 1 Steering 12 Gear 2 Multi-functional handle (left) 13 Centre console/Bottle holder 3 Multi-functional handle (right) 14 Headlamp switch 4 Tachograph 15 Glove box 5 16 Window regulator control buttons 6 Radio Air Conditioner/Heater switching unit 17 Digital indicator 7 Parking brake 8 Lighter / 12V outlet / 2 18 Ventilation and air conditioner/ heater air vents 9 Auxiliary heater digital control unit 19 Storage compartments 10 Control panel/control buttons 20 Camera 11 Ashtray 21 Rain sensor -5- 1 SAFETY Safety 2 -6- SAFETY Seat Belts Seat belts provided with your vehicle are the most important on-board safety equipment. Seat belts minimize the risk of injury by reducing the movement of the occupants in the direction of impact and their contact with the interior in case of a crash. Always fasten your seat belts while driving. Seat belt shall not loose or bent or shall not be blocked by another occupant or load. WARNING Seat belt cannot provide its protection function if you do not fasten it correctly or ensure that the belt lock is engaged properly. Otherwise, you may get seriously or fatally injured in case of an accident. Ensure that all occupants of the vehicle have properly fastened their seat belts to prevent this. WARNING While you are fastening your seat belt, ensure that, - it does not pass through your belly that it passes through your hip, e.g. your thighs - it is tight - it is not twisted any way - it passes through the middle of your shoulders - it does not pass through your neck or armpits - it is strained on your hips by pulling it upwards from the chest . Do not fasten the belt with heavy items and avoid wearing thick clothes. Do not fasten the seat belt over fragile objects in or on your clothes such as glasses, keys, pens etc. Use a seat belt for only one person. Never travel with your children on your lap and do not fasten the seat belt over them. WARNING Seat belts provide safety inside the vehicle when the occupants are seated in vertical position while the backrests of the seat are in vertical position. -7- Avoid seating position that prevents correct operation of the seat belts. Do not drive while the backrest is leaned backwards excessively. WARNING SEAT BELT REMINDER The system only provides protection when you wear your seat belt correctly. A warning light lights up and a beep sounds in the following situations: Driver seat occupied or front seat occupied. The front seat belts are not fastened. Your vehicle exceeds a relatively low speed. The warning light also comes on when the front seat belt is removed while your vehicle is moving. If you do not fasten your seat belt, the audible and visual warnings will stop after about five minutes. 2 SAFETY 2 Seat Belts WARNING Fastening the seat belt Seat belt cannot provide proper functionality when the belt or lock of the seat belt is damaged. To prevent this, check the seat belts for damage or jamming periodically. Otherwise, seat belt may be torn in case of an accident and cause serious or fatal injuries. Pull the seat belt continuously from the reel. Seat belt may be locked when it is pulled too fast or when the vehicle is on a slope. In this case, relieve the seat belt and allow it to retract a little, then try again. Hear the locking click when you are inserting the latch of the seat belt to the buckle. Otherwise, seat belt is not locked. -8- Press the red button on the buckle to release the seat belt. Then, release the belt slowly to allow that it is wound on the reel fully. Seat belt shall pass through the middle of your shoulder. And, the waist part shall be seated firmly on your hips, not on your stomach. SAFETY Park Brake Control Park brake is placed on the front console. Always apply the park brake after parking the vehicle. Chock the tires if the vehicle is parked on a slope. Then, bring the lever to park position (position 1) again. • Then, get off the vehicle and apply the trailer park brake. Park position Drive position: Bring the park brake lever to 1 position. Red P illuminates on the indicator when the park brake is applied. • TEST POSITION:(TRACTOR VEHICLES) After taking lever to position 1, check whether the vehicle with semi-trailer moves by pressing on the lever and pulling the lever down (position 3). Bring the park brake lever to 2 position. WARNING Do not apply the park brake while the brake drums or disks are very hot, wait for them to cool. -9- WARNING Park brake is spring type. If there is not enough pressure in the air tanks, park brake will not be released from the control lever. There shall be enough air pressure on the tanks to release the brake. If there is not enough pressure, the brake can be release by turning the setting mechanism of the adjustment bolt located on the park brake bellows. Before releasing the park brake spring, ensure the safety of your vehicle by chocking the wheels. Do not drive the vehicle if any park brake circuits are not working. Bellows may be frozen if the brakes cannot be released while the lever is released on winter. Spring is shrunk by rotating the bellows installation bolt in the tightening direction. To ensure that the emergency spring is fully installed, installation bolt shall be tightened until it does not turn anymore. 2 SAFETY 2 Tires and Wheels One of the most important safety elements on your vehicle is the tires. Check the tire pressure and condition periodically. Do not drive your vehicle with worn tires. -When the tire pressure is very low, tires may get extremely heated, worn and these may cause excessive fuel consumption. -When the tire pressure is very high, this may cause longer braking distance, worse handling and excessive wear on tires. -If the pressure loss happens continuously, this may be caused by external damages, cracks, foreign material in the tires and faulty tire valves leaking air. WARNING Tire profiles A minimum profile depth is prescribed for tires by law. Observe the legislation for the relevant country. For safety reasons, change your tires before reaching the legally advised minimum profile depth. WARNING An excessively low tire profile may cause loss of handling at high speeds in case of rain or snow mud conditions. You may loose your handling and cause an accident in these conditions. Please, observe the prescribed tire pressure for your vehicle. Very low tire pressure may cause blow-out of the tire at high speeds and loads. You can cause an accident and thus injuries to others due to this. - 10 - The Condition of the Tires Check the following conditions regularly every 2 weeks and before a long haul to inspect the condition of the tires: -External damage -Cracks and bulges on the tires, -Foreign material in the tire profile, - Irregular wear of the profile. WARNING Do not forget that the external damages, bulges and cracks on the tires may cause blowout of the tire. You may cause an accident in these conditions. SAFETY Tires and Wheels The Aging of the Tires - Aging of the tires reduces the operation and traffic safety of the tires. Even unused tires are aged. - Always replace your tires if they are aged more than 6 years. Tire Damages Tire damages are usually caused by the fol- lowing reasons: - Aging of the tire - Foreign material - Usage conditions of the vehicle - Weather conditions - Oil, fuel, grease etc. Contact with materials - Dragging on the sidewalks - Low or high tire pressure - 11 - WARNING When your vehicle passes over the sides of the sidewalks or objects with sharp edges, this may cause damages that cannot be seen externally. These damages can only be noticed in the future and cause a flat tire. Do not park your vehicle with some part of the tire on the sidewalk. 2 SAFETY 2 General Safety Warnings WARNING Failure to observe following conditions may cause accidents which may result in serious injuries. - Using a mobile phone while driving may distract you. - Do not adjust the seat and steering wheel while driving. - Occupants travelling on any other place than seats (e.g. on the bed) may cause seri- ous injuries while braking. - Do not put any objects on the beds inside the cab; this may cause serious injuries while braking. WARNING Make sure that the heater is off before refuelling of the vehicles with additional fuel tank for additional cab heater. WARNING Items that you may place on the toolbox compartment shall not exceed 8 kg. Also, precautions shall be taken against the risk of items moving and damaging the toolbox compartment when the vehicle is moving. WARNING Do not carry or store material harmful to the health inside the driver cab. Examples of these materials are: - Fuel - Acid - Lubricants and grease - Cleaning agents Vehicle Tracking Safety System Fleet tracking systems are also used for finding the location of the vehicle in case of car theft. However if the vehicle tracking module is removed, the location of the vehicle can not be found. Vehicle Tracking Safety System eliminates this problem which is the weak point of the fleet tracking systems, since the module can not be removed and prevents the stolen vehicle from being driving away. In vehicles with optional vehicle tracking safety system, starting may be last up to 35 seconds when the disconnecting switch shut off because of the safety package. - 12 - After the ignition is on, wait for the red immobilizer light to dim out before starting. VGS Active Vehicle tracking safety system warning indica- tor If the instrument panel and FMS cannot com- municate while the ignition is on, the vehicle cannot be started. This prevents the starting of the vehicle with- out GPS tracking. Vehicle cannot be started and indicates a warning in this case.This prevents the starting of the vehicle without GPS tracking. Vehicle can not be started and indicates a warning in this case. SAFETY General Safety Warnings Cleaning of Exhaust Filter The exhaust filter found in Euro 6 vehicles retains the smut coming from the exhaust gas and decreases the emission values. With the exhaust filter cleaning operation which can be performed automatically or manually, the smut retained in the filter is burned with regular intervals so that the filter is emptied before filling up and being clogged. In this operation, the exhaust gas is heated by the engine and smut is burned. Driver is informed about the exhaust filter cleaning of the vehicle through the messages displayed on the indicator panel and explained in detain in the Exhaust Filter Cleaning section. WARNING Since the exhaust gas shall heat up during the exhaust filter cleaning; ensure that the vehicle is not in the same place with flammable, inflammable and explosive materials or in enclosed space the exhaust filter cleaning prevention using exhaust filter cleaning prevention button. CAUTION Using exhaust filter cleaning prevention for prolonged time may cause the exhaust filter to be clogged and rendered unusable. Please observe the warnings provided in the indicator panel and do not use manual filter cleaning prevention unless necessary. CAUTION The “Emergency Call” Mode: Backlight of button “SOS” – red light, Backlight of button “Service” – white light. Backlight of the LED: -Switching on – red light 5 sec, then green flashing; -The “ERA” mode – green light; -Data transfer in the “Emergency Call” mode – green light; -Malfunction – red light. When there are personnel on the step at the rear of garbage trucks, vehicle speed is limited to 30 km/h and vehicle can not reverse. ERA-Glonass WARNING Ensure that vehicle exhaust cleaning is not performed in locations like hazardous material loading and unloading places or fuelling stations. When necessary, activate The “ERA” mode: Backlight of buttons “SOS”,”Service” – white light 1- Service Buton 2-Microphone 3-Protective cover 4-SOS Buton 5-Led - 13 - 2 Engine running? - 14 - Release all sequence lights x 4 times in Activate the park Switch BACK IT UP ROUTINE UNSUCCESSFUL Switch ROUTINE process completes COMPLETE AT 15 SECONDS ROUTINE process starts Preconditions to start ROUTINE seconds Flashes for 3 Hazard Light LEARNING PROCEDURE SUCCESSFUL Press Mirror Heat seconds. buttons and wait for 3 Yes engaged? Park brake is Press Mirror Heat Yes Yes Gear in Neutral? 2 Yes SAFETY General Safety Warnings Process steps of damper CONTROLS AND INDICATORS Safety 32 - 15 - CONTROLS AND INDICATORS Instrument Panel 3 - 16 - 1 Air pressure indicator 2 Engine oil pressure indicator 3 Speedometer 4 Tachometer 5 Engine coolant temperature gauge 6 Fuel gauge 7 Trip computer CONTROLS AND INDICATORS Instrument Panel FUNCTION SYMBOL COLOR BUZZER BUZZER Multi-functional handle (left) yes Left Signal Lamp Green Right Signal Lamp Green Low brake air pressure Red Instrument yes EBS Red / Amber Automatic n/a ABS Amber Automatic n/a High Beam Blue Multi-functional handle (left) n/a Alternator / Charging system Red Automatic n/a Park Brake Sign Red Park brake control n/a Cab Lock Sign Red Cab lifting mechanism yes - 17 - 3 CONTROLS AND INDICATORS Instrument Panel 3 FUNCTION SYMBOL COLOR BUZZER BUZZER Oil Pressure Warning Red Automatic yes Cold Starting Aid Amber Automatic n/a Height Engine Water Temperature Red Automatic yes Trailer ABS/EBS Amber Automatic n/a Trailer right/left turn signal warning Green Multi-functional handle (left) n/a Engine Warning Lamp Amber Automatic n/a Cruise Control Green Multi-functional handle (right) n/a Front Fog Lamp Green Headlamp switch n/a Seat Belt Warning Red Automatic yes - 18 - CONTROLS AND INDICATORS Instrument Panel FUNCTION SYMBOL COLOR BUZZER BUZZER Rear Fog Lamp Amber Headlamp switch n/a Fuel Level warning Amber Automatic n/a Air Pressure 1 Green Air pressure control button on the indicator n/a Air Pressure 2 Green Seat belt warning Red Automatic yes ESP Amber control button on the control panel n/a Immobilizer Red Automatic n/a MIL (malfunction indicator lamp) Amber Automatic n/a Steerable rear axle Blue control button on the control panel n/a - 19 - 3 CONTROLS AND INDICATORS Instrument Panel FUNCTION 3 SYMBOL COLOR BUZZER BUZZER Intarder Amber Automatic n/a Oil level warning Red Automatic n/a Engine brake Amber Multi-functional handle (right) n/a Information warning Amber Automatic n/a Lane departure warning system Amber Control button on the control panel yes Emergency braking system Amber Control button on the control panel yes Icing warning Red Automatic n/a Park lamp indicator warning Green Headlamp switch n/a Exhaust Filter Cleaning Green Automatic n/a High Exhaust Temperature Amber Automatic n/a ESP OFF Amber Control button on the control panel n/a - 20 - CONTROLS AND INDICATORS Instrument Panel Screen warning and error warnings... SYMBOL WARNING WARNING DESCIRPTION Drive at constant speed for DPF regeneration. Exhaust smut filter saturation is above the expected level. This might be caused by the style of driving or the driving time. For the vehicle to be able to conduct automatic filter cleaning, it is advised that you drive the vehicle with a fixed speed above 30kph when you see the green exhaust filter cleaning symbol. If the road conditions are not suitable, it is recommended to perform manual exhaust filter cleaning. Perform exhaust cleaning when parked for exhaust system efficiency (with the button). Exhaust smut fi lter is fi lled to the extent that the vehicle cannot perform automatic cleaning. In this case; park the vehicle to a safe location and make sure that the vehicle is not in contact with any fl ammable material, and then perform manual cleaning using the manual cleaning button. You can fi nd manual cleaning conditions in the manual exhaust fi lter cleaning section. Exhaust filter is too full. Exhaust filter is too full. Press the button for exhaust cleaning when parked. Reset manual inhibition when possible. Exhaust fi lter started to fi ll up excessively while the manual exhaust fi lter cleaning prevention is active. It is recommended that you lift the exhaust fi lter cleaning prevention before the fi lter is overloaded or allow manual fi lter cleaning. You can remove the fi lter cleaning prevention by keeping the fi lter cleaning prevention button for 3 seconds or by restarting the engine aft er turning off the ignition. DPF regeneration is active. Remaining: X min. Manual exhaust fi lter cleaning is active During exhaust fi lter cleaning, the exhaust gas temperature is increased to burn the soot inside the exhaust fi lter. Time remaining to the end of operation is shown in minutes. Regeneration can not be activated. Conditions are not met. Conditions are not suitable for manual exhaust fi lter cleaning. In this case, you have to ensure that the conditions written in the manual exhaust fi lter cleaning section are met The exhaust filter could not be cleaned while driving. The exhaust filter could not be cleaned while driving. Clean the exhaust when parked. DPF regeneration inhibition is set by driver. Exhaust fi lter cleaning prevention is activated by the driver. You can activate the exhaust fi lter cleaning prevention while loading hazardous materials or while driving the vehicle in an environment with fl ammable materials like grass, hay, petroleum products etc. Please keep in mind that the exhaust fi lter will be damaged in long blocking durations. The exhaust is cleaned with high temperature gas. Pay attention to the vehicle environment. This warning is for the purpose of informing the driver. Exhaust gas temperature is high due to driving under heavy load or exhaust fi lter cleaning. This warning is activated when the exhaust gas temperature is high and the vehicle speed is low. It is normal to see this warning during exhaust fi lter cleaning. When the warning is active, please ensure that the vehicle and exhaust fumes are not in the same environment as fl ammable materials like grass, hay, petroleum products etc. and that the vehicle is not in an enclosed area. Otherwise, fi re risk may occur! Poor Urea Quality. Use high quality urea for exhaust system efficiency. Material not conforming to ISO22241-1 standards detected in urea tank. Please discharge the urea tank and add urea conforming to standards. Please remove the error to prevent power cut off . - 21 - 3 CONTROLS AND INDICATORS Instrument Panel 3 SYMBOL SYMBOL WARNING WARNING DESCIRPTION Press clutch pedal select neutral gear to crank Change the gear lever to neutraland depress the clutch pedal to start the engine. N/A AEBS malfunction Service Required AEBS failure, Service Required N/A Front radar sensor blocked See Manual Front radar sensor is obstructed. N/A Front camera malfunction Service Required Front camera failure,Service Required N/A Front cameralow visibility low camera resolution.Clean See Manual the screen. WARNING WARNING DESCIRPTION Lift other axle first Rear axle did not raise. First raise the front axle. Autodrop vehicle Rear axle did not lower. Vehicle speed is speed limit high Autodrop vehicle overload Front axle did not raise. Vehicle loaded. Autodrop vehicle Front axle did not raise. Vehicle speed is speed limit high Autodrop vehicle unladen Front axle did not lower.Vehicle unloaded Autodrop vehicle overload Rear axle did not raise. Vehicle loaded. Autodrop vehicle speed limit Front axle did not lower. Vehicle speed is high Autodrop vehicle speed limit Rear axle did not raise. Vehicle speed is high Drop other axle first Front axle did not lower, fi rst lower the rear axle. Autodrop parking brake engaged Rear axle did not raise. Handbrake applied. Autodrop vehicle overload Rear axle lower. Vehicle loaded. Trailer brake system problem AEBS do not support trailer brake system LIM 30 km/h Speed Limit Speed limiter will be active after 60s Tachograph Break Time 4.5 hours driving time is over Give a break >40 km/h Overspeed Warning 40 km/h speed exceeded Slow down Dump lifting active Lifting Damper Active Battery Service Required Battery failure, drive to service. - 22 - CONTROLS AND INDICATORS Instrument Panel SYMBOL WARNING WARNING DESCIRPTION Autodrop parking brake engaged SYMBOL WARNING WARNING DESCIRPTION Rear axle lower. Handbrake applied. Check engine oil level Add oil to engine Autodrop vehicle overload Front axle lowered. Vehicle loaded. ECAS warning active Air suspension warning active Engine shutdown soon press any pedal to cancel Soon press any pedal to cancel (only manuel transmission vehicles) Engine oil change due Engine oil renewing time Air filter intake restriction Air cleaner must be changed as soon as possible. Service Required VGS active VGS active Steering low oil pressure WARNING Clutch over heated Warning, clutch overheated Oil level must be controlled when lit. If there is a leakage, request road assistance. If there is no leakage, drive to nearest workshop without exceeding 50 km/h speed. Fuel filter blocked Service Required WARNING Clutch protected Warning, clutch protection active Low engine coolant level Add engine cooling water, if warning light does not go out, drive to workshop as soon as possible. Lowliner active Cab raising active Discharge the water in the prefilter water tank Discharge the water in pre fuel filter drain, if warning light is still active, drive to workshop as soon as possible. Door ajar warning One of the doors is open autodrop failure.. see manuel Autodrop failure..see manuel Hill holder active Hill holder active Critical emissions failure Critical emission error. Perform Exhaust Filter Cleaning. Apply brake pedal test Brake pedal test shall be performed Fill Up urea There is not enough level of urea in the urea tank. Please add urea that conforms to the standards in order to prevent power cut off. Urea dosing malfunction Error detected in urea dosing system. Please drive to service to prevent power cut off. Urea level low Urea level low in urea tank. Please add urea that conforms to the standards in order to prevent power cut off. - 23 - 3 CONTROLS AND INDICATORS Instrument Panel 3 SYMBOL WARNING WARNING DESCIRPTION Clutch overheated under heavy strain. SYMBOL WARNING NAME WARNING DESCIRPTION Under heavy pressure, the clutch has overheated. Mechanical Maintenance Warning The time for mechanical maintenance is approaching Clutch wear is detected. Clutch wear detected, Service required Mechanical Maintenance Warning It's time for mechanical maintenance. Service Required Transmission Temperature The transmission temperature is too high. Transmission self check is active Transmission automatic control is active. Gas Pedal Release the accelerator pedal. Transmission Air Pressure Transmission air pressure is too low. Streerable tag axle The steerable additional axle was centered Streerable tag axle Steerable additional axle centering was cancelled Streerable tag axle Error code for steerable additional axle: please read the message - 24 - CONTROLS AND INDICATORS Instrument Panel Odometer Indicates the road speed (kilometer/hour). Tachometer 9 Lt vehicles Indicates the engine rpm. Operate your vehicle so that the indicator dial remains in the green zone as much as possible. Drive your vehicle considering the engine speed. Keeping engine speed in the green zone provides economy. Avoid excessive speeds in the red danger zone. Otherwise, your engine may get damaged. Ensure that the speed does not increase up to red danger zone, especially while driving down the hill. Green zone: economy zone Blue zone: zone where engine brake is activated Red zone: Danger zone Buzzer sounds when you exceed the maximum allowed engine speed. Lower the engine speed when you hear that warning. Engine brake is shut down over of 2400 rpm. 12.7Lt vehicles - 25 - 3 CONTROLS AND INDICATORS Instrument Panel 3 Engine coolant temperature gauge Indicates engine coolant temperature. If the dial of the indicator is in the red area, the engine may overheat. Fuel gauge Red warning light is illuminated on the indicator, and the buzzer sounds at 110 °C on vehicles with regulated air compressor. Red warning light is illuminated on the indicator, and the buzzer sounds at 104 °C on vehicles with non-regulated air compressor. Torque reduction values : 110 °C in vehicles with adjustable air compressor, 104 °C vehicles without adjustable air compressor. Perform the following when the red warning lamp is illuminated: • Stop the vehicle and operate the engine inidle. • Apply park brake, check for water leaks • under the vehicle (do not get under the vehicle.) check from the side.) • Open the hood and check for the water level in the engine auxiliary water tank. If the water temperature does not drop, stop the engine and tilt the cab. Inspect whether the engine belt is broke. • Check for water leaks in the thermostat area on the front of the engine. • Ask the support of a Ford Trucks authorized dealership, if required. - 26 - Indicates the fuel level in the tank. 0: empty 1⁄2: half full 1: full Amber warning lamp indicates low fuel level in the tank. Refill fuel immediately. System will take air if the fuel is lowered. Icing Warning Icing warning lamp will light up if outside temperature is between 0 and 4 degrees. If the outside temperature is below 0 degrees, icing warning lamp will blink with short intervals. CONTROLS AND INDICATORS Trip Computer Air pressure indicator There are 2 independent air system circuits that supply for the front and rear brake systems. You can read the pressures of these systems from a single air pressure indicator. Indicator shows the pressure value of the line with low pressure automatically. Indicator shows the pressure value of the line with low pressure automatically. If the indicator 1 indicates the circuit air pressure, light is illuminated. If the indicator pressure, 2 indicates the circuit air light is illuminated. Air pressure indicator always shows the air pressure of the circuit with the lowest air pressure. Press the button on the indicator if you would like to view the air pressure of the other circuit. Indicator will display the pressure of the circuit with the lowest air pressure automatically after a specified time. Normal operating pressure of the system is 10.5 bars. If any warning is displayed on the screen, the key on the instrument shall lose the function for tank selection as it will be used for conforming these warnings. If you would like to view the 2nd tank, you can do this by moving to another page from the information page. Air pressure audible warning If the air pressure goes below 6.5 bars, low pressure audible warning will be activated. Buzzer is turned off when system pressure reaches the normal operating pressure at both pressure circuits. Do not drive your vehicle before the audible warning is deactivated! If you hear the audible warning while driving stop your vehicle immediately. Block the wheels. Place road safety signs and call a Ford Trucks authorized dealer. - 27 - Oil pressure indicator Indicates engine oil pressure in "bars". Oil pressure varies depending on the oil temperature and engine speed. Operating pressure: 3 bar @ 90 °C, 2500rpm Idle pressure: 1.5 bars @ 90 °C, 550rpm The warning lamp will be illuminated when the oil pressure is low. Perform the following when the red warning lamp is illuminated: • Park the vehicle in a secure place, stop the engine. Contact a Ford Trucks authorized dealership. 3 CONTROLS AND INDICATORS Trip Computer 3 SYMBOL Information Battery Service Required DESCRIPTION Prove out Summary - 28 - It is recommended to you to drive to an authorized workshop in this case. CONTROLS AND INDICATORS Trip Computer 3 SYMBOL Trip Computer 2 DESCRIPTION 1-Average speed 2-Distance that may be covered with the remaining fuel Trip Computer 1 1-Mileage 2-Engine operating hours - 29 - Engine Work Hour Engine total operating hours CONTROLS AND INDICATORS Trip Computer 3 SYMBOL DESCRIPTION Consumption Oil Level Functions 1/2 1-Instantaneous fuel consumption 2-Average fuel consumption. Oil level Functions - 30 - CONTROLS AND INDICATORS Trip Computer 3 SYMBOL Oil Life Language English The remaining brake pad KM for each wheel is shown. DESCRIPTION Oil status indicator : Data is collected for calculation. --- : It may be one of the following reasons. a. Different wear between right and left linings b. Lining sensor error c. General Error d. Remaining lining life is below 6% e. Fitting lining worn below %35 - 31 - Language Selection CONTROLS AND INDICATORS Trip Computer 3 SYMBOL Battery Info DESCRIPTION Battery status Exhaust Info Exhaust info screen - 32 - Axle Load Axle load CONTROLS AND INDICATORS Trip Computer 3 SYMBOL Time zone setting DESCRIPTION Time zone setting streerable tag axle - 33 - CONTROLS AND INDICATORS Control Buttons 3 Trip computer shows information and warnings. Trip computer may be changed by pressing the menu button on the right multi-functional lever. WARNING You may reset trip computer information, which are allowed to be reset, by pressing the button on the lower right of the instrument panel. Note: The screen display for the information that will be reset shall be selected via the menu button on the right multi-function arm. As changing trip computer display settings while driving may adversely affect the driving attention, it may cause serious risk of accident. Settings shall always be performed while the vehicle is parked. - 34 - CONTROLS AND INDICATORS Control Buttons 3 - 35 - CONTROLS AND INDICATORS Control Buttons 3 DESCRIPTON FIGURE 1 A/C ON/OFF 14 CREEP MODE SWITCH 2 RECIRCULATION 15 REAR AXLE LIFTING 15 FRONT SUSPENSION CONTROL BUTTON 15 TAG AXLE LIFTING II SWITCH 16 DIFFERENTIAL LOCK 17 FRONT AXLE LIFTING 17 INTERMEDIATE SHAFT LOCKING 17 FRONT SUSPENSION LIFTING 17 TRACTION HELP SWITCH 18 REAR STEERABLE AXLE LIFTING SWITCH 18 TRAILER AXLE LIFTING 19 EMERGENCY BRAKING SYSTEM 20 LANE DEPARTURE WARNING SYSTEM 21 WARNING SWITCH HAZARD FLASHER 22 ELECTRICAL CIRCUIT BREAKER (OPT) 23 HANDBRAKE FIGURE SYMBOL 3 MIRROR HEATING 4 WINDSHIELD HEATER 5 ASR CANCEL/ ASR ACTIVE 5 ASR CANCEL/ ASR ACTIVE 6 SEMI-TRAILER BRAKE 7 AUTOMATIC HYBRID BRAKE 8 HILL LAUNCH ASSIST 9 DIESEL PARTICULATE CLEANING ACTIVE 9 DOME LAMPS (OPT) 10 DIESEL PARTICULATE CLEANING DEACTIVED 11 ROOF ON/OFF 12 13 POWER ROCKING OFF-ROAD ROCKING ECOROLL SWITCH AUTOMATIC TRANSMISSION MODE SELECTION SYMBOL Some features may not be available depending on the vehicle version. - 36 - GLASS SECTION DESCRIPTON FIGURE SYMBOL DESCRIPTON 1 INTERIOR LIGHTING 2 TIPPER LIFTHING 3 SIREN BUTTON (OPT) CONTROLS AND INDICATORS Multi-functional Handles Multi-functional handle (left) It is placed on the left side of the steering. Switch positions are as follows. 1. Horn 2. Right Direction Indicator 3. Left Direction Indicator 4. Windshield Water Spray 5. Wipers 5a. Wipers off 5b. Low speed wiping (long interval) ! (This position activates the automatic wiper function on vehicles with a rain sensor.) 5c. Normal speed wiping 5d. High speed wiping - 37 - 6a- High Beam (Flasher) Flasher is operated by pulling the handle brie y and releasing it. 6b- High Beam (Continuous) High beam is operated continuously when the handle is released after being pulled at full stroke. 3 CONTROLS AND INDICATORS Multi-functional Handles 3 Multi-functional handle (right) It has 5 steps in vehicles with Intarder. It has 2 steps in vehicles without Intarder. On vehicles without Intarder 2 step engine brake Engine Brake 1. Range Low Brake Power 2. Range High Brake Power This handle has the following functions: • Cruise control, increasing the speed, and decreasing the speed • Engine brake and Intarder 1- Activation of the cruise control and increasing the speed 2- Decreasing the speed 3- Deactivation of the cruise control 4- Activation of the engine brake 5- Resuming cruise control - 38 - 1 step engine brake 1st stage 100% engine brake while it is in "0" position, blending function is used in the vehicles with ebs. CONTROLS AND INDICATORS Multi-functional Handles Vehicles with Intarder: Engine Brake Bremsomat Reduced Brake Power Intarder Bremsomat (0%-100%) Intarder 1 Reduced Brake Power 25% Max. Brake Power Intarder 2 Reduced Brake Power 50% Max. Brake Power Intarder 3 High Brake Power 75% Max. Brake Power Intarder 4 High Brake Power 100% Max. Brake Power Activation of the gradual continuous braking operations Deactivation of the gradual continuous braking operations Bring the gradual braking lever from 1 to max. position. The vehicle is continually decelerated according to the selected position. Position 1 = low deceleration Max. position = more deceleration. • Gradual brake lever: • OFF position or position 1 = BREMSOMAT function. - 39 - 3 CONTROLS AND INDICATORS Tachograph 3 Operational elements Standard display(s) during trip ► Press any menu key, change to the desired display. (1) Time (with i= set local time) (2) "Operational mode" (3) Speed (4) Activity, driver 1 (5) Card symbol, driver 1 (6) Toplam kilometre (7) Card symbol, driver 2 (8) Activity, driver 2 (1) Display (2)Menu buttons / Select function / selection Confirm function / selection Exit, abort menu (3) Card slot 1 (4) Combination key Driver 1 Setting of activities and ejection of the driver card (1) Driving time Driver 1 since a valid break time. (2) Valid break time , in accordance with regulation (EU) no. 561/2006. (3)Time of driver 2; availability time . (5) Combination key Driver 2 Setting of activities and ejection of the driver card (6) Card slot 2 (7) Cutting edge (8) Printer drawer The option "VDO Counter" allows another standard display; for (9) Download interface details refer to the operating instructions. (a) Symbol for ADR variant - 40 - CONTROLS AND INDICATORS Tachograph Calling up menu functions Possible only when the vehicle is stationary! ► Use the buttons / to select the desired display. ► Use button to call up the main menu. ► Use / to select the listed / functions step by step. Print daily value: ► Enter "Out of scope" beginning / end: ► Enter Beginning of ferry / train: ► ► Set the current activity. Set Local time: ► Set Local time in steps of ± 30minutes. - 41 - 3 CONTROLS AND INDICATORS Tachograph 3 Insert paper roll Messages Times of the driver card(s) ► Presstheunlockingsurfaceontheprinterp anel,theprinterdrawer opens. ► Pull the printer drawer out of the DTCO. N O ► Insert new paper roll according to the illustration and guide it via the pulley (1). Make sure that the paper roll does not become jammed in the printer drawer and the start of the paper (1) extends beyond the edge of the printer drawer! (1) Pictogram and plain text of the message ! = Event, example [ driving without card] x = Fault, example [ x sensor fault] = Driving time warning break! Operational note, example (2) Error code For further messages and measures refer to the operating instructions. Acknowledge message: ► Presskey 2 times, the message disappears. ► Push printer drawer into the printer compartment until it engages. ► The printer is ready for operation. ► You can start a printout. - 42 - (1) Driving time since a valid break time. (2) Valid break time in accordance with regulation (EU) no. 561/2006. (3) Driving time over two weeks . (4) Duration of the set activity. CONTROLS AND INDICATORS Tachograph Insert driver card / Manual entries The set local time and the UTC time "05:35UTC" appear (time offset = 2 hours). The date and time of the most recent card withdrawal will be displayed in local time (symbol ). Driver 1 who will drive the vehicle inserts his driver card into slot 1. ► If necessary, switch on the ignition in case of the ADR variants. ► KeepthecombinationkeyDriver1formorethan2seconds. ► Set, acknowledge day, hours, minutes. Set, acknowledge the next activity. The card slot is opened. ► Open the card slot cover. ► Insert driver card into the card slot. ► Close card slot and push it in. ► Follow the menu guidance. Always keep the card shafts closed – except for the insertion or removal of your driver card! Please ensure the continuous recording of the activities on your driver card! Make manual entries with "Yes". If you do not want to add any activities/rest continue with example: periods, select "No". A/B/C Example A: Withdrawal (15.04.2017) Insertion (18.04.2017) 07:35 Local time 16:31 Local time ► Press and hold key . ► Automatic jump to the last entry field. ► Release button and press it again. Appears when "End country" was entered ► Acknowledge entry. = Trip can be started. - 43 - 3 CONTROLS AND INDICATORS Tachograph 3 Example B: Example C: Withdrawal (24.02.2017) Insertion (25.02.2017) 02:30 Local time 23:32 Local time Withdrawal (05.11.2017) 17:50 Local time Insertion (14.11.2017) 14:00 Local time 00:20 Local time ► Set, acknowledge activity . ► Set, acknowledge day, hours, minutes. ► Set, acknowledge the next activity . ► Press and hold the minutes blink). ► Release button and press it again. ► Acknowledge entry. - 44 - Use key n order to ... - abort the entry of a country, - select the possible variables (backspace) directly in the entry block. CONTROLS AND INDICATORS Tachograph Withdrawing driver card Setting activities = Driving time (automatic when driving) ► If necessary, switch on the ignition in case of the ADR variants. ► Press the corresponding combination button for more than 2 seconds. Follow the menu guidance. ► Select, acknowledge the country. ► If present, select region, acknowledge. ► With button you can abort the entry of a country if you, for example, want to continue your work shift. ► The card shaft is opened to withdraw the driver card. ► Withdraw driver card. ► Close card slot and push it in. = All other working times (Automatically when the vehicle is stopped, for driver 1) = Availability: Waiting times, co-driver time, sleeper-cab time during the trip (Automatically when driving or when the vehicle is stopped, for driver 2) = Break times and rest periods ► Driver1: Press the combination key Driver1 repeat edly for ashort time until the desired activity ( ) is shown in the display. ► Driver 2: Press the combination key Driver 2 repeatedly for a short time until the desired activity ( ) is shown in the display. At the end of a shift or during a break, always set activity " "! Automatic setting after ignition on/off (option): Signalled by flashing of the activity or activities for approx. 5 seconds in the standard display (a). Then, the previous display will appear again. ► Asrequired,change the activity accordingly! Symbol after ignition off means: IMS function (Independent Motion Signal) available. Symbol after ignition off means: The recording of position and vehicle data is switched on. - 45 - 3 CONTROLS AND INDICATORS Tachograph Simulator Unit 3 - 46 - OPERATION OPERATION 4 - 47 - OPERATION Opening and closing of the vehicle Keys Door Control: 2 keys are supplied with the vehicle, one for your use, and one as a spare. 4 • Door locks • Ignition • Front Hood • Fuel tank • Urea tank (only on Euro 5 and Euro 6 vehicles) WARNING Ignition key has an immobilizer feature against vehicle theft. New keys shall be programmed by Ford Otosan authorized dealerships. - 48 - You can lock and unlock doors with the remote control. 1- Locking button 2- Unlocking button Central locks are opened when the open button of the control is pressed. They are closed when the close button is pressed. If the direction indicators are illuminated for 2 seconds: Doors are locked. When any of the doors are not closed for any reason (mechanical or electrical), error is detected and both doors are brought to open position. However, central locking function on manual opening and closing is temporarily disabled until central locks are brought to the same position. Error is removed when doors are completely closed. OPERATION Opening and closing of the vehicle WARNING Doors are locked automatically when the speed of your vehicle exceeds 10 km/h. You may deactivate this feature if required. To do this, reading lamp button shall turned on and off 8 times within 10 seconds when the door is open and ignition is at position 2. Reading lamps shall flash 4 times if the operation is successful. Automatic locking feature when the vehicle speed exceeds 10 km/h is deactivated after this procedure. Perform the same procedure while doors are closed to reactivate the automatic locking feature. New remote controls shall be introduced to the vehicle when a new control is purchased. Please visit a Ford authorized dealer for the introduction of the controls. Doors are locked again if the central lock is opened with remote control and doors are not opened physically. Doors are locked automatically when vehicle speed exceeds 10 km/h. WARNING Module switches to protection mode if opening and closing operation is performed successively for 8 times in central locks both manually and via the remote control. System stops manual operation and operations by the control for 7 seconds. It performs the operations received after those 7 seconds later. This condition ends if you wait for 1 minute without any intervention. Note: Wait for 10 seconds if the procedure fails and then try the procedure chain. - 49 - Opening the Window with Remote Control Doors are unlocked and windows are lowered to the minimum level when opening button on the remote control is pressed for more than 3 seconds. This feature also includes the opening of sunroof with the windows on vehicles with power roof. Closing the Window with Remote Control Doors are locked and windows are closed automatically when closing button on the remote control is pressed for more than 3 seconds. This feature also includes the closing of sunroof after the doors on vehicles with power roof. Window closing operation is not performed if the “Quick Window Closing” feature is not set on the windows. 4 OPERATION Opening and closing of the vehicle Outer Handle Door Inner Latch Getting In and Out Of the Vehicle Use the 3 points principle while getting in and out of the vehicle. Do not hold the steering wheel while getting in the vehicle. 4 Don’t: Do not try to get in the vehicle by holding the steering wheel instead of the handle. Do not get off the vehicle facing outwards. Pull the latch towards you to open the door. Door is locked when key is turned clockwise, and unlocked when it is turned counter- clockwise. Pull the latch towards you to open the door from the inside. (1) Push the latch outwards of the vehicle to lock from inside (2) - 50 - Do not get off the vehicle by jumping from the steps. OPERATION Opening and closing of the vehicle Windows 1- Driver side window regulator button 2- Passenger side window regulator button Window moves to opening or closing direction while the opening/closing butons are pressed. Operation is stopped automatically when the window reaches uppermost or lowermost position. Buttons are active while the ignition is on and for an additional 30 seconds after the ignition is turned off. Quick Window Raising Window is closed automatically when the window closing button is pressed once for a short time. If jamming is detected while raising the windows, power windows are opened again to a specified level. CAUTION If the window is jammed thrice in a row while quick closing, window quick raising feature is deactivated. Window learning procedure shall be started when the doors are closed and lock is open. First, bring the window half way or at least one quarter closed position. Then lower the window to the bottom level and press the button until asher signal is received. - 51 - When the asher signal is received, bring the window to the top level with a single press and hold the button until off/on feedback is received from the locks. Window learning operation shall be performed separately for driver window and passenger window. These operations shall not be performed together. Quick Window Lowering When the on/off switch is pressed down for a short time and released, quick lowering feature is activated, and windows are lowered completely automatically. CAUTION System switches to self protection mode automatically when the window operating switch is pressed frequently. 4 OPERATION Opening and closing of the vehicle Opening/closing the front hood WARNING Hold and press the middle of the hood while opening and closing the hood. Do not press on one side of the hood. 4 To open: It can be opened by the ignition key. Turn the key anticlockwise. Raise the hood slightly, pistons shall open the cover. To close: Push to the cover to its original position and press on the locking areas. - 52 - OPERATION Cab Ventilation Manual Roof Flap Switching on: Push the cover up by tightly holding the front and rear rods. Opening the cover from rear or front is applied in two different steps. Open front side or rear side or both sides until required level is reached to obtain the required ventilation. Power Roof Flap Power roof moves to opening or closing direction while the opening/closing buttons are pressed. Operation is stopped automatically when the power roof reaches uppermost or lowermost position. Buttons are active while the ignition is on. Power roof is closed automatically when the control switch is pressed once for a short period while it is open. Power roof is opened automatically when the control switch is pressed once for a short period while it is closed. Power roof is controlled by a control switch located in the centre console. Air vent with diaphragms To close: Pull the cover down by holding the rod tightly. Your cab has a ventilation feature by the vent with 2 diaphragms on the back of the lower bed. - 53 - 4 OPERATION Seats and Beds Seats 4 - 54 - 1 Height adjustment 2 Shock absorber adjustment 3 Fast lowering 4 Horizontal yield 5 Fore and aft adjustment 6 Resting position 7 Seat inclination adjustment 8 Seat depth adjustment 9 Armrest 10 Armrest inclination adjustment 11 Heater 12 Backrest adjustment 13 Lumbar support OPERATION Seats and Beds Fast lowering Height adjustment Shock absorber adjustment 4 Seat may be lowered to the lowest position by pressing the button and securing it (before getting off the vehicle). Seat shall be lifted to the drive position when the button is pressed and released (after getting on the vehicle). Height adjustment is applied in 8 steps. By pulling or pressing the height adjustment latch, the seat height is changed one step up or down. When the seat height is changed up or down, lever is released before each step. - 55 - The absorbing harshness of the seat may be adjusted without any steps between soft and hard using the harshness adjustment button. 1: Soft absorbing 2: Middle absorbing 3: Hard absorbing OPERATION Seats and Beds Horizontal yield Fore and aft adjustment Seat inclination adjustment Operating the horizontal yield may be helpful in some operating conditions. Then, the impacts on the movement direction of the vehicle may be absorbed better. 0: Horizontal yield OFF 1: Horizontal yield ON Fore and aft adjustment is performed by moving the seat forward or backward while pulling the lock lever. Seat shall be locked with an audible click when the lever is released. Seat may be moved completely forward or backward. Pull the button on the left upwards to adjust the seat inclination. Seat may be adjusted to the desired position by applying your weight forward or backward at the same time. 4 Do not perform the fore and aft adjustment when the seat is lowered. Seat shall always be lifted for the fore and aft adjustment. - 56 - CAUTION Risk of accident! Do not operate the lock lever while driving. OPERATION Seats and Beds Seat depth adjustment Armrests Armrest inclination adjustment The inclination of armrests on the fore-aft direction can be changed by rotating the button. The front end of the moves upward when you rotate the button outwards (+ direction), and downwards when you rotate the button inwards (- direction). Pull the button on the right upwards to adjust the seat depth. Desired position may be achieved buy pushing the seat surface forward or backward at the same time. Armrests can be raised when required. - 57 - 4 OPERATION Seats and Beds Heater Backrest adjustment Electrical heaters on the backrest and seat cushion are operated in two steps by pressing the seat heater switch. To unlock the backrest, pull the lock lever upwards. Do not press on the backrest while opening the lock. 4 You can adjust the backrest by applying or releasing your weight simultaneously. Release the lever to lock again. Backrest shall be secured so that it cannot be moved to another position when it is locked. - 58 - OPERATION Seats and Beds Lumbar support Dirt may hinder the operation of the driver seat. Keep your seat clean to prevent this! Trims are not required to be removed from the seat frame for maintenance. CAUTION There is a risk of injury if the backrest bounces forward! Press the backrest by your hand if the backrest adjustment mechanism is operated while cleaning the backrest trim. Front arch adjustment of the backrest can be customized to the driver by using the front and rear switches (1 and 2). Air chambers are filled when the “+” end of this switch is pressed, and discharged when the “-” end of the switch is pressed. If the back cushion is not in ated when the “+” of the switch is pressed, this means that the front arch adjustment of the back cushion side supports is complete; release the switch. - 59 - WARNING Discharge the air by pressing the rapid lowering button when you are getting off the vehicle. This would increase the service life of the seat mechanism. CAUTION If the seat is used without air charge, this would damage the internal mechanism of the seat and render the seat out of warranty cover. 4 OPERATION Seats and Beds 4 fore and aft adjustment lumbar support armrest (left and right inclination adjustment backrest inclination adjustment seat depth adjustment seat heating fast lowering shock absorber adjustment seat inclination adjustment - 60 - height OPERATION Seats and Beds DRIVER SEAT PASSENGER SEAT 1- Seat inclination adjustment: Inclination of the seat can be adjusted between 2° and 12°. YES N/A 2- Shock absorber adjustment: Shock absorbers can be set in 4 positions from soft to hard with the adjustment button. Absorbers are adjusted to a softer setting when the button is pulled up and a harder setting when the button is pushed down. YES N/A 3- Height adjustment: You can adjust the height up and down for 100 mm without any step restriction. YES N/A 4- Rapid lowering: Makes getting in and off the vehicle easier. When the driver pulls up the button while he is getting off the vehicle, seat is lowered to the bottom position (by the discharging of air). When the driver gets back in the vehicle, he should push down the button to charge the air bellows of the seat foresetting the seat to the driving position. If the seat is used without air charge, this would damage the internal mechanism of the seat and render the seat out of warranty cover. YES N/A 5- Seat backrest inclination adjustment: Lean on the seat backrest. Pull the lever up, bring the backrest to the desired position and release the lever. YES YES 6- Fore and aft adjustment: It is possible to adjust the seat to fore and positions with steps of 10 mm within a limit of 210 mm. YES YES 7- Seat depth adjustment: 60 mm. Allows the setting of the depth of the seat within 60 mm in 5 stages. YES N/A 8- Seat heating: On/off button can be used to turn on the seat heater. Heater is deactivated after the seat is heated by switching off the button. YES N/A 9- Lumbar support adjustment: It may be set to the desired position without any stages. YES N/A 10- Armrest adjustment: • Armrest can be raised when required. • Armrest height may be set to the desired position without any stages. YES N/A WARNING CAUTION Discharge the air by pressing the rapid lowering button when you are getting off the vehicle. This would increase the service life of the seat mechanism. If the seat is used without air charge, this would damage the internal mechanism of the seat and render the seat out of warranty cover. - 61 - 4 OPERATION Seats and Beds 4 3. While getting off from the vehicle, seat can be taken to the bottom position. All air will be sent out by pushing the latch. Seat will be turn to the previous position by deactiving the latch. It is recommended to use the seat by air during the drive to prevent seat mechanism from damage. 1. Seat back support can be adjusted by front button, seat lumbar support can be adjusted by rear button.Support zones can be inflated by ‘+’ and deflated by ‘-‘ 2. Seat cushion angle can be adjusted by adjustment lever. Pull it to adjust and release. - 62 - 4. Vertical impact absorption can be adjusted in different levels by the shock absorber latch for different road conditions. It is recommended to use the seat shock absorber at hard level on bumpy roads in order to provide control on the vehicle and to use soft level at smooth roads in order to increase comfort. Levels increase from upward to downward (from rearside to frontside). 1- Softer Shock Absorber Level 2- Soft Shock Absorber Level 3- Hard Shock Absorber Level 4- Harder Shock Absorber Level OPERATION Seats and Beds Single Bed Upper bed CAUTION Do not carry load or occupants while the vehicle is moving. There is a risk of injury for both the driver and the passenger as it will be scattered around during braking and manoeuvring. CAUTION Upper bed shall be folded while driving. * Upper bearing is optional for high roof cabs. Upper bed is tied with a belt. * This belt shall be unfastened to open the bed (to bring it to horizontal position). * Raising the bed: Bed is raised to the upper position and tied with a belt. Bed is raised to the upper position and tied with a belt. - 63 - 4 OPERATION In-cab storage compartments Upper Console (Vehicles with high roof) CAUTION Shelves Do not put heavy items on upper console. Glove box 4 There are covered storage compartments on the right and left side of upper console. Press on both sides of the central button to open these covers. In the rear part of the vehicle, there are 2 shelves and 1 compartment with net both on the right and left. Total weight of the material placed on each shelf shall not exceed 2 kg. It is placed on the right side of the center console, in front of the passenger seat. Pull the latch towards you to open it. - 64 - OPERATION In-cab storage compartments Centre console Ashtray Cigar lighter 4 The multifunctional center console placed between the driver's seat and the passenger seat includes and storage compartments for maps, glasses, plastic bottles and other material. Ashtray is placed on the center of the console. Removable ashtray mechanism provides ease of use in the desired position for the driver. Hold the heated cigar lighter only from its handle. Only use the lighter when the traffic allows you to; otherwise it may distract you and cause an accident. CAUTION 24V lighter/power outlet shall be used for operation of the devices other than the lighter. - 65 - OPERATION In-cab storage compartments CAUTION 12 V outlet 24 V outlet 12 V outlet may provide power for devices up to 100W. Power required for devices may be taken from 24V outlet. Do not touch the cigar lighter end when it is hot. 4 CAUTION Do not hold the cigar lighter element pressed in after it is released. - 66 - OPERATION Steering CAUTION A minimum of 7 bar air pressure is required to adjust the steering mechanism. If the vehicle air pressure is low, operate the vehicle to ll up to the air tubes. You can adjust the steering angle and height in the most comfortable position for you while driving. 1. Turn the knob on the steering column anticlockwise. Thus, power assist to the system shall be activated and setting shall be allowed. 2. Adjust the steering to a proper position by moving it back and forth. 3. Rotate the knob clockwise without changing the position of the steering. - 67 - 4 OPERATION Mirrors Mirrors 4 There are 4 different types of mirrors on your vehicle: 1- Reversing mirror 2- Wide angle mirror 3- Kerb mirror 4- Front view mirror WARNING Adjust the rear view mirror (no. 1) by the rotating knob on the driver's door armrest. Bring the knob to position for the adjustment of the driver’s side mirror. Adjust the mirror by moving the knob forward and backward and left and right, then bring the knob to position. For setting the passenger side mirror: Bring the knob to position. Adjust the mirror by moving the knob forward and backward and left and right. Bring the knob to position. Check the settings before operating your vehicle. - 68 - OPERATION Mirrors Mirror Heater Mirrors 1 and 2 have heaters. Use the heater for ease of view on winter days. To activate the heater: Press “mirror heater’’ switch on the control panel while the ignition switch is at position 2. To deactivate the heater: heater shall be deactivated automatically after 10 minutes. - 69 - 4 OPERATION Lighting Headlamp Switch Headlamp levelling adjustment WARNING Headlamp levelling shall be adjusted before getting on the road to prevent dazzling the eyes of the drivers of the vehicles in the upcoming traf c in different road conditions. 4 CAUTION Headlamp switch is placed on the console to the left of the steering. – Headlamps off – Park lamps and indicator illumination – Park lamps, indicator lamps and low beam head lamps Low beam bulbs – Automatic – increasing the interior lighting brightness – decreasing the interior lighting brightness CAUTION Operating park lamps for a long time while the ignition off causes the battery to discharge. Press the knob in the middle for headlamp levelling adjustment. Knob shall come out as shown in the gure. When you rotate the knob to the left (counter-clockwise) headlamp level shall be lowered, and when you rotate the knob to the right (clockwise) headlamp level shall be raised. Press the button on the headlamp switch to make it come out. Rotate the button to set it to the required headlamp levelling adjustment. Press the button on the headlamp switch to bring it to the closed position. Headlamp levelling shall be performed as per the load of the vehicle. - 70 - The current capacity of the switch may only cover for the available system. Any additions may cause faults on the switch. If an additional illumination system is installed, additional lamps shall have wiring with relay control. Switch shall only control the relay. Audible warning signal is heard when the door is opened when the ignition is off and headlamps are on. OPERATION Lighting Autolamps (If Equipped) WARNING The autolamps switch position may not activate the headlamps in all low visibility conditions, such as daytime fog. Always ensure that your headlamps are switched to auto or on, as appropriate, during all low visibility conditions. Failure to do so may result in a collision Note: When the lighting control is in the autolamps position, while passing through viaducts or under bridges, under varying light conditions or during inclement weather conditions headlamps may automatically turn on and off. Direction Indicator Lever 4 Note: It may be necessary to switch your headlamps on manually in severe weather conditions. Note: It may be necessary to switch your headlamps on manually while entering some tunnels. Note: If you have autolamps on, you can only switch the front fog lamps on once autolamps has switched the headlamps on. When the lighting control is in the autolamps position, the headlamps automatically turn on in low light situations. - 71 - It is placed on the left side of the steering. Switch positions are as follows. – Right Direction Indicator – Left Direction Indicator – High Beam (Flasher) Flasher is operated by pulling the handle brie y and releasing it. – High Beam (Continuous) High beam is operated continuously when the handle is released after being pulled at full stroke. If the direction indicator lever is moved halfway to the and positions, direction indicators are illuminated for 6 seconds and then automatically turned off. This would increase attention on the road, especially when you are changing lanes. OPERATION Lighting Front fog lamp Rear fog lamp Front fog lamp is placed on the headlamp control panel. Turn this switch on to obtain better visibility and be visible to the incoming traf c in foggy conditions and where the visibility is low. Front fog lamp icon is displayed on the indicator when the switch is pressed. Rear fog lamp is placed on the headlamp control panel. Turn this switch on to obtain better visibility and be visible to the incoming traf c in foggy conditions and where the visibility is low. Rear fog lamps are illuminated when the low and high beam headlamps are activated only. Rear fog lamp icon is displayed on the indicator when the switch is pressed. 4 - 72 - OPERATION Lighting Interior lamp Dome (pilot) Lamps Reading lamp 4 Interior lamp is placed over the windshield on the center area. It is turned on/off by the switch on it. – Position: Continuously lit. – Position: Lamp does not turn on. – Position: Turns on with any door open. It is placed on the passenger side of bed area. There are 2 buttons on it; – Turn on/off the round lamp – Turn on/off the square lamp There are 2 pilot lamps, one on the driver side and the other on the passenger side, in the dome of the vehicle interior. These lamps are illuminated by a switch located in the centre console. - 73 - Button no. on the lower side controls round moveable lamp, and button no. on the upper side controls the square lamp on the left side. OPERATION Lighting High roof vehicles Interior lamp Dome (pilot) Lamps 4 Interior lamp is placed over the windshield on the center area. It is turned on/off by the switch on it. – Position: Continuously lit. – Position: Lamp does not turn on. – Position: Turns on with any door open. There are 2 pilot lamps, one on the driver side and the other on the passenger side, in the dome of the vehicle interior. These lamps are illuminated by a switch located in the centre console. - 74 - OPERATION Window Washing and Heating Systems Water spray Windshield Washer Reservoir Autowıpers (If Equipped) The autowipers feature uses a rain sensor. You will nd it on the lowe center part of the windscreen. The rain sensor monitors the amount of moisture on the windshield and automatically turns on the wipers. It will adjust the wiper speed by the amount of moisture that the sensor detects on the windshield. Press on the upper side of the multifunctional handle towards the steering column to spray wiper liquid to the windshield. Water spray function shall be stopped when you release the lever. Windshield washer reservoir is placed on the front of your vehicle. You may access it by opening the hood. Add water and cleaning agent regularly before you run out of washer liquid. - 75 - Wiper switch “Autowipers” position When you choose the autowipers position on the wiper switch, wipers will make a single wipe to show you that autowipers are activated. Then, wipers will operate automatically depending on the amount moisture detected on the windscreen. 4 OPERATION Window Washing and Heating Systems Note: Once you choose a different speed or park position on the wiper switch, autowipers feature will be deactivated, and wipers will operate according to the selected switch position. 4 Note: Fully defrost the windscreen before switching on the windscreen wipers. Note: Make sure the windscreen wipers are switched off before washing your truck. Note: Wet or winter driving conditions with ice, snow or salty road mist can cause inconsistent and unexpected wiping or smearing. In these conditions, you can do the following to help keep your windshield clear: • Switch to normal or high-speed wipe • Switch the autowipers off. Windshield Heating (Available on vehicles with Cold Climate pack only) Note: Clean the windscreen and wiper blades if they begin to leave streaks or smears. If that does not resolve the issue, install new wiper blades. Note: During driving, if the autowipers operate the wipers slower or faster than you expect, choose most suitable wiper speed manually on the wiper switch. To activate: press the button on the control panel while the engine is on. To deactivate: The resistor will automatically be disabled after 5 minutes. Press the button again to deactivate the heater when it is activated. Note: Keep the outside of the windscreen clean. Sensor performance will be affected if the blackened areas on the lower center part of the windscreen is dirty. The rain sensor is very sensitive and the wipers may operate if dirt, mist or ies hit the windscreen. - 76 - OPERATION Circuit Breakers Use the circuit breakers to disconnect the electrical current in your vehicle. Using the external switch Vehicles without ADR Vehicles with ADR 4 An ADR switch shall be available on vehicles that transport ammable, explosive, combustible material. ADR switch cuts all electricity of the vehicle off. There are 2 ADR switches on your vehicle; one is inside the cab, and one is outside. Both switches have the same function. To cut the circuit off, it is adequate to turn off one. Using the internal switch To cut the circuit off: Raise the safety cover and raise the switch. To re-activate the electricity supply of the vehicle: Put the switch down. Close safety cover. To cut the circuit off Lift the safety cover. Raise the switch. To re-activate the electricity supply of the vehicle: Put the switch down Close safety cover. CAUTION Using this switch frequently may damage electronic devices on the vehicle. When any one of the cab interior and exterior breaker switches is activated, some electrical loads are deactivated within 1 second. After 10 seconds, all electrical connection shall be disconnected. - 77 - OPERATION Circuit Breakers Turn the switch counter-clockwise to cut the circuit off. Turn the switch clockwise to re- activate the electricity supply of the vehicle. 4 CAUTION Use the circuit breaker at least 2 minutes after you have stopped your vehicle. Otherwise, engine electronic control unit (and Denox control unit, if available) may be damaged. CAUTION Disconnect the battery terminals in case of any welding operation on your vehicle. If it is not possible to disconnect terminals, electricity supply shall be cut off with circuit breakers. - 78 - CAUTION Vehicles with ADR carrying fuel oil and dangerous goods shall always be degassed before entering the service. OPERATION A/C and Heater A/C and Heater To operate the A/C of your vehicle, bring the heat control Adjust the blowing direction To cold (blue) position while the engine is on. blows to the windshield. blows from opposite direction. – Blower speed setting – Heat control (hot/cold setting) – Blower direction setting Press the A/C and recirculation buttons on the front panel. You can adjust the fan speed in 3 steps. 0: Off 1: Low speed 2: Middle speed 3: Fast - 79 - blows to the leg level and from opposite direction. blows to the windshield and to the legs. On hot days, we advise you to open the windows for a few minutes to equalize the temperature inside and outside of the vehicle before turning the A/C on and take some cold air inside the vehicle if the vehicle is moving to obtain better ef ciency. 4 OPERATION A/C and Heater 4 NOTE: To get a better performance from your vehicle's A/C, turn it on even in winter for 5 minutes every 15 days. It is not required to set the knob to cold position during this usage. Mist that forms on the windshield in cold weather conditions may be cleaned much more easily if the A/C and hot air is operated for a few minutes. Then turn the A/C off. The gas type and amount of the gas used in A/C is printed on the sticker. (Adding oil to the A/C compressor is not necessary unless all gas drains from the A/C. Your vehicle's A/C will not require maintenance under normal conditions. However, we may advise you to remove and clean the fly screen located in front of the radiator periodically to obtain a better efficiency. And replacing the filter that dries air every 3 or 4 years will increase the performance of A/C. CAUTION Cabin Air Filter Replacement Auxiliary heater Dry Type Heater Cabin air filter catches the particles in the air incoming to the cabin and ensure that the cabin is free of said particles. If the air flow to the cabin is decreased, the filter shall be replaced before the periodic maintenance intervals. Filter shall be replaced rather than having been cleaned Eberspacher airtronic D2 dry type heater is used. This device is placed under the lower bed inside the cab. Control panel is placed on the center console. Auxiliary heater can also be operated when the ignition is off. CAUTION On vehicles with dry type cab heaters, air may enter to the fuel line and prevent system operation when the fuel level in the fuel tank is decreased to a certain level. - 80 - OPERATION A/C and Heater When error codes F01 / F02 / F07 are read on the cab heater digital indicator, fill the fuel level and turn the cab heater switch off and on. Repeat this procedure until the air inside the cab heater fuel system is completely eliminated, and cab heater operates normally. (Do not turn the heater switch off and on before filling the fuel tank) When any error code is repeated less than 3 times, cab heater continues to operate normally. However, when (an) error code(s) are repeated more than 3 times successively, cab heater switches to protection mode and indicates an F12 error. In this case, circuit breaker shall be turned off and on again, and thus cab heater shall be reset after refilling the fuel tank. When the reset procedure is completed, cab heater switch shall be turned off and on. Error F12 may be indicated 1 or 2 times as per the air amount in the cab heater fuel line. In this case, resetting procedure shall be repeated. CAUTION Pump is delicate. High quality diesel fuel shall be used against freezing. Fuel consumption: 0.7 l/h during the initial start-up when the temperature inside the cab is low; and 0.4 l/h for the operating phase. Blowing temperature from the nozzle is 75°C. Thermostat operates between +5°C and -28°C. Do not cover the blower and the intake nozzle inside the cab. This is important as it affects the service life and the speed of the motor. CAUTION In-cab auxiliary heater hot air outlet is behind the driver’s seat. Therefore, dangerous material such as flammable or explosive material shall not be placed between the driver’s seat and bed. - 81 - Wet type heater 4 Eberspacher hydronic M2 is used. Cab is heated by heating the engine coolant with diesel fuel. This unit is placed under the right step on the vehicle. OPERATION A/C and Heater Wet type fuel tank Controls CAUTION The unit intakes fuel supply from the specially designed fuel tank that houses the freezing- proof (Arctic Diesel, kerosene etc...) fuel. Turn off additional heating system(s) when refuelling. 4 CAUTION Heater should not be operated in enclosed areas as it produces exhaust gas. Malfunction This device has hoses on its own for exhaust and combustion air requirements. perates with diesel fuel. There is a separate fuel tank on the vehicle. This unit adjust the cycle automatically and takes fuel from dosage pump with the help of an element sensible to the in-cab temperature. It is controlled by the digital control unit display panel or by the switch on the reading lamp side of the lower bed. If the heater has a fault, check the fuse harness for safety. Contact a dealership if the precautions below do not solve the problem. CAUTION The auxiliary heater digital control programming feauture is deactivated for safety reasons for the vehicles (with ADR) carrying hazardous substances - 82 - OPERATION A/C and Heater Auxiliary Heater (EBERSPÄCHER) Main functions of the buttons With the button, you may operate the heater or confirm the inputs. With the button, you may turn off the heater or stop the functions. With keys , you may select the functions and perform settings. Operating the heater immediately Heating starts immediately if you press the key 2 seconds. All functions are ended if you press the key 2 seconds. CAUTION Ending the heating operation by pressing the button for a long time auxiliary unit function It may be activated by Eberspaecher authorized services. ventilation symbol is displayed only if the operating unit is connected to heaters that support this function (dry type heaters). Press the functions. Heating Starting the heating operation immediately by pressing the button for a long time Press the Press the key for 2 seconds. key for 2 seconds to end all Ending the heating operation by pressing the button for a short time When the heater symbol is selected on the screen; key; heating shall be ended. Ventilation Starting the ventilation With keys, select symbol from Starting the heating operation by pressing the button for a short time the menu and confirm with the set the operating time with Press the key. § Set the desired ambient temperature value (only for dry type heaters) and operating time with keys, and Confirm the settings by pressing the key. confirm by pressing the Press the entered. key. key to confirm the values - 83 - and confirm by pressing the key, keys, key. 4 OPERATION A/C and Heater Ending the ventilation operation by pressing the button for a long time Press the key more than 2 seconds, all functions shall be ended. 4 Ending the ventilation operation by pressing the button for a short time When the ventilation symbol is selected on the screen; Press the shall be ended. key; ventilation Auxiliary unit Starting the heating operation with the auxiliary unit With keys, select symbol from the menu and confirm by pressing the key. With keys, select symbol and confirm by pressing the key. § Set the desired ambient temperature value (only for dry type heaters) and operating time with keys, and confirm by pressing the key. Press the key to confirm the settings. Ending the heating operation with auxiliary unit by pressing the button for a long time Press the key for 2 seconds, all functions shall be ended. Ending the heating operation with auxiliary unit by pressing the button for a short time Select the auxiliary unit symbol on the screen, Ending the ventilation operation with auxiliary unit by pressing the button for a long time Press the key more than 2 seconds, all functions shall be ended. Ending the ventilation operation with auxiliary unit by pressing the button for a short time Select the auxiliary unit symbol on the screen. Press the key, auxiliary unit shall end the ventilation function. Press the key, auxiliary unit shall end the heating operation. Program Programming Starting the ventilation operation with the auxiliary unit With keys, select symbol from the screen and confirm by pressing the With keys, select symbol on the screen and confirm by pressing the key, Select one of P1, P2 or P3 programming memories with the keys and confirm with the key. With keys, select confirm by pressing the Set the operating time with symbol and key. keys, and confirm by pressing the Confirm by pressing the - 84 - key. key. key. OPERATION A/C and Heater Activation of the saved program With keys, bring the program to “ON” and confirm with the key. Cancellation of a selected program With keys, bring the program to “OFF” and confirm with the key. Changing the settings of a selected program With keys, select symbol from the menu bar and confirm with the key. Selecting the weekly program mode or day With the keys, select one of the weekly modes, e.g.Mon - Fri, Sat - Sun, Mon - Sun; or select a day, e.g.Mon, Tue, Wed, Thu, Fri, Sat, Sun and confirm with the key. Setting travel dates or starting time Set the hours with keys and confirm with the key. Set the minutes with confirm with the keys and key. Selecting the operation mode With keys, select the heating symbol or the ventilation symbol and confirm with the key. Setting the cab temperature (only for dry type heaters) Set the desired cab temperature with keys and confirm with the key. Setting the heating level (only for wet type heaters with the automatic operating time function activated) With keys, select one of the ECO (economical) or HIGH (high) heating levels and confirm with the key. - 85 - Setting the operating time Set the operating period with keys and confirm with the key. Settings With keys, select symbol from the menu bar and confirm with the key. Setting the time Select symbol and confirm with the key. Set the hours with confirm with the key. Set the minutes with confirm with the key. keys and keys and 4 OPERATION A/C and Heater Setting the date 4 CAUTION With keys, select symbol and confirm with the key, Set the date with keys and confirm with the key. The auxiliary heater digital control programming feauture is deactivated for safety reasons for the vehicles (with ADR) carrying hazardous substances Setting the time format You may select operating period of your heater as you desire; you do not need to turn on the ignition for unlimited operation. Heater may be operated for the desired period even if the ignition is off. With keys, select symbol and confirm with the key. With keys, select the time format and confirm with the key. - 86 - The main switch button shall not be switched off before the auxiliary heater is halted. If the button is turned off before the heater goes through a certain reoperation period, it may be damaged. OPERATION A/C and Heater In the event of a fault the followıng dısplays are possıble DISPLAY DESCRIPTION REMEDY/CUSTOMER Automatic detection is active. The EasyStart Timer has been disconnected from The power supply and then reconnected. "Wait until the automatic detection has finished, then set the time and weekday. No communication. "Check and if necessary renew the heater fuse. Visit your vehicle workshop. 1st heater fault. Visit your vehicle workshop. 2nd heater fault. Visit your vehicle workshop. Voltage too low. Charge battery, if necessary visit your vehicle workshop. Temperature sensor is defective Visit your vehicle workshop. - 87 - 4 OPERATION A/C and Heater Heater Turns Off By Itself CAUTION 4 If you cannot resolve the fault by yourself, please contact your authorized service. Entering the service menu to learn the error code: With the keys, navigate to symbol on the start screen, and enter the settings menu with the key. Fault Description Remedy Does not ignite during operation Turn the heater off and on once Flame goes off during operation Turn the heater off and on once Heater overheats Check for blockage in the air input and output channels. Then cool down the heater and turn the heater off and on once. Voltage value of the vehicle is inadequate Check the heater. Turn the heater off and on once. Press and hold the key for more than 5 seconds in the settings menu. Code shown in the menu no.1.1.1 on the screen is the error code for heater no.1. If there is a 2nd heater in the vehicle, navigate to menu no.1.1.2 with the key to see the error code for heater no.2. WARNING Service menu shall only be used for displaying the error code. Changing the settings on the service menu may damage your heater. Please use the service menu for displaying the error code only. - 88 - OPERATION A/C and Heater Heater Bring the heat control to red position for hot air ow. You can adjust the fan speed in 3 steps. 0: Off 1: Low speed 2: Middle speed 3: Fast 4 Adjust the blowing direction blows to the windshield. blows from opposite direction. blows to the leg level and from opposite direction. blows to the windshield and to the legs. - 89 - OPERATION Driving Before taking off: Starting the engine CAUTION Wait for the period determined by the electronic control unit (10 to 40 seconds) before starting again after a start failure. Do not attempt to start in this period. 4 Cold Start • Turn the ignition on. (position ). Cold starting lamp will be continuously on Check the air pressures on the brake circuits. Turn the ignition on. • Turn the ignition switch to position Wait until the engine warning lamp is turned off. refer to maintenance and service chapter MIL lamp • When gear idle, (press clutch for manuel transmission vehicles) and. Start the engine by turning the ignition switch to position (max.10 seconds) • Wait for 15 seconds if the engine does not start and repeat the same procedure in the same order. - 90 - • Start the engine (position ) when the cold start lamp turns off, • We advise you to apply the clutch pedal to lower the load on the engine. • If the engine does not start, switch the ignition off, wait for 1 minute and repeat the steps above. OPERATION Driving Starter Protection System Starter Protection System is a system that prevents the burning of the starter due to unnecessary starting operations. Electronic control unit calculates the maximum appropriate duration of a starting operation by gathering many data via the sensors on the engine to protect the starter. When the user exceeds the specified maximum start duration, he is prevented from starting again. The system allows starting again at the end of the period determined by the electronic control unit. Please follow the instructions below in such a case. CAUTION If your engine is not started after some attempts, there may another problem in another system of your engine. First complete the other checks, and attempt to start again. To stop the engine Do not stop the engine immediately when the vehicle is stopped. Wait until the turbo speed is decreased by operating the engine in idle. If the engine is stopped immediately when the vehicle is stopped, the turbo which is rotating in high speed shall not be adequately lubricated. CAUTION Applies for Tractors and Road Trucks. Fixed spoilers are provided on Construction series. - 91 - Air deflector Adjust the air deflector on the cab according to the trailer. Note: A correctly adjusted air deflector reduces the fuel consumption. There is a risk of falling down from the cab and being injured while adjusting the air deflector. We advise you on that adjustments on the air deflector shall be performed by FORD OTOSAN authorized dealership with the required expertise and special equipment. Smart acceleration feature: Acceleration of the vehicle is controlled by limiting the engine acceleration profile to a specified percentage of the maximum weight that can be carried by the variant for trucks, and maximum load that can be drawn for the tractor trucks. Abrupt and unintentional accelerator responses of the unloaded vehicle have been prevented, and thus driveability of the vehicle is improved besides providing fuel economy. Smart acceleration function is deactivated especially in uphill start and climbing manoeuvres and it is optimized to prevent adverse effect on the vehicle performance. 4 OPERATION Driving Cruise Control 4 Pull the lever towards you to activate, (position ) shall be displayed on the indicator. - Increasing the speed - Decreasing the speed - Deactivation - Engine brake and retarder - Resuming cruise control Driving speed is set by the multifunction lever on the right of the steering. Engine electronic control unit adjusts the throttle setting required for driving the vehicle at the set speed. Vehicle is driven in the set speed without the need for the driver's applying the accelerator pedal. When the cruise control is activated, it is automatically deactivated in the following conditions: • Applying the brake • Applying the clutch (in vehicles with manual transmission) • In case activating the engine brake, cruise control is deactivated automatically When cruise control is activated, it is shown as figure depicted below on the cluster information menu. - 92 - CAUTION Vehicle cuts throttle if the set speed is exceeded, and engine brake is activated if the engine speed is over 1000 rpm. • Cruise control cannot be activated for vehicle speeds under 30km/h. • Cruise control cannot be activated for vehicle speeds over the speed limit. • Cruise control is deactivated automatically if it is active when speed limit is exceeded. • For convenience of use, cruise control remains active until gear is changed when the clutch is applied for 5 seconds in vehicles with manual transmission. OPERATION Driving Hill holder On Vehicles with Manual Transmission: On Automated Manual Transmissions: 1- Stop the vehicle with service brake. 2- Activate the hill launch assist by pressing the button on the center console. 3- Depress the clutch pedal. 4- Engage proper starting gear. 5- Release the brake pedal, brakes of the tractor and semi-trailer holds automatically. 6- Release the clutch pedal to drive off the vehicle and press the accelerator 7- Hill holder feature, 1- Stop the vehicle with service brake. 2- Activate the Hill holder by pressing the button on the center console. 3- Release the brake pedal. 4- Hill holder holds the brakes for a maximum of 2,5 seconds. If the engine torque reaches the speci ed level earlier, Hill holder assist is deactivated before 2,5 seconds • is deactivated automatically when the clutch is released or engine torque reaches a specified value. - 93 - hill start assist active warning is displayed on the instrument when the hill start assist is active 4 OPERATION Braking Disc brake system 4 Brake System: Arvin Meritor Elsa 225H air disc brake with sliding brake calliper. Disc: 430 mm anti-conical disc with air ducts. System Air Pressure: 10,5 bar Brake friction pads The new brake pad thickness is 19mm. Brake pads should be replaced when they fall to 3 mm thickness. Vehicles with disc brakes have a sensor on each brake that constantly measures the amount of wear. The display screen shows how many kilometers the pad of the brake pad on each axle will go in <>. Data is collected for a predetermined period of time based on the driver and usage conditions, and is displayed on the display as an hourglass. Different wear between right and left brake pad, brake pad sensor error, general error, remaining brake pad life under 6% and installing worn brake pad under 35% are shown on the display in <<--->> and the problem should be solved by going to service. When the amount of brake lining in any brake approaches the end, the driver is informed with the warning light. After the warning light turns on, the problem should be solved by going to the nearest service Weared lining information is shown on the display. On which axle the brakes shall be replaced can be seen on the display. Linings of both left and right brakes on the relevant axle shall be replaced at the same time. An indicator lever is available on the brake to allow monitoring of the lining thickness besides the percentage indication on the display. Linings shall be replaced when the indicator lever is fully worn. As the service life of the lining shall differ greatly due to causes such as vehicle load, operating conditions etc., monitor the lining thickness periodically from the display or check it every month with the indicator lever on the brakes when it is not possible to monitor it from the display. - 94 - 50% Wear 25% Wear 75% Wear Fully Worn OPERATION Braking Drum Brake System The thickness of the new discs is 45 mm. Discs shall be replaced when the thickness becomes lower than 39 mm. Check the disc thickness every three months as the service life of the disc shall differ greatly due to causes such as vehicle load, operating conditions etc. Inspect the disc surface against cracks during thickness inspection. 4 Replace the disc if the cracks on the surface has reached air ducts or grown up to 25% of the lining pressure surface. Cracks that have not grown up to 25% of the surface do not affect the performance, you may continue to use the disc. Z-cam brake system is a lining-drum type braking system. Brake lining wear is inspected from 4 holes on the brake plate. Remove the plugs on the plate for inspection, and replace them after inspection. Blue areas on the disc surfaces indicate that they have been subject to excessive heating. We recommend you to machine the disc as the structure of these areas have been deformed. Linings that have been subject to excessive heating shall also be replaced. *Z-cam brake system is optional. - 95 - OPERATION Braking CAUTION Even if one of the mutual linings is worn, replace both linings. 4 CAUTION Install the plugs again after lining inspection. Otherwise, dust and dirt ingress between the lining and drum may cause premature lining wear and damage to the drum. Lining wear inspection may also be performed visually from the inspection holes on the brake dust plate. If the thickness of the lining remaining on the brake pad is less than 8mm, we recommend that you shall have your lining replaced in a Ford authorized service immediately. - 96 - OPERATION Braking Emergency brake bellows Discharging the emergency bellows Brake air bellows on the drive axle of your vehicle have emergency feature. Emergency bellows are activated in 2 conditions: To discharge the emergency bellows, turn the bolt behind the bellow in tightening direction (clockwise) completely. • When the park brake is applied • When there is not enough air in air tubes to brake the vehicle CAUTION Install the plugs again after lining inspection. Otherwise, dust and dirt ingress between the lining and drum may cause premature lining wear and damage to the drum. CAUTION To start park brake mechanism again, please contact to the authorized workshops or refer to the repair catalogue. If the vehicle is going to be parked for more than one month, perform the following to protect the linings and drums. - Park the vehicle, chock the wheels and release park brake lever. - Drain air tanks completely. - Release the park brake unit as specified depending on the vehicle model. - Run park brake unit and refill the system with air when you will drive the vehicle again. - 97 - 4 OPERATION Braking Engine brake (Standard) Activation of the engine brake 4 Figure-1 Figure-2 Your engine provides the engine brake feature as standard. At the end of the compression cycle (Fig. 1), before several degrees from the Top Dead Center, a special equipment in engine pistons opens the exhaust valves a little and releases the pressure grown inside the cylinder (Fig. 2). Thus, braking torque of the compression cycle is used. Engine Brake Intarder is activated by the 5 step lever on the right of the steering. 1. Range Reduced Brake Power Engine Brake 2. Range High Brake Power Engine brake is activated by the lever on the right of the steering. warning is displayed on the indicator. Intarder / optional Intarder is a special brake system for decelerating the vehicle and maintaining the speed in downhill travels, and also known in the market as "drive shaft brake". systems. Intarder provided in your vehicle has a hydrodynamic braking system also known in the market as uid type. • Braking Moment: 3500 Nm • Braking Power: 600 kW • Weight: 70 kg . • Operating principle: Hydrodynamic braking • Fully compliant with ABS-EBS system - 98 - Intarder Bremsomat Reduced Brake Power Bremsomat (0%-100%) Bremsomat Reduced Brake Power 25% Max. Brake Power Intarder 2 Reduced Brake Power 50% Max. Brake Power Intarder 3 High Brake Power 75% Max. Brake Power Intarder 4 High Brake Power 100% Max. Brake Power warning is displayed on the display when the intarder is activated. Bring the intarder lever to 0 (off) position when the required speed is reached. When the intarder lever is pulled, rear brake lamps are turned on when the vehicle reaches a specified braking power. (-0.7 m/s2). OPERATION Braking Bremsomat: WARNING When the retarder lever is pulled 1 step while driving downhill, intarder is activated in the required amount so that the vehicle speed hold constant. Bremsomat feature turns off when the lever is brought to 0 or any position from 2 to 5. Intarder oil is cooled with the engine coolant. Check whether the coolant is heated excessively from the coolant temperature indicator especially when the intarder is used in long intervals. CAUTION Intarder braking force has a technical limit. In Bremsomat position, force acting downhill due to the road inclination and load status may exceed maximum braking force of the intarder. In this case, vehicle shall be accelerated. When the coolant has reached 105 °C, intarder is deactivated automatically to prevent excessive heating of the engine. CAUTION Intarder requires maintenance. The oil filter should always be changed at every replacement interval of the transmission oil. - 99 - CAUTION Using Intarder for any type of deceleration will extend service life of the brake linings. 4 OPERATION Braking Automatic hybrid brake mode CAUTION If the right multifunction lever is brought to any position other than (0), automatic hybrid brake mode is deactivated until the lever is brought to position (0) again. 4 Air tubes Drain the water in the tanks every day. Pull the ring attached to the cock until all air is discharged to drain the water inside the tanks. When the air tanks are drained, low pressure warning should sound as the ignition is switched on. If the warning system is not operated due to a fault on the warning circuit, the fault on the system should be repaired immediately. Do not drive your vehicle until the normal pressure is displayed on the air pressure indicators. Air drier filter may be not operating if greasy mud deposit is seen during the air tank draining procedure. Replace the filter of the air dryer. When the “AUTO” button on the center console is pressed, intarder and engine brake may be activated by the foot brake. Thus, when the brake pedal is applied, intarder* and engine brake is applied as proportional to the pedal travel besides the service brakes. *intarder is not provided in standard vehicle package; it is optional. - 100 - OPERATION Braking Air Dryer (APU) CAUTION Auxiliary Air Line Air drier filter shall be replaced in periodical maintenance intervals. If the drier filter does not operate properly, it may cause damage to itself and the air valves. 4 When air bleeding is required for special functions (e.g. air horn, air gun), connection shown in the figure shall be used. The air drier unit on your vehicle includes air heating, separating the oil in the air, air discharge and 4-way relief valve functionalities besides the air drying function. A tire in ation port is available on the air drier inside the chassis. CAUTION Do not take air directly from the tubes. - 101 - OPERATION Braking 4 Reverse test request There are some kind of failures which can’t be detected by EBS directly, only via monitoring of the behavior of the vehicle and the brake system. These monitoring functions are called plausibility checks. If a plausibility failure is detected by the EBS, it can be restored according to the legal requirements only if EBS carries out system test (called reverse test) and the result of the test is positive (operation of the brake system is correct). It means when the cause of the failure is eliminated (it was just a temporary failure, or the vehicle is repaired), than a reverse test has to be carried out. To make EBS to be able to carry out the reverse test, the driver has to activate the brake pedal once under a defined condition. When EBS requires such a pedal activation to restore the failure, it will send a request with the following failure code: Path: 253 (Vehicle brake system) Type: 201 (Press brake pedal request) (SPN 64969) It is highly recommended to give a clear text on the instrument cluster to the driver when this pedal activation requested and the user manual of the vehicle should describe clearly the conditions how to do it. The pedal activation has to be carried out on the following way: After fault detection, the ignition must be switched off and on in order to reset EBS: • The ignition-off phase must be at least 5 sec., to allow power-down of EBS, and • During ignition-off phase the brake pedal must be released, to avoid braking in wake-up mode without reset of EBS. • After ignition is switched on, for at least 7 sec.: • The vehicle must be in stillstand, and • • Brake pedal must be released. • Supply voltage EBS sufficient for electronically controlled braking. • Parking brake should be released in case of TCM failures. • Warning lamp is on, system restriction is active. • Brake pedal actuation, with the following features: • During standstill, the driver is instructed via dashboard symbol "braking" to do a braking. • Pedal actuation does not start before 7 sec. after ignition is switched on. • Pedal actuation must increase to full brake position, without any condition. • Full brake position must be hold for at least 3 sec.. - 102 - • Pedal decrease until fully release, without any condition. • Brake pedal must be fully released for at least 3 sec.. • Warning lamp is on. System restriction is not active during braking. Braking is controlled by electronic pressure control. Brake pedal test is successful: • No fault is detected during the braking. • Warning lamp is switched off, system restriction remains not active. Brake pedal test is not successful: • A fault is detected during the braking, or • Maximum braking time of 25 sec. is expired, or • The vehicle starts moving. • Warning lamp remains on, system restriction is activated. • An ignition reset is needed to start brake pedal test again. OPERATION Shifting Manual transmission and shifting Manual gear High range 5-6-7-8 Half gear (boost) Low range 1-2-3-4 There are 16 forward and 2 reverse (in high and low ranges) gears. All gears other than the reverse gears have synchronizers. Shifting from low to high range and selection of half (boost) gears is made via the latches on the gear knob. As shown in the diagram below, the latch in the front side of the gear knob allows selection of the low range (1-2-3-4) and the high range (5-6-7-8). When the latch is down, the transmission is in the low range; and when the latch is up, the transmission is in the high range. The latch on the side of the gear knob allows selection of half (boost) gears. When the latch is down, the transmission is in boost gear; and when the latch is up, the transmission is in normal gear. Note: To shift from low range to high range during acceleration in transmissions with 1H gear system: 1. Press the latch upwards in the 4th gear. 2. Depress the clutch pedal. 3. Select neutral. 4.Shifttheleverfromneutr alto1⁄2rangeandthen1/5gear. Transmission will shift to 5th gear when it is in high range. 5. Slowly release the clutch pedal. 6.Leavethelatchinhighrange. Transmissions have a shift prevention mechanism to protect the transmission against incorrect shifts when the vehicle has reached a certain speed. These mechanisms prevent shifts to 1⁄2 range in certain speeds for low and high ranges, and shifts from high range to low range. Below are the cases re ecting the above mentioned circumstances and where the protection mechanisms are activated for errors likely to be experienced when driving: 1- Driver wants to shift from 4th to 5th, but forgets the switch the latch to high range (upwards) when the vehicle is accelerating: The gear knob cannot be moved to 1/2 position, changing to an incorrect gear is prevented by the system. 2- Driver wants to shift from 6th to 5th, but switches the latch to low range inadvertently when the vehicle is decelerating: As the transmission will try - 103 - to shift to 1st in this condition, the shift prevention mechanism is activated and prevents the shift operation, and moves the shift lever to the 3⁄4 range, and changing to an incorrect gear is prevented by the system. 3- Trying to shift from 8th to 5th when the vehicle is movingwithacertainspeed: Selectorlever1 The gear knob cannot be moved to 1/2 position, changing to an incorrect gear is prevented by the system. 4- Trying to shift from low range to high range when the vehicle is moving with a certain speed: System denies the shift to the low range. Driver is not allowed to shift to low range. Prevention mechanisms of the 16 S 2230 transmission specified above are intended to protect the gear and synchronizer mechanisms in the transmission, and these are not error modes. CAUTION Service life of the clutch is proportional with its correct usage. Incorrect usage of the clutch reduces its service life and clutch is damaged because of overheating in a short period of time. Do not hold the vehicle on slopes with semi-applied clutch. 4 OPERATION Shifting 4 In order to shift into gear, fully press the clutch pedal before shifting and remove your foot when shifting occurs. Do not hold your foot on the clutch pedal on driving conditions where operation of clutch is not required. Choose a lower gear during take-off to ensure that your clutch has a longer service life. In case of any load, take off with low range 1 on hills, and high range 1 gear on straight roads. Do not use reverse gear when the transmission is in high range. Do not use your vehicle in neutral. Transmission may be damaged as the lubrication inside the transmission while the vehicle is moved in neutral for a long time will be inadequate. and in the high range when the latch is pressed upwards. Eaton ESO14409 Manual transmission and shifting 2. Depress the clutch pedal. CAUTION Do not take off with your vehicle when the vehicle is loaded and the transmission is in high range. Stop the vehicle completely to engage reverse. Wait for 8 to 10 seconds, and shift into reverse. Your vehicle’s transmission may be damaged if you try to shift to reverse when the vehicle has not come to a complete stop. Do not shift to neutral while driving down a slope. Do not take off with your vehicle when the transmission is in high range • During the acceleration, to switch from the low range to high range: 1. Press the latch upwards in the 4th gear. 3. Select neutral. (Planetary gear set will be disabled then, and the transmission will shift to high range) 4. Shift the lever from neutral to 1⁄2 range and then 1/5 gear. Transmission will shift to 5th gear when it is in high range. It has 9 gears: 8 forward + 1 crawler gears. 5. Slowly release the clutch pedal. First 4 gears are called as low range, and the remaining 4 gears are called as high range. Switching between low and high ranges is provided by the up and down movements of the latch on the gearshift lever. As shown below, the transmission will operate in the low range when the latch is pressed downwards, 6. Leave the latch in high range. • Transmissions have a shift prevention mechanism to protect the transmission against incorrect shifts when the vehicle has reached a certain speed. These mechanisms prevent shifts to 1⁄2 range in certain speeds for low and high ranges, and shifts from high range to low range. - 104 - OPERATION Shifting • The situations that the driver may experience with the prevention mechanisms are listed below: Transmission Information on the display: 1. Driver wants to shift from 4th to 5th, but forgets the switch the latch to high range (upwards) when the vehicle is accelerating: Shift lever cannot be shifted to 1⁄2 range and the driver is warned about this. 2. Driver wants to shift from 6th to 5th, but switches the latch to low range inadvertently when the vehicle is decelerating: As the transmission will try to shift to 1st in this condition, the shift prevention mechanism is activated and prevents the shift operation, and moves the shift lever to the 3⁄4 range, and driver is warned about this. 3. Trying to shift from 8th to 5th when the vehicle is moving with a certain speed: Shift lever cannot be shifted to 1⁄2 range and the driver is warned about this. 4. Trying to shift from low range to high range when the vehicle is moving with a certain speed: System denies the shift to the low range. Driver is not allowed to shift to low range. • Prevention mechanisms of the transmission specified above are intended to protect the gear and synchronizer mechanisms in the transmission, and these are not error modes. "Shift up" warning: engaged gear is smaller than required by the engine speed. Shift up. CAUTION Driving in lower gears than required increases fuel consumption. As the engine speed shall be higher in smaller gears, it will tire the engine more. Engaged gear is displayed on the upper left corner of the trip computer. D: forward gear R: Reverse Example: D4 Forward 4th gear Downshift Downshift 2 gears - 105 - Shift up when on the display. warning is displayed CAUTION On vehicles with a manual transmission, do not travel by keeping your hand on the gear lever, the pressure applied on the gear lever may slightly damage the gear internal mechanism. 4 OPERATION Shifting Automated transmission and shifting 4 In Ford Trucks vehicles with automated transmission; it is used in gearboxes with 12 forward-2 reverse and 9 forward -1 reverse gears. No clutch pedal is available in the vehicle. Clutch release/clutch operation is performed by the mechanism controlled by the electronic control module. System components Shift Lever: D: forward gear N: N/A R: Reverse Gear DM: Forward Manoeuvre (only used while coasting) RM: Reverse Manoeuvre (only used while coasting) Information Display: In automatic mode Engaged gear is displayed on the upper left corner of the trip computer. D: forward gear R: Reverse Example: D4 Forward 4th gear In Manual mode Up/Downshift will be done with +/buttons where is on the shift knob. Drive -Manual toggling will be done whether driver pushes the minus or plus button more than 1 sec. Locking mechanism enables to have secure shifting movement between each gates, prevent to shifting N to D or N to R mistakely. - 106 - Downshift Downshift 2 gears Automatic and Manual Operation: Automatic: Transmission electrical control unit selects the best gear according to the engine and load status. Gear selection and shifts are performed automatically. False gear selection is not possible. * Transmission decides take-off gear and gearshifts. *: Automated transmission is not provided in standard vehicle package; it is optional. **: Transmission model code can vary according to the features such as PTO and/or intarder. OPERATION Shifting Automatic and Manual Operation: Automatic: Transmission electrical control unit selects the best gear according to the engine and load status. Gear selection and shifts are performed automatically. False gear selection is not possible. Transmission shifts to most economical mode if engine brake is not activated (low engine speed) If the engine brake is activated, transmission shifts down to increase engine speed Clutch movement and shifts are performed automatically Gears may be corrected manually. False shifting is not possible. Initial operation (lifting the vehicle) Moving the Vehicle Make sure that the air is filled up adequately. You can tell whether the air is filled or not by the air pressure section of the instrument panel. Or you may wait until the driver's seat is completely filled with air. If the driver's seat is filled with air, this means that there is enough air for the transmission. AL warning shall be displayed on the screen if the air in the vehicle is inadequate. Shift to D for moving forward When you shift to D, the transmission shall start in automatic drive mode and shall select the starting gear itself, depending on load and inclination. D shall be displayed on the screen, indicating that the vehicle is started in automatic mode. WARNING In some cases, the transmission software may not be able to calculate the starting gear (when the vehicle is started recently, when no information received or due to calculation errors). If you think that the transmission can not select the appropriate gear according to the vehicle load and the inclination of the road, you may change the take-off gear with the + and - commands on the shift knob. (Max. 5th gear may be selected for take-off) Before moving, observe that the transmission has selected the gear on the display Release the park brake and press on the accelerator slowly. Transmission shall slowly release the clutch and allow the vehicle to move. - 107 - CAUTION If the vehicle is on a slope when you release the park brake, it may slip backwards or forwards if you do not press the accelerator. Keeping the vehicle uphill and slightly depressing the accelerator pedal shall cause the transmission to halfclutch, the clutch shall start to slip and it shall warm up. CL shall be displayed on the screen if the clutch is overheated. If you see this warning, either press on the accelerator a little to allow the vehicle to move or press on the brake to hold the vehicle. Otherwise, clutch may burn out on early mileages. If you see the CW warning on the screen, this means that the clutch is worn out. Vehicle shall not move in such a case. Call the authorized workshop. Using in Manoeuvre Mode The automatic transmission has manoeuvring modes to move the vehicle forward and backward precisely. When in the manoeuvre mode, the transmission does not close the clutch fully or closes the clutch in a very a long time than normal. This prevents the vehicle from moving forward abruptly and provides driving safety in approaching manoeuvres that require precise movement 4 OPERATION Shifting 4 Switch to DM to use the vehicle in forward manoeuvre mode, and to RM to use the vehicle in rearward manoeuvre mode. Manoeuvre modes are not auxiliary shift modes, they may cause damage to the clutch by overheating the clutch when the vehicle is operated under load or on a slope for a long period of time. Initial Movement Downhill or Uphill • If the gear is shifted and brakes are released while the engine is operated • If the gear is shifted to D or DM and the vehicle is downhill, transmission closes the clutch slowly and vehicle starts to move slowly. • If the gear is shifted to R or RM and the vehicle is uphill, transmission closes the clutch slowly and vehicle starts to move backwards slowly. • If the gear is shifted to D or DM and the vehicle is uphill, transmission does not close the clutch, vehicle slips a little backwards and transmission starts to open and close the clutch and to shake the vehicle in order to warn the driver. • If the gear is shifted to R or RM and the vehicle is downhill, transmission does not close the clutch, vehicle slips a little backwards and transmission starts to open and close the clutch and to shake the vehicle in order to warn the driver. Driving Automatic Driving Mode Automatic transmission detects the road and load conditions and calculates and selects the appropriate gear according to the driver's pressing on the accelerator. When you think that the automatic transmission does not select the appropriate gear, you may upshift or downshift by pushing / pulling the gear lever in the + / - direction. M shall be displayed on the screen temporarily if the gear is upshifted or downshifted with the gear lever. After some time, transmission shall return to automatic mode again, and D shall be displayed on the screen. - 108 - On automatic drive mode (D), the transmission adjusts the shifting speed according to the pressing level on the accelerator. Shifts gear at low speeds for economy when the accelerator is pressed lightly, and shifts gear at high speeds for performance when the accelerator is pressed strongly When the accelerator is pressed fully, it finds another level that can be sensed with the foot, too. If you press beyond this level, transmission downshifts for higher power and allows the engine to reach a higher speed. This feature, called as “kickdown”, helps the vehicle to accelerate while overtaking another vehicle or when power is required. OPERATION Shifting CAUTION DM and RM modes shall only be used for coasting, and only as it is required. CAUTION DM and RM modes are not ‘boosts.’ The duration of DM and RM modes is limited by the transmission control unit. Manoeuvre mode (DM and RM) puts a strain on the clutch lining when it is used for a long time, then warning is displayed on the display; shift the transmission to neutral and wait for a while. Transmission is faulty. Stop the vehicle and contact a Ford authorized dealership. Manual Use: • Take-off gear is automatically determined. • Clutch movement and shifting operation is automatic when the gear is shifted manually with the shift lever. • False shifting is not possible. • Manoeuvre operation is available in automatic mode only. If the vehicle is driven in manoeuvre mode despite the warning on the display, transmission shifts to gear automatically. In this case, vehicle may be accelerated. CAUTION Do not to exceed the maximum engine speeds allowed during manual operation. Display warnings: Transmission warnings are displayed as 2 digit abbreviations on trip computer. - 109 - System Check: System checks itself whenever the ignition is switched on. Forward Manoeuvring Mode. This shall be used while coasting only. Neutral Gear shift to neutral. 4 OPERATION Shifting Reverse, high range Reverse, low range 4 Reverse Manoeuvring Mode. This shall be used while coasting only. Air pressure low: A separate air tube is available for the automated transmission in your vehicle. If the air pressure in the transmission air line goes below 5.8 bar, AL warning shall be displayed. WARNING • Attempting to shift while the air pressure is low may cause shifting of the transmission to neutral. In this case, exhaust brake shall not be active. • When the air pressure drops, it is not possible to disengage the clutch. Clutch Control Clutch position cannot be calculated by the system. Clutch is overloaded. This is displayed when you attempt to take off the vehicle with a gear higher than required in manual mode. Select a lower gear and take off the vehicle in this condition. Clutch lining wear Clutch lining wear has reached limit value. Please visit a Ford Trucks authorized dealership in the shortest possible time. Electronic fault. Communication error between the instrument cluster and transmission electronic control unit. Please visit a Ford Trucks authorized dealership in the shortest possible time. Accelerator Pedal: Remove your foot from the accelerator when this warning is displayed. If the warning is not removed, there is a fault in the system. Please visit a Ford Trucks authorized dealership. - 110 - Shift to neutral. When the vehicle is left in D while being parked for a long time, this applies a load on the clutch. When NS warning is displayed, transmission control unit indicates that the vehicle is left in D without moving for a long time. Shift to neutral. Transmission oil temperature has reached upper limit. Stop the vehicle. Please contact a Ford Trucks authorized dealership. OPERATION Shifting High speed drive mode Off-road driving mode Tractor and Road series vehicles may some times require to operate at high speeds continuously. Construction series vehicles may require to operate at high speeds continuously on off-road conditions and to prevent unnecessary shifting. On off-road conditions where unnecessary shifting shall be prevented, or where quick shifting or operating at high speeds are required, you may turn on the off-road mode of the transmission and 4 ensure that transmission shifts as per the soft ground and rough terrainconditions. To activate the power mode, press the offroad/Rocking switch on the front panel once. Press on the switch again when you want to deactivate it. OFR flashes on the information display when the off-road mode is active When high speed and power are required, you may turn on the power mode of the transmission, and allow the transmission to shift quicker at higher speeds. To activate the power mode, press the power rocking switch on the front panel once. Press on the switch again when you want to deactivate it. PWR flashes on the information display when the power mode is active - 111 - 4 OPERATION Shifting Oscillation mode 4 All vehicles with automatic transmissions feature an oscillation function that oscillates the vehicle to recover it when the drive wheels are stuck on soft ground. To activate the oscillation mode, press the off- road/Rocking switch on the front panel for 3 seconds. Press on the switch again for 3 seconds when you want to deactivate it. ROC flashes on the information display when the oscillation function is active. Differential locks are also activated automatically when the oscillation function is activated. To oscillate the vehicle after activating the oscillation function, press on the accelerator and release it quickly and allow the vehicle to oscillate forwards and backwards. - 112 - OPERATION Power take off Power Take Off Illustration is for informational purposes only. There are no adaptors or pumps on the vehicle. PTO is the unit connected to the transmission to operate the equipment that will be operated by taking power from the transmission (such as pumps). It transmits the power it takes from the transmission to the pump. PTO installation is optional and can be performed on both manual and automated transmissions during production in the factory. Contact a Ford Trucks authorized dealership for the retrospective PTO installations. Engine electronic control unit on your Ford Trucks vehicles allows that the engine is operated at a constant speed when PTO is activated. Speed parameter on the control unit may be set by the Ford Trucks authorized dealers. PTO on Vehicles with Manual Transmission Operating speed can be 2 different speeds according to the half gear latch on the shift lever. Set the half gear latch up or down before activating PTO. Do not tamper with the latch while PTO is operated. Pump shall operate with higher speed when the latch is up, and with lower speed when the latch is down. Activating the PTO • Stop the vehicle and apply the parking brake. • Shift to neutral, set the engine to idle Depress the clutch pedal and hold it pressed. - 113 - • 10 seconds later, press the switch on the center console. Yellow light on the switch shall be illuminated. • Take your foot off the clutch pedal. Deactivating the PTO • Fully depress the clutch pedal for 10 seconds without taking your foot off (on vehicles with clutch pedal) • Press the switch on the center console, yellow light shall be turned off. • Take your foot off the clutch pedal (on vehicles with clutch pedal). PTO on Vehicles with Automated Transmission • PTO can only be activated when the vehicle is stationary and rotating knob is at position "N". PTO is activated by pressing the PTO on the console. • Shifting is not possible when PTO is activated and vehicle is moving. • PTO cannot be activated when the vehicle is moving. 4 OPERATION Power take off Symbol shall be illuminated on the functions section of instrument when PTO is active. 4 PTO valve switch.. Control unit is used for lowering the bed in dump trucks. Button #12 is used for slow lowering, button #13 is used for fast lowering operation. Use the 'PTO (power take-off)' button in the panel to raise the bed. - 114 - OPERATION While driving WARNING The driving, braking and manoeuvring behaviour of the vehicle varies according to the type, weight of the load, and the location of the center of gravity. Make sure that the vehicle is loaded in balance and avoid an unbalanced weight distribution. Secure the load to prevent sliding when required. Otherwise, you may loose the control of the vehicle and cause and accident. CAUTION Observe the allowed axle loads, wheel loads (half of the axle load) and maximum total weight of the vehicle. Otherwise, damage to the tires, chassis and axles may occur. Otherwise, damage to the tires, chassis and axles may occur. Observe the indicators on the instrument panel while driving. WARNING Make sure that the driven wheels are held on the road while driving, and especially on the off-road. Prevent the spinning of the driven wheels (Differential damages). Activate the differential lock. CAUTION Driving the too much off-road may cause damage to the vehicle. The obstacles may not be noticed in time and the structure of the ground may not be assessed properly. E.g.deep tracks formed before may damage • Axles • Driveshafts • Fuel tanks • Compressed air reservoir • Engine • Transmission May damage it. Therefore, always drive slowly off-road. If you need to drive over the obstacles, codriver should provide directions. Always observe the height of the vehicle from the ground. Avoid obstacles whenever possible. - 115 - WARNING In the vehicles with engine driven power output (Engine-PTO), Trucks Concrete Mixer series in particular, the angle of the shaft mounted at this point by the superstructure manufacturer with respect to engine shall not exceed the value of 3°. Make sure that the superstructure of your vehicle was constructed accordingly. Otherwise, it may result in vibration, balance and thus serious engine and superstructure problems. CAUTION You may not observe the obstacles in time or assess the structure of the ground properly. Always drive slowly off-road to prevent damages to the vehicle. Vehicle may slip sideways or turned over. Never drive the vehicle in direct angle to the slope, always drive in parallel to the slope. Do not manoeuvre in the opposite direction. If your vehicle cannot take a slope, drive in the reverse gear. You may lose the control of the vehicle when you shift to neutral or press the clutch or try to brake the v ehicle with the service brake only in slopes. Do not let your vehicle to move in neutral or with the clutch activated. 4 OPERATION While driving 4 If you load your vehicle excessively, this would increase the risk of turning over. Do not exceed the maximum permissible axle load. Maintain the center of gravity as low as possible when you are loading your vehicle. Materials that lower that the effect of braking, such as sand or water mixed with oil, may enter the brakes if you drive your vehicle on muddy or swampy areas frequently. This may cause excessive wear and a decrease in the braking effect. A risk of not being able to use the braking effect fully in emergency conditions is present. Test the brakes after any off-road drives. If the braking effect is lowered or that rubbing noises are present in this test, make sure that your brake system is checked by a FORD OTOSAN authorized dealership. WARNING Acceleration forces act on your body from all directions due to the improper nature of the ground. There is a risk of bouncing off the seat and injuring yourself. Always fasten your safety belt in the off-road drives, too. Drive systems for off-road driving Driving systems and equipment described below allows you to drive your vehicle safely offroad: • Disengagement of the ASR. • Differential locks. WARNING The steering wheel may strike back and cause injuries on the thumbs of your hands when driving over obstacles or the tracks formed over the road. Hold the steering wheel tightly with your both hands. Consider the high forces occurring for a short period of time while driving over the obstacles. • Stop the vehicle and engage a lower gear before driving off-road. • Always drive the vehicle with the engine running and a gear engaged while driving off-road. • Drive slowly and with a stable speed. Drive with the crawling speed if required. • Make sure that the wheels are always held on the road. • Activate the differential lock. • Drive with extra care in an unknown or a non-visible area. Get off the vehicle first, and inspect the terrain for safety reasons. • Check the depth of the water before - 116 - driving through the water. • Observe the obstacles like rocks, holes, trunks and trenches. • Avoid skirts of the ground that the ground may be torn. Before driving off-road • Engagement of the differential lock • Disengagement of the anti-skid control • Equipment specified below should be available on the vehicle: • Shovel • Climbing hawser with bolted Y anchor . After driving off-road WARNING Faults caused by off-road driving may cause accidents or prevent some parts from operating. Clean and check your vehicle after driving off-road. Have the fault repaired before next operation of the vehicle. • Disengage the differential lock • Engage the anti-skid control (ASR) • Clean the vehicle • Check the vehicle for any damage. OPERATION While driving Fuel consumption Workstations Fuel consumption depends on the conditions below: • Model of the vehicle • Driving style • Operating conditions • Tire dimensions, tire profile, tire pressure, condition of the tires • Upper structure, air deflector • Drive train for the drive applications • Auxiliary applications (A/C and heater, auxiliary power outlet, viscous fan) Fuel consumption depends on the conditions below: • Highland conditions • Traffic in cities and short distances • Vehicle load • Operation while the vehicle is parked • Frequent starting when the engine is cold Fuel consumption information may be displayed on the standard on-board computer. Thus, it is not possible to provide a certain value for the fuel consumption of the vehicle. Driving style To lower the fuel consumption: • Avoid frequent acceleration and braking • Drive carefully by paying attention on the road • Drive within the economic engine speed limits - 117 - 4 OPERATION ECAS (Electronically Controlled Air Suspension) Manual Control Unit (In Vehicles with Air Suspension ) Using Manual Control Unit (Only In Vehicles with Air Suspension) 4 Chassis height of the vehicles with 4 air bellows on rear axle may be adjusted by the control. ECAS control is placed on the left of the driver's seat over the fender. WARNING Do not change the chassis height of your vehicle by the manual control unit when driving. Use the manual control unit when your vehicle is stationary and parking brake is applied. This is important for the safety of you and your vehicle. 1- N/A 2- Rear axle activation light 3- N/A 4- Driven axle selection button 5- M1 Memory button 6- M2 Memory button 7- Normal drive height button 8- Lifting button 9- Lowering button 10- Stopping button - 118 - 1. Ignition switch should be in position to activate the air control system by the "manual control unit". 2. Functions desired can be performed after pressing the driven axle selection button. 3. Press the "STOP" button if you need to stop the operation during any procedure. 4. If you want to record a certain chassis height, press the "STOP+M1 or M2" buttons for 2 seconds at the same time. This would record the height to the system. In the future, when you want to adjust the vehicle to this height, press M1 or M2 button after you press the "front selection - rear axle" button. NOTE: marked buttons are not active. Symbol is illuminated on the instrument when the vehicle is not at driving height OPERATION ECAS (Electronically Controlled Air Suspension) Manual Control Unit (In Vehicles with 6 x 2 Air Suspension) Chassis height of the vehicles with 6x2 air suspension may be adjusted. ECAS control is placed on the left of the driver's seat. 1. 1- N/A- This button is not active. 2- Rear axle activation light 3- N/A- This button is not active. 4- Driven axle selection button 5- M1 Memory button 6- M2 Memory button 7- Normal drive height button 8- Lifting button 9- Lowering button 10- Stopping button 11- Lifted axle selection button - 119 - Ignition switch should be in position to activate the air control system by the "manual control unit". work has been performed. 2. Functions desired can be performed after pressing the driven axle selection button or lifted axle selection button. 3. Press the "STOP" button if you need to stop the operation during any procedure. 4. If you want to record a certain chassis height, press the "STOP+M1 or M2" buttons for 2 seconds at the same time. This would record the height to the system. In the future, when you want to adjust the vehicle to this height, press M1 or M2 button after you press the "front selection - rear axle" button. In the future, when you want to adjust the vehicle to this height, press M1 or M2 button after you press the "front selection - rear axle" button. WARNING Do not tamper with the rear suspension load detection sensor connections of your vehicle and do not have ECAS values changed. 4 OPERATION ECAS (Electronically Controlled Air Suspension) 4 Front Axle Height Adjustment Mechanism On vehicles with an automatic transmission: Front axle lifting system shall be deactivated when the ignition is switched off and vehicle shall be lowered to drive level. In this case, use care for the relationship of the parts of the vehicle approaching the ground with the surroundings. Front axle lifting system shall be deactivated when 30 km/h speed is exceeded and the vehicle shall automatically be adjusted to driving height An audible warning signal with a gong sound is heard and symbol is displayed on the indicators. When the rear axle lowered drive level control button is pressed, symbol is displayed on the indicator. This allows lowering of 5th wheel level by lowering the rear axle that is taken to drive level in ECAS manual control. Operating Instructions for Front Axle Height Adjustment Mechanism (Only for Vehicles that the height of the 5th wheel is lowered) Ignition switch should be in position 2 to activate the air control system by the "Lifting Switch". When the front axle lifting switch is pressed, front suspension bellows start to raise the front chassis of the vehicle. While the system is active, on vehicles with Manual transmission: An audible warning signal with a gong sound is heard. - 120 - OPERATION Air Suspension Mechanical Level Adjustment 32XX S Self Steering In Vehicles with Air Suspension CAUTION In reverse manoeuvres you should wait 8 to 10 seconds after the forward manoeuvre to allow the wheels turn in the opposite direction. CAUTION Do not perform a reverse manoeuvre when the gear is in neutral. In 32XXS four axle vehicles the second axle is self-steered and has an air suspension. This axle facilitates vehicle's manoeuvring by complying with the turn of the front axle in forward and backward manoeuvres. When the vehicle is shifted to reverse, the caster mechanism allows the axle to perform a backward manoeuvre by automatically adjusting the axle's caster angle. Additionally, the self-steered axle can be lifted by a control switch in the cab. - 121 - 4 OPERATION Tag Axles System description 4 Axle raising feature in 6x2, 8x2C and 8x2S Series trucks with mechanical suspension is controlled by the equipped AutoDrop (Automatic Axle Lowering) System. Axle positions are checked by the system in terms of vehicle safety and performance in case of driving conditions of your vehicle such as ignition on, park brake, vehicle speed conditions. Pressing the Button While Axle is Lowered If the system allows, relevant axle is raised, icon is displayed on the Function menu of the instrument panel and the light on the button is illuminated. Not allowed conditions: Park Brake In order to improve the performance of park brake, system lowers the tag axle if it is raised or does not allow it to be raised if it is already on the ground while the park brake is active. A warning message shall be displayed on the instrument panel in this case. Vehicle Speed Axle raising functions are cancelled for safety reasons if the vehicle speed is over 30 km/h. Axle raised is lowered again for traction assist. In this case, when the button is pressed to raise the axle, the axle positions do not change and a warning message is displayed on the instrument panel. WARNING This applies to tag axle only, it does not apply to self-steered axle. WARNING Air pressure available in the vehicle shall be over 6 Bars in order to release the park brake. If the system does not allow, relevant axle is not raised, warning message is displayed on the Information menu of the instrument panel and the light on the button is not illuminated. - 122 - Axle Weights When the vehicle is loaded over the limits allowed for axles loads, axle(s) which have been raised before are automatically lowered or if they are lowered, they are not allowed to be raised. System calculates the weights per axles as per the information taken from the sensors connected to the vehicle. Therefore, weight limits specified for each axle are controlled. OPERATION Tag Axles Therefore, you should avoid unstable loading of the truck in order to use the axle raising system better and to obtain a better efficiency. 4 System Error System has the feature to detect any faults that may occur in electronic components such as axle raising valves. In such a case, a warning message and the symbol are displayed, and the axles are brought to ground position for safe driving. Take your vehicle to an authorized workshop to have the fault repaired in such a case. Pressing the Button While Axle is Raised Unloaded Vehicle Condition (For 8x2S only) If the system allows, relevant axle is lowered, icon disappears from the Function menu of the instrument panel and the light on the button is turned off. If the system does not allow, relevant axle is not lowered, warning message is displayed on the Information menu of the instrument panel and the light on the button is not turned off. Not allowed conditions: In 8x2S vehicles, is automatically raised and not allowed to be lowered again in unloaded vehicle condition - until live and tag axles have been loaded up to 12 ton approximately in total - in order to improve the handling, braking and lifecycle performance of the self-steered axle. A warning message shall be displayed on the Information Menu in this case. Vehicle Speed Axle lowering functions are cancelled for safety reasons if the vehicle speed is over 30 km/h. In this case, when the button is pressed to lower/raise the axle, the axle positions do not change and a warning message is displayed on the instrument panel. - 123 - Axle Weights When the vehicle is loaded over the limits allowed for axles' loads, axle(s) which have been raised before are automatically lowered according to the loading amount and a warning message is displayed on the Information Menu. OPERATION Tag Axles To control these situations, system rejects the relevant requests and a warning message is displayed on the Information Menu. 4 WARNING Axle load limits are increased 30% up to a speed of 30 km/h to obtain a better traction during take-off. After a speed of 30 km/h, limits return to original values, so the system may activate and lower the axles! WARNING As shown in the figure, the tag axle shall not raised when the self-steered axle is on the ground, or the self-steered axle shall not lowered when the tag axle is raised. WARNING Sensor positions and maintenance System includes displacement sensors in order to send vehicle weight information to the Electronic Brake System (EBS). Positions of the sensors used for calculating the axle weights on the vehicle are shown in the figure. There are 4 sensors in total on the vehicle, these are 1 for each of right and left chassis arm on the tag axle, 1 for live axle crossmember connection and 1 for front axle right chassis arm. - 124 - Sensors are calibrated during production, do not tamper with sensor connections to ensure safe driving. Remember that brake system shall also be affected in this case. We recommend you to visually inspect the mechanical connections of the sensors in weekly intervals. WARNING Never raise the tag axle when the vehicle is loaded. OPERATION Tag Axles Steering Additional Axle Indicator Interface and Control Panel The status of the steering axle can be monitored during the steering additional manoeuvre via the trip computer functions screen and the information menu. When it is thought that the additional axle tires may be damaged by dragging against the pavement or an obstacle during the parking manoeuvre, the “additional axle centring” ( ) button on the control panel should be pressed in order to centre the additional axle. When the “additional axle centring” button is pressed, symbol will appear on the functions screen. After the vehicle has moved, the risk for the additional axle tires is eliminated. When the “additional axle centring” ( ) button is pressed again, the steering function will be activated and information screen. will appear on the When the warning “Rotatable rear axle has failed. Go to the service.” Comes up, a red symbol will appear. In this case, service intervention is required to rectify the fault. Steering Additional Axles Warnings A warning will be given on the information display for possible malfunctions of steering axle system. When the "rotatable rear axle is overheated" warning appears, a yellow symbol will appear. The warning will disappear when the system is expected to cool down without stopping the vehicle and making a steering action. When the warning “Temporarily disabled” comes up, a yellow symbol will appear. In this case, there is a possibility that the warning will disappear at the next contact engaging. If the yellow symbol and “Temporarily disabled.” warning continues, the vehicle should be taken to the service. - 125 - 4 OPERATION EBS-ESP CAUTION 4 ESP is an auxiliary brake system. Always remember that no system can change the physical laws. Driving safety is responsibility of the driver despite all auxiliary systems. EBS (Electronic Brake System) EBS (Electronic Brake Control) is an integrated braking system that includes sub-systems. 1- Braking power control: EBS control unit adjusts the braking power on the wheels automatically based on the information from the load sensor and the brake pedal travel applied by the driver. 2- Automatic braking power distribution between axles: EBS adjusts the braking power that will be applied to the axles based on the axle load. 3- ABS: ABS maintains steering control by preventing the locking of wheels during brakes. 4- Automatic Traction Control: Main purpose of this function is to prevent skidding of driven axle wheels. a) Braking power control: The speeds of the wheels of the driven axle are equalized by decelerating the skidding wheel by braking. b) engine torque is automatically limited to ensure that the vehicle moves stably. 5- Inertia torque control: Wheels may skid due to the engine inertia in slippery surfaces. Especially, when the transmission is downshifted and/or intarder is activated, wheels may have an inclination to skid. Inertia torque control system sends a signal to engine control unit and adjusts the engine torque to overcome the inertia of the engine. CAUTION Intarder may cause the vehicle to skid in slippery road conditions. 6- Emergency brake assist system: System senses the braking operation and increases braking power according to the pedal travel. - 126 - CAUTION Emergency brake assist cannot increase the maximum capacity of braking power. Vehicle shall be braked in the limits of maximum braking power. 7- Tilt prevention system: System senses the risk of tilting automatically when the brake is applied and decreases the braking power of front wheels and increases the braking power of rear axle. Thus, vehicle is prevented from tilting. OPERATION EBS - ESP ASR Deactivation Mode: 4 You may want to disable ESP on soft road conditions. In this case, press the ESP cancel switch located in the centre console. light is illuminated on the display when this mode is active. - 127 - OPERATION Differential Lock 4 What is differential lock? Engagement of the differential lock Differential lock is a system that increases the capacity of transmission of power to the surface. Lock gear is consists of the yoke that moves the gear and an air operated piston. Engine torque transmitted to the left and right sides of the vehicle and wheel speeds are equalized when the differential lock is engaged. Activate the differential lock in bad and slippery road conditions where high and stable traction power is required. 1) Activate the differential lock before running into worsening road conditions. Ensure that the road is not slippery and any wheel is not skidding or slipping. Ensure that the wheels are not on slippery surface and stop the vehicle completely. Engage the differential lock button(s) in the instrument cluster. 4x2, 6x2 and 8x2 vehicles have optional one differential lock; 6x4 and 8x4 vehicles have front differential locks (FDL), rear differential locks (RDL) and inter-axle differential locks (IADL) as standard. On X2 vehicles, light will be illuminated on the instrument panel when differential lock is engaged, and a warning buzzer shall sound if available. On X4 vehicles both FDL light and RDL light will be illuminated when differential lock is engaged and a warning buzzer shall sound if available. - 128 - CAUTION If the differential lock is not used properly, there is a risk of heavy damage to the differential unit and/or a serious risk of accident. Differential faults caused by using improper use of differential lock are out of warranty cover OPERATION Differential Lock The points to be considered when the differential lock is activated: If required, the differential lock shall be engaged prior to go through the rough surface at the required distance and its engagement and disengagement shall be monitored via the illuminated warning sign on the instrument cluster. Vehicle may move outward of the curve in turns while the DCDL is completely activated. Do not use differential lock on paved roads, and never perform turns when the locks are engaged. When turning, make sure the differential lock is disengaged. Otherwise the differential of your vehicle may be damaged severely and you may have to call for AAA. The maximum speed shall be 20 km/h when differential lock is engaged. Deactivating the differential lock: 1. When it is safer to drive above certain speeds as soon as road conditions become normal, differential lock must be deactivated. Vehicle shall be stopped and differential lock shall be disengaged after making sure that the vehicle moved far away from the slippery surface. Ensure that the wheels are not on slippery surface first and stop the vehicle completely. 2. Deactivation of the differential lock is performed when the warning light on the instrument panel is turned off and this may take about 500 meters sometimes. Turn the differential lock switch(es) on. Drive the vehicle very slowly by applying the accelerator slowly to deactivate the differential lock. 3. The differential lock will disengage once the illuminated warning sign on the instrument cluster and the warning buzzer, if any, will stop. 4. You can continue driving observing the legal speed limits according to flow of the traffic. - 129 - CAUTION Vehicle should always be decelerated in sharp curves, and it is advised that the differential lock is deactivated in sharp curves. User is informed by buzzer on that differential lock is activated. CAUTION Deactivate the differential lock when driving the tractor vehicles down the slopes. Trailer may be folded due to the loss of the vehicle dynamics. 4 OPERATION Differential Lock Usage of the driver controlled inter-axle differential lock (IADL): 4 Ford-Otosan Inter-Axle Differential Lock (IADL) is driver controlled system operated by the pressurized air; it allows that the traction torque is distributed evenly to the front and rear axles and ensures that the axles speeds are equal. WARNING IADL shall be disengaged in standard road conditions i.e.when the tyres are not slipping. Activate all differential locks to evenly distribute the traction to the front and rear axles in slippery and snowy road conditions. Deactivate the IADL when the vehicle is returned to normal road conditions. It is available on 6x4 and 8x4 models only. IADL button is on the centre instrument cluster. It is also known as "Interdifferential power distributor" or "3rd differential". - 130 - OPERATION Lane Departure Warning System WARNING LDWS is only a warning system and does not interfere with dynamics of the vehicle. Always drive attentively and do not try to test the system on the road. LDWS will not warn if emergency lights are active LDWS will not warn if LDWS warning lamp is constantly on, meaning that system is not active due to driver deactivation or an error. In order not to get lane departure warnings for the intended lane changes, always operate turn signal to the direction of lane change. The system does not relieve you of your responsibility to drive with due care and attention. At all times driver is responsible for controlling your vehicle, supervising the system and intervening if required. The sensor may incorrectly track lane markings such as other structures or objects. This can result in a false or missed warning. In cold and severe weather conditions the system may not function. Rain, snow, spray, worn or dirty lane markings and large contrasts in lighting can all influence the sensor. The system may not operate in areas during roadwork construction. The system may not operate on roads with sharp bends or narrow lanes. Do not carry out windshield repairs in the immediate area surrounding the sensor. The system may be impaired or may not operate properly if: • Visible lane markings are not continuous • There is glare due to oncoming traffic, direct sunlight or reflections or from wet surfaces • Front camera visibility is low due to insufficient road illumination or due to snow, rain, fog or heavy spray - 131 - • Lane markings are not detected due to vehicles driving in front • The part of the windscreen where front camera is located is dirty, misted up, damaged or covered • No lane markings or several ambiguous lane markings are present, i.e.lanes branch off, cross or merge Note: The system may assist you when driving on fast main roads and freeways. Note: The system may operate with a minimum of one tracked lane marking. Note: The system may only operate above vehicle speeds of approximately 60km/h. Principle of operation Lane Departure Warning System sensor is located behind lower part of the windscreen. It continuously monitors conditions to alert the driver of unintentional lane drifting at high speeds. Once vehicle speed is above 60kph, if there are visible lane markings on each side of the road, lane markings may appear on the LDWS page of the cluster display showing that system is active and ready to warn. 4 OPERATION Lane Departure Warning System vehicle is once again fully within the lane markings. 4 LDWS icon on cluster display Warnings consist of audible and visual warnings with spatial indication about the direction of unintended drift of the vehicle. In order to make the warning more audible, system mutes radio and stops the blowers of air conditioning system until the end of the warning. • If unintended lane departure is detected from left lane marking, LDWS page, shown in the figure above, will popup with a blinking left lane marking, a blinking LDWS warning lamp and an intermittent warning sound coming from left hand side will be activated. • If unintended lane departure is detected from right lane marking, LDWS icon shown above will pop-up with a blinking right lane marking, a blinking LDWS warning lamp and an intermittent warning sound coming from right hand side will be activated. Once LDWS has issued a warning, further warnings will only be issued when the Switching the System On and Off When the ignition is turned ON, LDWS will be automatically active unless there is no error. To switch off, press the LDWS button . Then, LDWS warning lamp will light up constantly on the instrument cluster. To switch the system back on, press the LDWS button once again and visually verify that LDWS warning lamp on the instrument cluster turns off. The system is configured to warn on unintended lane departures only. Driver's awareness of the situation is monitored via driver inputs listed below. If these driver inputs explicitly show that there is an attentive driver, lane departure warnings are suppressed. • Rate of lane departure, i.e.how fast is the lane being departed • Brake pedal usage • Steering wheel turning rate, i.e.how fast the steering wheel is turned • Direction indicator activation for the side lane being departed - 132 - Note: If the left / right turn signals are active for a minute longer, these signals will not prevent the system from giving a warning LDWS on/off switch Note: In case camera vision is obstructed, driver may get below message on the cluster display. Front Camera Low Visiblity Clean Screen Note: The message above is a clear indication that the sensor view is obstructed in a way that LDWS operation is negatively affected. OPERATION Lane Departure Warning System Note: LDWS may get deactivated due to blockage, illuminating the LDWS warning lamp constantly. When the message above is seen on the cluster display: Note: If LDWS warning lamp gets constantly illuminated and stays illuminated for a long time, there may be an error in the system, causing deactivation. • In case camera vision is obstructed due to heavy rain or snow, try to activate wipers at a correct speed or activate Auto-Wipe feature to enhance LDWS performance. • In case windscreen is dirty, activate the washer to remove the dirt. • In case windscreen is misted up, turn on the defrosters to remove the mist on the windscreen. Note: If the information message below appears on the cluster display, this means LDWS needs to be inspected by an authorized Ford Trucks Service, and LDWS will not be available till the inspection. Front Camera Malfunction Service Required - 133 - 4 OPERATION Emergency braking system Advanced Emergency Braking System 4 Principle of operation If your vehicle is rapidly approaching another stationary vehicle or a vehicle traveling in the same direction as yours, and if the Advanced Emergency Braking System (AEBS) detects that a rear end collision situation gets imminent with a motor vehicle ahead, the system is designed to provide two levels of functionality: 1. Collision warning 2. Emergency braking Collision Warning: If the system determines that a collision is imminent, AEBS warning lamp flashes, an intermittent warning tone sounds, and a warning message pops-up in the information display. In order to make the warning more audible, system mutes radio and stops the blowers of air conditioning system until the end of the warning. If the system detects that you still do not take control of your vehicle to avoid the accident and collision is still found to be imminent, AEBS may apply partial braking along with acoustical and optical warnings to further draw your attention. Emergency Braking: If the collision is still found to be imminent, the system may apply full braking to reduce the impact damage or avoid the crash completely. Note: AEBS is not active if you are driving below 15kph. Note: AEBS will not warn or brake if the relative speed between your vehicle and the lead vehicle is below 10kph. Note: Deactivation of the ESP feature via the ESP switch will deactivate the AEBS as well. WARNING Note: If the AEBS warning lamp is constantly ON, this means either system is deactivated by the driver, or AEBS shut off due to an error. In this case, AEBS is OFF. The system will not warn or intervene. WARNING If you receive an AEBS warning, which means a rear-end collision is imminent, always apply brakes yourself to avoid the accident and try to take evasive action. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. - 134 - AEBS visual warning on cluster display AEB System is a collision avoidance system. However, AEB System is not a substitute for safe and attentive driving. AEB system has its own limitations for certain traffic scenarios. Note that AEB system might not work in all conditions as expected. The system does not relieve you of your responsibility to drive with due care and attention. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. AEBS is not able to guess other drivers' intentions. Always maintain a safe distance with the vehicle in front of you. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. OPERATION Emergency braking system AEB system is designed to provide active driver assistance to avoid rearend collisions or mitigate the effects of a possible collision in real traffic situations in certain frontal collisions only. AEB System may not always recognize a collision situation and/or may not be able to avoid an accident. AEBS is neither designed to recognize complex traffic situations, nor to avoid all kinds of accidents. It is your responsibility to drive carefully at all times. Always pay careful attention to the traffic situation and be ready to brake. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. The system does not react to cyclists, motorcyclists, pedestrians, animals or vehicles that are driving in a different direction. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. AEBS is not designed to avoid accidents against stationary vehicles. AEBS may only reduce the effect of a rearend accident with stationary vehicles on certain conditions. The system may not operate when driving around sharp curves and wavy roads. Failure to take care may lead to a crash or personal injury. The system may or may not operate or may operate with reduced function during cold or severe weather conditions. Snow, ice, rain, spray and fog can influence the system. Keep the front camera and radar free of snow and ice. Failure to take care may result in the loss of control of your vehicle, serious personal injury or death. The system may not operate correctly if you replace the windshield with a non-Ford windshield. Do not carry out windshield repairs in front of the sensor. Failure to adhere to this warning may lead to an accident or injury. If something hits the front end of your vehicle or damage occurs, the radar sensing zone may change. This could cause missed or false vehicle detections. Contact an authorized dealer to have the radar checked for proper coverage and operation. The system may not detect objects with surfaces that absorb reflections. Failure to take care may result in the loss of control of your vehicle, serious personal - 135 - injury or death. System performance may reduce in situations where the camera's detection capability is limited. These situations include but are not limited to direct or low sunlight, vehicles at night without tail lights, narrow vehicles and unconventional vehicle types. Do not rely on this system to replace driver judgment and the need to maintain distance and speed. AEB System effectiveness depends on many factors, such as speed, driver input, incremental precipitation, lead vehicle behavior, your vehicle's state and road conditions AEBS may not work as expected if your vehicle is not inspected by Ford Trucks Service on regular maintenance checks. It is driver's responsibility to switch off the AEB system during being towed via AEBS deactivation switch. Otherwise, AEBS may warn and/or brake unexpectedly. AEBS shall be turned off by the driver while driving off road. 4 OPERATION Emergency braking system How to maintain Advanced Emergency Braking System? 4 Note: If a message regarding a blocked radar sensor is shown in the information display, the radar signals are obstructed. The radar sensor is located behind a fascia cover integrated to the middle-bottom of the upper grille. With obstructed radar, the Advanced Emergency Braking System does not function and cannot detect a vehicle ahead. Note: If something hits the front end of your vehicle or damage occurs, the radar sensing zone may change. This could cause missed or false vehicle detections. Contact an authorized dealer to have the radar checked for proper coverage and operation. Note: It is driver's responsibility to keep the radar sensor behind the front grille clean. Make sure that cover of the radar sensor is free of mud, packed snow or any other foreign object. Note: Do not mount any attachments in front of the radar sensor. Do not cover or paint the cover of the radar sensor. Any modification on the cover of the radar sensor could cause AEBS failure or reduced functionality. Front Camera Low Visibility Clean Screen Camera sensor blockage message AEBS usage with trailers: WARNING Front Radar Sensor Blocked, See Manual. Radar sensor blockage message the camera. Have any windshield damage in the area of the camera's field of view repaired. Radar location to be kept clean Note: If a message regarding low camera visibility is seen in the information display, camera sensor view is obstructed. With the front camera obstructed, AEB System function may reduce or get deactivated. It is driver's responsibility to keep the windscreen area clean where camera sensor is located to maintain full functionality. Make sure that there are no stickers or sun blocking films on the windscreen blocking the field of view of - 136 - After connecting a new trailer to your vehicle, if ignition is already ON, you shall turn the ignition OFF and ON to get a fully functional AEBS. AEBS will get deactivated if a trailer without ABS/EBS or with a faulty ABS/ EBS is detected. AEBS usage is restricted to vehicle combinations with one trailer only. It is driver's responsibility to switch off the AEBS when more than one trailer is connected to the vehicle. OPERATION Emergency braking system Switching the System Off and On Note: AEBS will be automatically ON everytime ignition is turned on, if there is no error detected by the system. Note: To deactivate or activate the AEBS, press the AEBS switch on the dashboard shown in the figure below. When switched off, AEBS warning lamp on the instrument cluster will light up. To switch the AEBS on again, short press AEBS switch. In this case, AEBS warning lamp will turn off to show that AEBS is operational again. AEBS deactivation switch Why AEBS warning lamp may be constantly ON? • You may have switched off the AEBS via AEBS switch. • ESP may be switched OFF. • If something hits the front end of your vehicle or damage occurs, the radar sensing zone may change. This could cause missed or false vehicle detections. Contact an authorized dealer to have the radar checked for proper coverage and operation. In such a case, AEBS malfunction may be displayed on the information display as shown below. • If system emergency braking occurs two times in one ignition cycle, AEBS will get deactivated to prevent possible unnecessary interventions. In such a case, visit an authorized Ford Trucks Service to activate the system. AEBS Malfunction Service Required • There may be temporary or permanent errors on other components of the vehicle that cause the AEBS to be automatically deactivated. If the AEBS - 137 - warning lamp stays illuminated constantly for a long time, visit an authorized Ford Trucks Service. This may mean that AEBS is deactivated due to an error in the system. How to override an AEBS intervention AEBS may warn and brake even if the traffic situation is not dangerous. Be prepared to suppress the AEBS. You can suppress an AEBS warning or stop an ongoing AEBS warning, if you: • use left/right turn signal • depress the brake pedal • depress the accelerator pedal • press the AEBS deactivation switch You can abort an AEBS triggered emergency braking intervention, if you; • depress the accelerator pedal beyond the pressure point (kick down) • press the AEBS deactivation switch 4 OPERATION Emergency braking system 4 If you are brought to a halt via an AEBS triggered emergency braking, AEBS will keep the brakes until you override by; • depressing the accelerator pedal or • pressing the AEBS deactivation switch. WARNING Important Note: In such a situation, take control of your vehicle and make sure that you activate the parking brake before leaving your vehicle. Take all necessary safety measures to secure yourself and your vehicle. - 138 - USE OPERATION Useful Information CAUTION! PLEASE HAVE IT CALIBRATED IN AN AUTHORIZED DEALERSHIP SPECIFIED IN THE TACHOGRAPH MANUAL PROVIDED - 139 - 4 4 USE OPERATION Useful Information • You have made an excellent choice by purchasing a Ford Trucks vehicle. Congratulations. • Please consider the following points and read this manual to obtain best performance and service life from your vehicle. 4 4 1. Air and oil filters • Replace the air filter element when air filter warning light is illuminated inside the cab. Always refer to the warranty and service manuals for the main filter element replacement intervals. • Use oil and air filters approved by Ford Otomotiv Sanayi only. 4. Injector pump • Injector pump available in your vehicle is completely adjusted and sealed in factory. • Do not let tampering of injector pump by any other workshops other than authorized dealerships. 2. Adding oil • Do not add oil until the oil level is reduced to min.line. • Never add oil over the max.line. • Add oil to the engine when the oil level warning light is illuminated. 3. Engine • Do not increase the engine speed until oil pressure is increased after starting. • We advise you to operate your vehicle in the green zone tachometer to obtain best traction. (1050-1600 rpm) • Operate your engine at idle for 1 minutes before stopping the engine in order to allow continued lubrication of the turbocharger unit. • We advise you to use the vehicles with automated transmissions in automatic mode as much as possible. 5. Wheel nuts • Your vehicle is equipped with a system that prevents starting of the engine while transmission is shifted to a gear. • Always observe starting instructions provided in the manual • Have the wheel nuts tightened to the specified torque values after 500 km from the first loading point of your vehicle. This operation should be repeated after each nut removal. (750 +-50Nm) - 140 - USE OPERATION Useful Information 6. Wheel alignment 10. Upper bed • Do not lower the upper bed while the vehicle is moving. • Have the front alignment adjustment of your vehicle checked, and have it adjusted by service support if needed in the first 1000 to 5000 km. 11. Refuelling • Turn off the auxiliary cab heater before refilling fuel. 7. Braking system • Drain the water in the air tanks every day. 8. Differential lock • Contact authorized dealership when the differential lock warning lamps is illuminated while the differential lock switch is not pressed. The maximum speed shall be 20 km/h when differential lock is engaged. 12. Tyre pressures • Your vehicle is provided with low tire pressures from the factory. Adjust tire pressures according to the tire pressure values given in the manual before first loading. 9. Cab lift • Ensure that park brake is applied, transmission is in neutral and hood is open before lifting the cab. - 141 - 4 4 OPERATION USE Useful Information 4 4 When your engine has been idling for a long time, smart engine off system warns you 30 seconds before turning off the engine and informs you about the fact that the engine is being turned off when a predefined time period has expired in idle with the smart engine off feature. All you need to do to prevent engine from being turned off is to press any of the clutch, brake or accelerator pedals within this period. Thus, you shall deactivate this feature until you restart the engine when you do not want your engine to be turned off. Other conditions when this feature is automatically deactivated is as follows: • When engine speed control applications (for example: PTO) are operated • When the park brake is not applied • When DPF regeneration is activated • This feature would provide significant fuel saving and you shall enjoy the privilege of being a Ford Trucks owner. You may increase or decrease the idling speed using speed control buttons when your vehicle is stationary. All you need to do is to bring the speed control handle to "resume" position and to activate this feature. After that, you shall simply decide at what speed the engine will run using "Set +" or "Set -" buttons. You may also use this feature in PTO applications, too. Thus, you can set the engine speed to the optimum point in various load conditions and obtain the highest efficiency from the PTO. PTO applications are used in mixer vehicles, concrete pumps and in many other similar vehicles today. It is very easy to operate or turn off the engine or control the engine speed remotely by a remote control with a similar special applications in vehicles such as concrete pump. Thus, remote operation is possible without requiring the operator to work inside the vehicle. In emergency conditions, you may deactivate the engine speed control by using the "off' position in speed control or by pressing the clutch or brake pedal as specific to application. - 142 - MAINTENANCE AND SERVICE MAINTENANCE AND SERVICE Attaching and Detaching a Trailer 5th Wheel (Platform) - Attaching the Semi- Trailer (for 5th wheels of SAF HOLLAND brand) (see Figure 1 and Figure 2) 4-Position the vehicle so that there is a clearance of 20 to 50 mm between the bottom of the semi-trailer and the 5th wheel platform (see Figure 1) Set plate Figure-5 5 Figure-1 1- Block the wheels of the semi-trailer. 2- Check that 5th wheel lock is open. The port for the semi-trailer pin should be open. (see Figure 1) Figure-3 5-Lift 5th wheel with the help of the air suspension until the semi-trailer is slightly raised. (see Figure 3) Safety Lever 7- Get off the vehicle and visually check that 5th wheel lock has fully engaged. If the lock is fully closed, the safety lever should be in the upper position and the small adjustment plate on the lock lever should contact 5th wheel platform. (see Figure 5 and Figure 6). As shown in Figure 6, the latch on the safety lever should be in the upper position. Set plate Safety Lever Latch Safety Lever Figure-2 3-Position the truck in front of the semitrailer. Figure-4 6- Reverse the vehicle slowly until 5th wheel coupling engages. (see Figure 4) The spring safety lever should return to its original position automatically. (see Figure 5) - 144 - Figure-5 MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Trailer Pin Lock Jaw Figure-7 8- As shown in Figure 7, carry out the visual check for fully locking in order (A, B, C). Check A: Check the safety lever, the latch on the safety lever and the adjustment plate. The safety lever and the latch on the safety lever should be in the position shown in Figure 7-A. Check B: There should be no gap between the semi-trailer and 5th wheel. Check C: The Locking Jaw should cover the semi-trailer pin securely. CAUTION If any of the above conditions are not met, restart the entire locking procedure from the 2nd step. The starting test is not sufficient for secure locking. Visual checks should be performed. If the locking procedure is not completed successfully, a secure connection cannot be made (see Figure 9). The tag on the lock lever should be checked during visual checks. Figure-9 10- Connect the supply lines and connection cables between the truck and the semi-trailer. 11- Complete the procedure for attaching the semi-trailer as per the instructions of the vehicle manufacturer. CAUTION Figure-8 9- Perform a starting test. Apply the brakes of the semi-trailer and start the truck at low gear; the semi-trailer should not be detached. Attach the cables in such a manner that the pressure air and hydraulic hoses are not tense, they are not bent or rubbing and the canopy can easily follow the trailer in curves, etc. Pay attention to the voltage of the consumers on the semi-trailer before - 145 - connecting the cable. 5th Wheel (Platform) - Detaching the Semi-Trailer (for 5th wheels of SAF HOLLAND brand) 1- Park the vehicle on flat and solid ground. 2- Secure and support the semi-trailer as per the instructions of the vehicle manufacturer. 3- Disconnect the supply lines and connection cables between the truck and the semi-trailer. 4- Unlock the 5th wheel lock with the opening lever, (see Figure 10-11) Figure-10 5- Press the safety lever down with your thumb -Arrow 1- and rotate the unlocking handle counter-clockwise - Arrow 2-. Extract the unlocking handle fully - Arrow 3- and attach the part near 5th wheel platform. At this point, the adjustment plate should not contact 5th wheel platform, there should be a gap between them. (see Figure 10). 5 MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Note: Once the 5th wheel lock has been unlocked, the locking lever is ready to be slid inside again automatically (the unlocking lever can be slid inside), (see Figure 13) 5 Figure-11 6Make sure that the locking jaw is fully open for attaching/detaching the semi-trailer pin and the locking lever can be slid inside. (see Figure 11) Figure-13 Note: Figure 13 shows the unlock position for the locking lever. At this point, the adjustment plate is away from 5th wheel body and the safety lever is down. Figure 14 shows the closed position of the lock. At this point, the adjustment plate is contacts 5th wheel body and the safety lever is up. CAUTION If there is a damage/flexion on 5th wheel locking lever and the safety lever, visit the workshop and do not attempt to attach a semi-trailer; a secure connection might not be established. Check all parts for wear/corrosion/ damage. 5th Wheel (Platform) - Attaching the Semi-Trailer (for 5th wheels of JOST brand) 1- Block the wheels of the semi-trailer. Figure-12 7- Drive the truck away from the semitrailer slowly and straightly. (see Figure 12). 8- Complete the procedure for detaching the semi-trailer as per the instructions of the vehicle manufacturer. Figure 13) Figure-14 - 146 - 2- Pull the platform locking lever, the port for the semi-trailer pin will open. MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Lower the legs of semi-trailer so that they are on the ground. Disconnect the brake connections and wiring. Trailer brake Reverse the vehicle until the trailer king pin is engaged on the seat on the 5th wheel. Spring release lever will return to its original position. 5 CAUTION Attach the cables in such a manner that the pressure air and hydraulic hoses are not tense, they are not bent or rubbing and the canopy can easily follow the trailer in curves, etc. Pay attention to the voltage of the consumers on the canopy/ the trailer before connecting the cable. Detaching the Semi-trailer Detaching the Semi-trailer 1- Block the wheels . 2- Pull the 5th wheel (platform) lock lever. 3- Drive the vehicle so that it will leave the trailer. CAUTION If there is a damage/flexion on 5th wheel locking lever, visit the workshop and do not attempt to attach a semitrailer; a secure connection might not be established. Check all parts for wear/corrosion/ damage. - 147 - Eases the trailer connection or disconnection operation by braking the trailer while connecting the vehicle to the trailer or disconnecting it from the trailer Attaching the Semi-Trailer: 1- Bring the vehicle close to the trailer at a distance where you can install the air hoses and connect the air hoses of the trailer and vehicle. MAINTENANCE AND SERVICE Attaching and Detaching a Trailer 2- After performing the air connections, press the trailer brake switch on the center console of your vehicle, trailer brakes shall be active when you press the switch. 3- Then, perform the connection by aligning the 5th wheel (tray) of the vehicle to the trailer connection pin. 5 If the icon on the display is illuminated, this means a fault in the system. CAUTION System shall not be activated when the button is pressed below 8 km/h. A Dimmed light on the semi-trailer switch is illuminated continuously is for control purposes. A yellow light shall be illuminated when the switch is pressed. CAUTION Remove the rear fender upper part when you use the vehicle with a semi-trailer. In case of adding or not subtracting functions to the trailer connectors; check that the gasket which provides leak tightness in trailer connectors is fitted correctly in place. Ignition shall be turned off when the electrical connection of the trailer is performed. Greasing (for 5th wheels of SAF HOLLAND brand) - 148 - The surface of the platform should be greased with a sufficient quantity of durable, high pressure grease containing MoS2 or graphite additives prior to the first attachment of a trailer. Without detaching the semi-trailer, grease through the nipple near the platform regularly at every 10.000 km. • Clear the used grease on the surface with a scraper before each lubrication. • However, the greasing periods should be adapted to the relevant operating conditions; shorter or longer intervals are possible. Greasing (for 5th wheels of JOST brand) At every 10,000 km: Apply grease from the grease fitting on the side of the 5th wheel (platform) without detaching the trailer. Every 50,000 km for vehicles used in normal operating conditions. MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Every 25,000 km for vehicles used in heavy operating conditions Detach the semitrailer. Remove the grease on 5th wheel (platform) and king pin. Apply grease to the areas shown with yellow color on the illustration. WARNING Upper part of the live axle fender with 3 parts is advised for operation without trailer. The upper part shall be removed when the vehicle is operated with trailer and during the removal/installation manoeuvres of the trailer to the vehicle. FORD OTOSAN will not be responsible for any damages to occur in the upper part during use with a trailer. WARNING Attach the cables in such a manner that the pressure air and hydraulic hoses are not tense, they are not bent or rubbing and the canopy can easily follow the trailer in curves, etc. Pay attention to the voltage of the consumers on the canopy/trailer before connecting the cable. A 15 – 15 pin connector shall be used in vehicles with ADR. Contact Authorized Workshop when you want to install Trailer Axle Lifting function on the vehicle. Connection of a Trailer WARNING CAUTION Always have the brake compatibility test performed at an Authorized brake test center that is capable of taking compatibility graphics. CAUTION If you shall connect a Trailer to your vehicle for the first time, have a brake compatibility test performed to prevent a brake force difference due to the difference of the systems. Otherwise, braking system of the Tractor or trailer may overheat and as a result, the life cycle of the system components may be reduced. In tractor vehicles, the distance between lower side of the stop lamp on the rear left fender and upper side of the license plate's sheet plate should be 40 mm. - 149 - 5 MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Trailer Tractor Vehicles - Coupling Coupling (Rear Drawbar Coupling) is placed on the chassis rear cross and it shall be used together with the trailer tractor with rotating table (Fig.1) Ford trailer tractors use different types of couplings. 5 Figure-1 CAUTION The engine of your vehicle is designed to operate with EURO DIESEL complying with EN590 standards. Thus, usage of cheap diesel fuel causes a high risk for the function of the engine and its components. Use of bad fuel known as cheap fuel oil Opening lever Plastic cover Figure-3 VBG 8500 Brand Coupling, Rubber Brace and Rubber Brace Description Label Coupling opening lever and the plastic cover to the right of the coupling is shown in Fig.4. Rubber brace and rubber brace description label on the front face of the coupling is shown in Fig.5 and Fig.6. Figure-2 - 150 - Figure-4 VBG 8500 brand couplings, shall be used with the rubber brace couplings delivered as installed on the component. Rubber brace has a hole on one end and the other end offers a handle and a slot. (See Figure -5) MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Slot Hole area Handle Figure-5 Figure-6 Connecting the coupling - For Coupling with VBG 8500 Brand 1. Rubber brace of the coupling is delivered as installed under a plastic cover on the right-hand side of the coupling ex factory as shown in Fig.7. 2. There is a rubber brace description label affixed on the front face of the coupling (See Fig.6). Position No.; 1 and 2 can be seen on the label. Position No.1 indicates the position of the rubber brace when the coupling is open and Position No.2 indicates the position of the rubber brace when the coupling is closed. 3. If the brace is not installed under the plastic cover on the right hand side of the coupling, it shall be installed again. Remove the plastic cover on the right hand side of the coupling for this purpose (See Fig.6 and Fig.7) 4. Engage the holed area of the rubber brace to the pin under the cover and push the rubber brace down to the end of the pin (See Fig.7). 5. Install the plastic cover back (See Fig.7, Position No.1) - 151 - Figure-7 6. Perform the automatic locking of the trailer drawing eye and the coupling while the rubber brace is installed under the plastic plug. Small pin on the side of the locked coupling enters its seat after locking. A visual inspection shall be performed. Additionally, the larger pin that enter the drawing eye of the coupling shall be visually inspected, too (See Fig.7) 5 MAINTENANCE AND SERVICE Attaching and Detaching a Trailer 5 Figure-8 7. After locking the coupling with the drawing eye, put the rubber brace released on the right hand side of the coupling under the coupling carefully (See Fig.6, Position No.2) 8. Hold the rubber brace from its handle and place the slot on the brace to the end of the opening lever of the coupling and push it to the end (See Fig.6, Position No.2). 9. Opening the coupling - For Couplings with VBG 8500 Bran 10. After stopping the vehicle and cancelling the trailer air/power connections, remove the coupling from the opening lever first by pulling it out from rubber brace slot handle installed on the coupling. After removing the rubber brace from the opening lever, open the coupling by rotating the coupling opening lever (See Fig.9). When the coupling is opened, the small pin on the left hand side of the coupling moves out of its slot automatically as shown in Fig.9. A visual inspection shall be performed. Then, check if the coupling lock pin is opened or not, too. Thus, the coupling shall be completely open. Leave the rubber brace at Position No.1 on Fig.6. Figure-6 - 152 - Figure-9 CAUTION Refer to the parts manual for lubrication and wear details of all coupling types. Refer to the parts manuals to connect and open the couplings of all models in addition to the information given here. MAINTENANCE AND SERVICE Attaching and Detaching a Trailer Connecting the coupling - For Couplings with Ringfeder Brand (4040 and 5050) Opening the coupling - For Couplings with Ringfeder Brand (4040 and 5050) A drawing eye installed to the coupling with an open lock pin in order to lock the Ringfeder coupling. Coupling closes automatically. Locking is inspected visually, check if the lock pin of the coupling is inside the drawing eye. Small pins on the coupling shall enter inside after the locking of the coupling. A visual inspection shall be performed. Open the opening lever of the coupling and see if the small pin on the coupling comes out automatically to open Ringfeder couplings. A visual inspection shall be performed. Also visually inspect if the coupling lock pin is completely opened or not, too. Remove the drawing eye (See Fig.10). Figure-11 Figure-10 - 153 - 5 MAINTENANCE AND SERVICE Fuel Quality and Refueling Fuel Tank We advise using Euro Diesel (complying with EN 590 standards) to prevent any problem on the fuel system. CAUTION Do not mix petrol in the fuel tank. 5 Original steel and aluminium fuel tanks approved by Ford Otosan should be used in Ford Trucks vehicles. Using third party fuel tanks other than the tanks designed and test by Ford Otosan may render the warranty void for any fault on the fuel injection system and the vehicle. CAUTION The engine of your vehicle is designed to operate with EURO DIESEL complying with EN590 standards. Thus, usage of cheap diesel fuel causes a high risk for the function of the engine and its components. Usage of bad quality fuel, also known as cheap diesel fuel, reduces the power of our engines and shortens their service life. Fuel Tank Flap (lockable) CAUTION Paraffin forms in the cold weathers in fuels without any precautions. Paraffin not only clogs the filter elements, but also clogs the fuel pipes. It is very difficult to melt the paraffin once it is formed. Therefore, winter type diesel fuel should be used in the areas where the weather is always cold in winter. Tractor vehicles Ford Fuel tank flap opens counter clockwise in a single action in single-stage. The flap returns to the position where you will lock it in a single action in single-stage when turned clockwise. Cleaning of the fuel tank is essential. Wipe the flap and surroundings without opening the fuel filler flap. - 154 - An aluminium fuel tank is available on the right of the vehicle. Vehicles with double tanks have auxiliary fuel tanks on the left. MAINTENANCE AND SERVICE Fuel Quality and Refueling Spark Arrester Spark arrester shall be installed at hazardous material loading, unloading locations and fuel stations during fuel filling or draining. When the vehicle is out of the station, the spark arrester shall be removed. Put on a pair of gloves before installing spark arrester as the muffler is hot. Hook the spark arrestor from its clips to the hangers in the muffler. Close the clips and retain the spark arrestor to the exhaust. CAUTION Put on a pair of gloves before removing spark arrester as the muffler and spark arrestor is hot. The spark arrester is removed from the exhaust pipe by loosening the brackets on it. Spark arrester shall be cleaned by water jet to cleanse its pores after every 25 uses. Urea system is sensitive to dirt, dust and soil. During urea filling, ensure that dirt, dust or contaminants do not go in the urea tank. - 155 - 5 Various sensors and urea injector shall be available on the exhaust muffler. (On Eu5 vehicles the urea injector is on the exhaust pipe) When you wash your vehicle, do not apply water jet on the urea injector on the muffler, sensors and the electric connections. DOC, DPF and SCR catalyst are available in the exhaust muffler. These parts are ceramic-based bricks, and it is definitely not allowed to wash these parts. Do not attempt to wash inside the muffler from the muffler outlet or from the injector housing by removing the urea injector. MAINTENANCE AND SERVICE Cleaning of Exhaust Filter Cleaning of Exhaust Filter 5 The exhaust filter retains the smut coming from the exhaust gas and decreases the emission values. With the exhaust filter cleaning operation which can be performed automatically or manually, the smut retained in the filter is burned with regular intervals so that the filter is emptied before filling up and being clogged. In this operation, the exhaust gas is heated by the engine and smut is burned. Driver is informed about the exhaust filter cleaning of the vehicle through the messages displayed on the indicator panel and explained in detain in the following sections WARNING Since the exhaust gas temperature is high during the exhaust filter cleaning; ensure that the vehicle is not in the same place with flammable (dry grass, leaves), inflammable and explosive materials or in enclosed space Otherwise, fire risk may occur. WARNING Ensure that vehicle exhaust cleaning is not performed in locations like hazardous material loading and unloading places or fuelling stations. When necessary, activate the exhaust filter cleaning blocking using exhaust filter cleaning prevention button. WARNING During exhaust filter cleaning and right after the cleaning; a metallic smell or crackling sounds may come out of the exhaust side. Automatic Cleaning of Exhaust Filter Exhaust filter cleaning requirement is automatically determined according to the amount of soot accumulated in the filter, the distance the vehicle has travelled, amount of fuel consumed and the engine running hours. In this case, exhaust filter cleaning starts automatically. During the automatic filter cleaning process, the instrument panel shall display green coloured exhaust filter cleaning symbol. When this symbol is displayed, vehicle should be driven normally. When the fill rate of exhaust filter exceeds 100%, 9th level of the graphic shall start to flash. You may continue normal operation of your vehicle in this case. Optionally, you may perform a manual exhaust filter cleaning on your vehicle. When the last level of the graphic is filled, final 2 levels of the graphic shall start to flash. In this case, your vehicle is prevented from performing an automatic exhaust filter cleaning to protect the exhaust filter. You shall have a manual exhaust filter cleaning performed as soon as possible. If the graphic does not go below 10th level after a manual exhaust filter cleaning operation, you shall take your vehicle to the service. Exhaust Information WARNING When you see the Exhaust filter cleaning symbol, you should continue driving normally; there's no need to idle the vehicle and wait. WARNING Fill rate of the exhaust filter is shown in the graphic available on ‘Exhaust Information' screen. By this graphic, for which an example is given below, you may monitor the soot amount in the exhaust filter. When the graphic reaches 100%, your vehicle shall start the exhaust filter cleaning operation automatically, and the soot inside the filter shall be burned. - 156 - Graphic Example WARNING When the exhaust filter reaches a specific fill rate, automatic filter cleaning operation shall start and the soot inside the filter shall be burnt under high temperature. It may be difficult for exhaust gas to reach high temperatures and automatic filter cleaning may be required to be repeated in vehicles that are used with low loads, frequent start and stop operations, operated in idle for long periods and used in short distances (e.g.construction vehicles, mixer series). MAINTENANCE AND SERVICE Cleaning of Exhaust Filter If your vehicle performs automatic exhaust filter cleaning 2 times (or more) in the same day, it is recommended to perform manual exhaust filter cleaning. Manual Cleaning of Exhaust Filter The button in the middle console, shown with the red arrow above, is Manual exhaust cleaning button. You can perform manual exhaust filter cleaning of the vehicle using this button. WARNING Exhaust gas temperature will be high during manual exhaust filter cleaning, so make sure that the vehicle is not in an enclosed space and the exhaust gases do not come into contact with any flammable, inflammable or explosive material. Before starting manual exhaust cleaning, please make sure the following conditions are met. Vehicle speed must be "0" Parking brake must be applied Gear must be neutral Gas, brake and clutch pedals must not be pressed PTO must not be active Engine coolant temperature shall be above "40" or above There must not be any error codes that prevent exhaust filter cleaning After you ensure that the conditions above are met: Keep the manual exhaust cleaning button pressed for 3 seconds After this operation, the vehicle check for suitable conditions for filter cleaning and start the manual filter cleaning. When exhaust filter cleaning starts, the instrument panel shall display the exhaust filter cleaning symbol and "Exhaust filter is cleaning" warning for information. If the necessary conditions for exhaust cleaning are not met, "Conditions not suitable for exhaust filter cleaning" warning is displayed. If "conditions not suitable for exhaust filter cleaning" warning is received, the conditions above must be checked again. When the manual exhaust filter cleaning starts, the engine revolution of the vehicle will increase automatically. The operation shall continue as below: Heating 1 - 1200rpm 1 minute (minimum) - 157 - Heating 2 - 1800rpm 2 minutes (minimum) Filter cleaning mode - 1800rpm 15 minutes (minimum) - 45 minutes (maximum) Cooling mode - 1200rpm 3 minutes (maximum) WARNING You may monitor the time remaining to the end! of manual exhaust filter cleaning from the message on the instrument panel. As you may 1 see on the sample message below, time remaining to the end of exhaust filter cleaning is shown in minutes. Information Exhaust filter is being cleaned Remainder: 25 min. Sample Message WARNING Exhaust filter cleaning duration may change depending on the amount of smut in the filter and the heating time. Filter cleaning mode can take between 20 minutes minimum and 45 minutes maximum, depending on the amount of smut. 5 MAINTENANCE AND SERVICE Cleaning of Exhaust Filter 5 When the manual exhaust filter cleaning operation is completed, the engine speed will again decrease to idle rpm. If you want to stop the cleaning operation; you can stop the operation by pressing gas, brake or clutch pedal or keeping the exhaust filter cleaning block button pressed for 3 seconds. In that case, vehicle shall decrease to normal idle rpm. Please see the details about Exhaust filter cleaning block button from the relevant chapter. WARNING Since exhaust gas temperature shall be high and vehicle speed shall be "0" during manual exhaust filter cleaning, the indicator panel may display "High exhaust gas temperature, please pay attention during parking" information warning. The detailed explanation about this warning can be found in the warnings section. Exhaust Filter Cleaning Prevention The button in the middle console, shown with the red arrow above, is Exhaust filter cleaning block button. You can prevent the exhaust filter cleaning of the vehicle using this button. When exhaust filter cleaning is prevented, the instrument panel shall display "Exhaust filter cleaning is prevented by the driver" warning. The detailed explanation about this warning can be found in the warnings section. WARNING If exhaust filter cleaning is blocked by using Exhaust filter cleaning prevention button for a long time, the filter may fill with soot and clog up. When "Please remove exhaust filter cleaning prevention when possible" warning is displayed on the instrument panel, the prevention should be lifted and filter cleaning should be performed as soon as possible. Detailed information about this warning can be read in warnings section. - 158 - WARNING The purpose of exhaust cleaning block button is to prevent the vehicle from cleaning the exhaust whenever the vehicle is near a flammable, inflammable or explosive material. To activate exhaust filter cleaning prevention, Keep the exhaust filter cleaning prevention button pressed for 3 seconds When the blocking is activated, instrument panel displays "Exhaust filter cleaning is prevented by the driver" text. To remove exhaust filter cleaning prevention, Keep the exhaust filter cleaning block button pressed for 3 seconds, or Keep the manual exhaust filter cleaning button pressed for 3 seconds (This will start manual exhaust filter cleaning operation) or, Shut off the engine of the vehicle and then restart it You can confirm that the cleaning prevention is lifted when "Exhaust filter cleaning prevented by the driver" warning is not displayed on the instrument panel. MAINTENANCE AND SERVICE Urea System Your Ford vehicle with Euro5 or Euro6 emission system is equipped with urea tanks with a capacity of 55 or 75Lt. WARNING Your Ford vehicle with Euro 5 or Euro6 emission system is equipped with an Urea system. Urea system is a selective reduction method that removes NOx gases, which are harmful to the environment and human health, from the exhaust gas. Do not turn the switch of your vehicle off for 60 seconds when you stop the engine of your vehicle to allow that the urea left in the Urea system is returned back to urea tank. Urea left in the system may harm urea system components by freezing in cold weathers. WARNING Important Points: Take extra care for cleaning. Urea system is sensitive to dirt, dust and soil. During urea filling, ensure that dirt, dust or contaminants do not go in the urea tank. Pay attention to prevent dirt ingress to the tank. Wipe the dirt and mud around the ap before opening the tank ap. Fill urea uid directly from its package (can). Make sure the funnel is clean if you will use a funnel. Do not use funnels contaminated with fuel. Urea system is sensitive to contaminants. DEF (Diesel Exhaust Fluid): Urea system operates by spraying urea solution to the exhaust gas. Urea solution used in the urea system is defined with DIN 70070 and ISO 22241-1 standards. If you prefer to filling with a funnel, keep a separate, clean funnel to fill urea available. Do not use funnels contaminated with diesel fuel to fill urea. Urea indicator - 159 - 5 MAINTENANCE AND SERVICE Urea System Do not fill the urea tank with any material other than urea. Fill the tank with adblue complying with DIN 70070 / ISO 22241-1 standard only. • Do not fill the tank with diesel fuel. • Do not add water to the tank to increase urea level. 5 Quality of the fuel and engine oil used affects Urea system. a-) Sulphur Content in the Fuel Low quality fuel contains high sulfur ratio. Sulfur may cause blockage of catalyst, a component of the SCR system. You should use EuroDiesel only in your vehicle. b-) Engine Oil Low quality and/or wrong viscosity oil increases the oil vapour in the exhaust. This may cause blockage of the catalyst. Catalyst is a non-serviceable component that cannot be cleaned. Exhaust box shall be replaced as a whole when it is blocked. Pay attention to the quality of the urea, fuel and engine oil used and apply all instructions about urea system with care in order to avoid damages with high costs. If the exhaust temperature is consistently low (buses, delivery trucks), efficiency of Urea system may be reduced and ammonia may come out. Contact your workshop if you continuously smell ammonia. WARNING Exhaust gas reaches very high temperatures during regeneration or while operating under high load. “HES” light shall be illuminated on the warning panel of your vehicle in high exhaust gas temperatures. Switching off your vehicle while this light is illuminated may cause damage to urea system components. Average Urea Consumption User should carry out following precautions to prevent faults and damages in this system. Otherwise any faults occurring should be considered outside of the warranty cover and Ford Otosan will not take any responsibilities! The legal rules for the prevention of accidents are to be considered! - 160 - 13L 480PS 13L 420PS 13L 420PS Urea/Fuel Ratio Range Euro V 6-9% 6-9% 6-9% Euro VI 1,5* 1,1* 0,7* * Average urea consumption values are calculated based on vehicle and dynamometer test results. These values may vary according to vehicle load conditions, environmental conditions (Ambient airtemperature and pressure, relative humidity), engine and urea quality. MAINTENANCE AND SERVICE Urea System WARNING When improper urea or fuel is used or urea system is rendered inoperable because of contaminants mixed in the urea system, "MIL” lamp shall be illuminated on the instrument cluster and engine power shall be reduced by the engine control unit as the targeted emission values cannot be reached. In order to avoid accident risk or problem, it is recommended to refill urea before the urea level falls below a specified critical level. Engine power shall be reduced %40 by the engine control unit immediately after running out of all urea in the urea tank of your vehicle with Euro 5 emission level. High temperatures that may occur on the urea injector within this period may cause malfunction of the component. Engine power shall be reduced %25 by the engine control unit when the urea level is reduced to a level under 3% in your vehicle with Euro 6 emission level. When the urea level is %0, vehicle speed shall be limited with 20km/h by the control unit. Cluster Warning EURO6 EURO5 Cluster Level Indicator EURO5/EURO6 Inducement Level EURO6 EURO5 Urea level Low Urea level Low Fix No inducement active No inducement active Urea level Low Urea level Low Fix No inducement active No inducement active Fill up urea Urea level Low Blinking No inducement active No inducement active Fill up urea Fill up urea Blinking inducement active %75 torque reduction No inducement active Blinking Severe inducement active Max. Vehicle speed 20 kph inducement active %60 torque reduction Fill up urea Fill up urea Restraints that are applied because of reduced/run out of urea as specified above shall be removed when urea is added. Urea solution complying with DIN70070/ ISO22241 standards is used in your vehicle in order to reduce the exhaust emission. As this solution will be reduced in time, you shall check the urea solution level in your vehicle from the urea level indicator on the instrument panel and add urea before it is completely run off. - 161 - Usage of this solution is legally mandatory; and penalties may apply if you do not comply with this requirement. 5 MAINTENANCE AND SERVICE Tires and Rims Tire profiles WARNING A minimum profile depth is prescribed for tires by law. Observe the legislation for the relevant country. 5 For safety reasons, change your tires before reaching the legally advised minimum profile depth. WARNING An excessively low tire profile may cause loss of handling at high speeds in case of rain or snow mud conditions. You may loose your handling and cause an accident in these conditions. The Condition of the Tires Check the following conditions regularly every 2 weeks and before a long haul to inspect the condition of the tires: - External damage - Cracks and bulges on the tires, - Foreign material in the tire profile, - Irregular wear of the profile Do not forget that the external damages, bulges and cracks on the tires may cause blow-out of the tire. You may cause an accident in these conditions. CAUTION Do not use radial and transversed tires mixed on your vehicle. Use same type of tires on both sides of the same axle. Do not use radial tires on front axles if the rear tires are transversed. Wrong maintenance on the wheels may be extremely dangerous. Follow the instructions below strictly: - Do not attempt to replace the tires if you are not familiar with the required tools, and always follow the instructions. - Deflate the tires completely before removing the valve. Thoroughly drain the fluid. - Do not inflate the tires without a protection cage except normal pressure adjustments. - Always check the tire pressures with the wheel is cold. - 162 - Check the wheel nut torque when you load the vehicle with full load for the first time. (750 Nm +- 50Nm for front and rear wheels) Tighten the wheel nuts alternately. IMPORTANT 1- If the wheel nuts are removed and fitted back for any reason, the wheel nuts shall be checked 50 km after the operation. If the torque values are not suitable, the wheel nuts should be tightened to the suitable torque. 2- When a new or newly painted rim is used, tighten the wheel nuts after 1000 to 5000 km of driving. MAINTENANCE AND SERVICE Tires and Rims CAUTION Please check the wheel nut torque when you load the vehicle fully for the first time. Check the tire pressure periodically to prevent irregular tire wear. Do not use radial and transversed tires mixed on your vehicle. Use same type of tires on both sides of the same axle. Do not use radial tires on front axles if the rear tires are transversed. Wrong maintenance on the wheels may be extremely dangerous. Follow the instructions below strictly: - Do not attempt to replace the tires if you are not familiar with the required tools, and always follow the instructions. - Deflate the tires completely before removing the valve. - Do not inflate the tires without a protection cage except normal pressure adjustments. - Always check the tire pressures with the wheel is cold. Tire pressure Tyre/wheel replacement Check the pressure of all tires including the spare wheel. All tires should have the specified pressure, and tread depth of the tires should never be under the limit value (6 mm). Also check for damage on the tires. Adjust the pressure of your vehicle's tires by referring to the "Tire pressure" table. Your wheel is specially designed to maximize the appearance performance. Ensure that equipment used for tire replacement do not damage the wheel surface. If it is required to replace the valve during the replacement operation, ensure that alloy wheel valve is issued in Ford Workshops is used. The Aging of the Tires - Aging of the tires reduce the operation and traffic safety of the tires. Even unused tires are aged. - Always replace your tires if they are aged more than 6 years. Wheel maintenance Tire Damages Tire damages are usually caused by the following reasons: - Aging of the tire - Foreign material - Usage conditions of the vehicle - Weather conditions - Oil, fuel, grease etc. - Contact with materials - Dragging on the sidewalks - 163 - Clean your wheel frequently. Thus, you may take maximum advantage of appearance performance. Never use brushes, sanders or acidic fluids that may cause scratches on the wheel during cleaning. A damp soft cloth and cleaning agents commonly used for vehicle cleaning is adequate as a special transparent paint is used on the wheel surface. 5 MAINTENANCE AND SERVICE Tires and Rims WARNING 5 Your wheel is specially polished and covered with a transparent protection layer to protect its brightness. Never re-polish. This polishing operation would damage the protective layer on the surface. On vehicles with aluminium alloy wheels, wheel but caps shall be removed with the wheel nut cap pliers delivered with the tools before removing the wheel nuts. CAUTION Check the tire pressure periodically to prevent irregular tire wear. Use snow chains only on the outer tyres of your vehicle. Over inflated Deflated Proper Tire Pressure Low pressure cause wear on the shoulder areas of the tire. High pressure cause wear on the back areas of the tire. WARNING Please, observe the prescribed tire pressure for your vehicle. Very low tire pressure may cause blow-out of the tire at high speeds and loads. You can cause an accident and thus injuries to others due to this. Remove the wheel nut caps with the special pliers provided in the toolbox of the vehicle for aluminium alloyed wheels. Do not attempt to remove with sharp objects such as screwdrivers etc. - 164 - MAINTENANCE AND SERVICE Tires and Rims Wheel position replacement Wheel surfaces of your vehicle are polished specially and coated with protective transparent paint. Use your wheels in their original positions only. Or observe the following replacement chart. A wheel replacement other than the application specified below shall cause appearance problems. 1. Aks 2. Aks CAUTION 3. Aks As seen in the table, relocating your tyres at every 40,000 km will enhance the product life of your tyres. 4. Aks - 165 - 5 MAINTENANCE AND SERVICE Tires and Rims TIRE PRESSURE [Bar] Tire Size Rim 295/60 R22,5 9.00X22.5 5 Load Index 150/147 Tire 6,0 6,25 6,5 6,75 Single - Double - - - - 9000 315/60 R22,5 9.00X22.5 154/148 Single 5420 5600 152/148 Double - 5780 Single 5420 5600 5780 - 7,0 7,25 7,5 7,75 - - - 10000 5955 6130 6305 8,0 8,25 - - - 10500 - - - 11000 6480 6650 6825 10000 10300 10600 10800 - - 8,5 8,6 - - - - 11600 - 6990 7160 8,75 9,00 - - 12000 12300 7500 - 7330 11600 12000 - 12300 12600 6990 - 7330 7500 Double 9685 10005 10325 10640 10955 11270 11580 11890 12195 12450 12800 - - - Single - - - - 6000 6200 6400 - - - Double - - 10000 - 10700 11000 11400 11700 12000 12300 12600 - - - 315/80 R22,5 9.00X22.5 156/150 Single Double - 6200 6400 8000 - - - - 10400 10800 11100 11400 11800 12000 12400 12700 13000 13400 - - - Single - - 5560 - 5950 - 6330 - 6720 - 7100 - - - Double - - 9880 - 10560 - 11240 - 11920 - 12600 - - - 8920 9000 - - Double 12000 12390 12790 13180 13500 13960 14340 14720 15100 15480 15850 16000 - - 315/70R22,5 9,00x22,5 154/150 295/80 R22,5 9.00X22.5 152/148 12R 22,5 13R22,5 12.00 R24 9.00X22.5 152/148 9,00x22,5 156/150 8,50x24 160/156 5955 6130 6305 6600 6800 7000 7200 - 6700 7400 7600 6900 7800 7160 7100 Single 6360 6540 6730 6910 7280 7460 7640 7820 8000 - Double 10650 10960 11270 11580 11890 12200 12500 12800 13100 13400 - Single 6750 6970 7190 7410 7100 6480 6650 6825 7630 7850 8070 8280 8490 8710 - Contact your dealership to select the correct size when you replace the tire. - Always check the tire pressures with the wheel is cold. - 166 - MAINTENANCE AND SERVICE Tires and Rims DIAGNOSTIC CHART FAULT DIAGNOSTIC CHART POSSIBLE CAUSE OF THE FAULT If the vehicle skids to the side when brakes are applied • Brake adjustment is faulty If the vehicle drags to left or right when the steering is released • Incorrect tie-rod adjustment (toe angles) • Tires have different pressure values. FAULT If the tires are worn on both sides If the steering excessive play or looseness Curves are taken with high speed. Vehicle is used with high speed. Wheel rotation is not applied. • Irregular wear on the tires • Pressure value of the worn tire is faulty. • Tires have different pressure values If it is difficult to steer the vehicle POSSIBLE CAUSE OF THE FAULT Vehicle is used with excessive load. • Tire is underinflated. If a tire is worn more than the other • Vehicle is excessively loaded. • Brake adjustment is faulty • Toe angles are faulty • Steering system shall be checked. • Shock absorbers are faulty • Wheel bearings are loose • Wheel rotation is not applied. • Ball joints are loose If the front wheels have excessive vibration • Bushings are worn • Tire pressure is high. • Tires are flattened. • Track rod is loose/worn • Balancing is faulty • Steering gears or bearings are worn • Ball joints are worn If the outer side of the tire is worn • Excessive toe-out is applied If the inner side of the tire is worn • Excessive toe-in is applied If the tire is worn on the shoulder areas • Tire pressures are low. If the tire is worn on the back areas • Tire pressures are high. If the vehicle is shuddering • Tire pressures are high. • Tires are flattened. • Balancing is faulty. - 167 - 5 MAINTENANCE AND SERVICE Tires and Rims Spare Wheel and Tire Replacement Jacking The Vehicle Jack can be mechanically geared type or hydraulic type. Before lifting the vehicle, park the vehicle on a level ground and apply the park brake. 5 Do not jack the vehicle from the chassis arms. If the vehicle is on a slope and it is to be lifted without applying the parking brake, chock all other wheels. Spare wheel is on the chassis on your vehicle Carefully lower the spare tire. Take necessary precautions to prevent the tire from falling over your foot. It can be moved to any position on the vehicle by the vehicle owner when the upper structure will be installed. Remove the Upper Spare Bracket before attaching a trailer to your vehicle. The jack should be placed under the leaf spring as shown in the figure and must be placed on the ground firmly. CAUTION lf you need to get under a vehicle lifted by a jack, provide additional support under the frame pedestals. There may not be enough space under the front axle while replacing a flat tire. Place the jack under the leaf springs on the closest point to the axle when there is not enough space. Pay attention not to damage the steering linkages while lifting the vehicle with a jack. Use wooden blocks if required. Check for an obstacle under the vehicle when lowering the vehicle. - 168 - On vehicles with lowered ride height: MAINTENANCE AND SERVICE Tires and Rims Spare Wheel and Tire Replacement CAUTION Carefully lower the spare tire. Take necessary precautions to prevent the tire from falling over your foot. Spare wheel is on the left side of the chassis on vehicles with single fuel tank. To remove the spare wheel from its seat, loosen four bolts connecting it to the holder with the 24 spanner on the toolbox. Spare wheel is hanged with a cable. To release the cable, install the wheel brace to the rotating arm. Turn the brace anticlockwise. Installation: Check the connection cable before installing the spare tire. Cable shall be replaced if it is damaged. Connect the end of the cable to the tire again. Lift the tire with the hexagon wrench and tighten all nuts. 5 Spare wheel is on the chassis on vehicles with an optional secondary fuel tank. Side skirt shall be removed to take the spare wheel out. Remove the Upper Spare Bracket before attaching a trailer to your vehicle. - 169 - MAINTENANCE AND SERVICE Tires and Rims Side skirt opening mechanism Side skirt panel is moved to the outwards of the vehicle on direction 2 after it is released of its locks. 5 Side skirt panel is released of its locks with the movement of yellow locks on both front and rear sides to the direction of 1. Side skirt panel is moved to the upwards on direction 3 after it is released from the rope hooks on the front and rear sides and it is released from its hinge connections. - 170 - MAINTENANCE AND SERVICE Driver Cab Tilting The Cab: CAUTION Vehicles without bed Do not work under the cab before tilting it completely. This brings a fatal accident risk. CAUTION If you do not take the necessary precautions and pay necessary attention to the cab lifting procedures, this may cause fatal accidents. Before tilting the cab: • Ensure that no one is standing in front of the vehicle. • Ensure that adequate space is available in front of the vehicle. • Ensure that no freely moving objects are available in the vehicle. Hard objects may break the windshield when they fall while the cab is being tilted. Do not tilt the cab uphill. As the gradient of the slope acts to move the cab in the closing direction, this may cause risk for the person under the cab. Always tilt the cab on a level surface. If the conditions require that the cab is tilted on a slope, place a safety element between the cab and chassis. WARNING Doors are heavy components; if the doors are opened while the cab is tilted, abrupt opening of the doors may cause serious injuries. If the door should be opened, it shall be opened by supporting from the lower side and slowly. Always open the hood before tilting the cab. - 171 - 5 Cab tilt cylinder is located behind the fender on the right side of the vehicle. MAINTENANCE AND SERVICE Driver Cab Vehicles with bed 5 b) Lift the latch on the cab tilt cylinder down. Cab tilt cylinder is located behind the fender on the right side of the vehicle. Use the brace provided in the toolbox of your vehicle to tilt the cab and then to bring it to the driving position. To use the jack, remove the specified cover. 1- On vehicles with manually controlled cab tilt cylinder: Tilting the cab: a) Open the hood of your vehicle. - 172 - c) Using the wheel brace provided in the toolbox of your vehicle rotate the hexagonal head bolt on the cylinder in the direction of arrow until the cab is tilted completely. MAINTENANCE AND SERVICE Driver Cab Returning the cab to driving position: c) If the warning is illuminated on the display when you get in the vehicle, this means that cab is not locked correctly. Check it. CAUTION a) Lower the latch on the cab tilt cylinder up. Fully open and close the latch on the cab tilt cylinder while you are tilting and bringing the cab back to driving position, respectively. Do not tilt the cab or bring it back to driving position while the latch is in half-open or half- closed position. Otherwise, you may cause faults in the cab tilt cylinder. b) Using the wheel brace provided in the toolbox of your vehicle rotate the hexagonal head bolt on the cylinder. - 173 - 5 MAINTENANCE AND SERVICE Driver Cab On vehicles with power cab tilt cylinder (optional) Tilting the cab: 5 Returning the cab to driving position: DIAGNOSTICS: On manually controlled tilt cylinders: 1) Lower the latch on the cab tilt cylinder up. 1) Lift the latch on the cab tilt cylinder down. Cab cannot be tilted Check the position of latch on the tilt cylinder. It shall be on the tilt direction. • Tilt cylinder is also serves as the hydraulic oil tank. Open the cover after cleaning the surroundings of the upper cover. Check with your finger, your finger shall touch the oil. • Check for oil leaks through the tilt cylinder, hoses, lift hydraulic line. • Please visit a Ford Trucks authorized dealership if the fault persists. On power cab tilt cylinders: 2) Hold the yellow button pressed if the 2) Hold the yellow button pressed To operate the power cab lifting system, ignition switch shall be at position 2, park brake shall be applied and gear shall be shifted to neutral. warning is illuminated on the display when you get in the vehicle, this means that cab is not locked correctly. Check it. - 174 - Cab cannot be tilted • Check the position of latch on the tilt cylinder. It shall be on the tilt direction. • Press the yellow button on the tilt cylinder. • Check the fuse of the tilt cylinder. • Check for oil leaks through the tilt cylinder, hoses, lift hydraulic line. • Please visit a Ford Trucks authorized dealership if the fault persists. MAINTENANCE AND SERVICE Engine Running-in Daily Inspections • Check the coolant level. If the level is at minimum or less, add 50% distilled water and 50% antifreeze (WSS M97B44 D) mixture. • Check the brake hydraulic fluid level, add brake hydraulic fluid if the level is at minimum or less. • Check windshield washer liquid level, add clean water if the level is dropped. • Check for any oil or liquid leaks in general. • Check the operation of the service and park brakes. • Drain the water and oil collected in the air tanks completely by pulling the drain ring. Engine management is provided by the state- of-the-art electronic control unit. CAUTION Remove the plugs of electronic control unit before welding on the vehicle. Otherwise, there is a risk of permanent damage to the electronic control unit. Welding operations shall be performed while the main switch is off. There is no need to perform a special application in the running-in period of the engine. Drive the vehicle with the proper gear so that tachometer remains in the green zone as always. - 175 - 5 MAINTENANCE AND SERVICE Engine 5 Weekly Inspections: • Check the engine oil level. • Check the tire pressures (while the wheel is cold), tread depth and damage condition on the tires. • Check the clutch hydraulic fluid level, add hydraulic fluid if the level is dropped. • Check the wear on the brake lining wear by looking through the lining inspection hole. • Lubricate the semi-trailer connection platform. Monthly Inspections • Check the power steering fluid level. Engine Oil Level Inspection Engine oil level shall be inspected weekly. Engine oil dipstick is placed on the right side of the vehicle. • Park the vehicle on a level ground. Switch off the ignition, apply the parking brake, and take the necessary precautions. • Wait for 10 minutes to allow flowing of the oil to the oil pan. • Tilt the cab. • Take the dipstick out. • Wipe with a lint-free clean cloth, install the dipstick again and secure it. - 176 - • The oil level must be between the MIN and MAX lines. The difference between "MIN” and "MAX” on the dipstick is 15 liters. CAUTION Use oil with the specifications approved by Ford Otosan only for your engine. Using improper oil for your engine may cause serious and costly faults. MAINTENANCE AND SERVICE Engine Adding Fluid When the engine oil level is reduced to critical level, red “Engine oil low” Add oil if the level is less than MIN, engine oil filler cap is on the cylinder head cover. Wipe the surroundings of the cap before opening it. Pay attention to cleanliness if you would use equipment such as measuring container, funnel etc. Fuel consumption value: Oil consumption amount of the engine between 2 maintenances depends directly on the operating conditions of the vehicle (loaded-unloaded, short-long haul, fuel quality, engine oil quality). Under normal operating conditions, engine oil consumption up to 0.8 lt / 1,000 km between 2 maintenance operations is acceptable. These consumption values may vary under heavy operating conditions. warning shall be displayed on the instrument. In this case, engine oil shall be brought to required level by adding engine oil within 500 km maximum. We advise you to have the engine oil adding operations performed in Ford Otosan authorized dealerships. CAUTION Do not replace engine filters and tamper with its connections when the ignition switch is at position 2. Important Points: 1. When the warning light illuminates, lacking amount of oil in the engine is about 15 liters. Oil shall be add until the level observed on the dipstick reaches a level between MIN and MAX marks. Add oil gradually and in a controlled manner. Run the engine for a few minutes after each oil adding operation. Stop the engine, wait for 10 minutes, and check the engine oil level with oil dipstick. 2. Do not add oil more than required. Excessive engine oil may cause faults such as deterioration of seals, excessive heating, blocking of catalyst, oil leaks from various points on the engine. - 177 - 3. Engine oils may lose their specifications if engine oils with different specifications and different brands are mixed. In order to prevent costly damages to your engine out of warranty cover, we recommend you to top up the oil in your engine with oils with the same brands and specifications when adding oil is required between 2 maintenance operations. CAUTION When the engine oil level is reduced to the minimum level, “engine oil level warning light” is illuminated on the display In this case: 1. It is possible to drive up to the first rest stop. Road assistance is not required. 2. Vehicle shall be parked on a level ground on the rest stop area, park brake shall be applied and required safety precautions shall be taken. 3. When the vehicle has rested for 75 minutes with ignition off, oil shall completely flown to the oil pan. 4. Without turning the ignition / engine on, cab shall be tilted and oil level shall be measured with the engine oil dipstick. 5 MAINTENANCE AND SERVICE Engine After the measurement: 5 a. If the engine oil level is not under MIN level and oil level warning light is turned off after 75 minutes, it would be adequate to drive the vehicle to the authorized workshop as soon as possible. Road assistance is not required. b. If engine oil level is under MIN level, you shall add engine oil with the specifications given with the required amount. Oil level warning light shall be turned off after waiting for 75 minutes with the ignition off. Road assistance is not required for this application, too CAUTION Excessive oil is harmful for your engine. This may cause overheating of the engine, damage to the seals and oil leaks from several points of the engine. It may also cause blockage of the exhaust catalyst pores. We advise you to have the maintenance of your vehicle by specialists in Ford Otosan authorized dealerships. Engine oil pressure and oil level is checked by the sensors, and the driver is informed with a warning light in case of an abnormal condition. Low Engine Oil Pressure Turn the engine OFF. Contact a Ford Trucks Authorized Dealership. Low engine oil level Tilt the cab, and check the engine oil level with oil dipstick. Oil maintenance interval reached Take your vehicle to a Ford Trucks Authorized Dealership as soon as possible for oil maintenance. Engine coolant temperature warning - 178 - This informs the driver about overheating of the engine. Stop the vehicle immediately and run the engine at idle for a few minutes. Check for coolant leaks. Stop the engine if the coolant temperature does not drop. Check the water pump drive belt, fan and shroud, and the coolant level. (see Engine coolant level) Contact an authorized dealer. MAINTENANCE AND SERVICE Engine Engine and drivetrain system malfunction This indicates a malfunction in the engine and/or drivetrain components. Vehicle may continue normal operation or engine may reduce the power based on the severity of the fault. Please visit the nearest Ford Trucks authorized dealership. MIL (malfunction indicator lamp) MIL indicates a malfunction in the vehicle central information system when illuminates in the instrument panel. Engine may be power off according to the seriousness of the malfunction. It is recommended that you ask the support of a Ford Trucks authorized dealership. MIL (malfunction indicator lamp) (In EURO-6 vehicles) Before starting the engine: Engine malfunction lamp of your vehicle will self check by illuminating for 5 seconds when the ignition switch is on (before engine start). This is the lamp check phase. The lamp will be dim out for 10 seconds after that. Then it will be illuminating again for 5 seconds. This is the preparation phase. If all data is ready for examination the lamp will stay illuminated for 5 seconds, if not, it will blink 5 times in 5 seconds. (This does not affect the function, and is not a sign of malfunction.) Before going to the next phase, lamp will dim out for 5 seconds. If a malfunction is detected, lamp will show one of the 4 following behaviours till the engine start: • Lamp will light up continuously. It is recommended to you to drive to an authorized workshop in this case. • Lamp will light up 3 times in 5 seconds, and dim out for 5 seconds. It is recommended to you to drive to an authorized workshop in this case. • Lamp will light up 2 times in 3 seconds, and dim out for 5 seconds. It is recommended to you to drive to an authorized workshop in this case. • If there is no errors, it will light up for 1 second and dim out for 5 seconds. - 179 - After starting the engine: If there is an error, lamp will light up in 2 ways according to the error type, • Lamp will light up continuously. It is recommended to you to drive to an authorized workshop in this case. • Lamp will light up for 15 seconds, and dim out completely. It is recommended to you to drive to an authorized workshop in this case. • If there is no error, lamp will not light up. Cleaning the engine: Do not apply pressurized water to the sensors and electronic control unit while you are washing the outer surface of the engine with pressurized water. Water ingress to electronic units will cause short circuits on the electrical pins, thus malfunctions on the engine. 5 MAINTENANCE AND SERVICE Engine On-chassis fuel filter (Fuel pre-filter) Fuel does not ow to the engine and system takes air when the vehicle runs out of fuel or when the low quality fuel is frozen in the filter. Remedial operation required Tractor vehicles On-chassis fuel filter (Fuel pre-filter) 5 Fuel pre-filter performs the initial filtration of the fuel drawn from the fuel tank. Also, it separates the water inside the fuel and provides fuel separated from water to the engine. Filtered water is collected in the container under the filter assembly. If the “water in fuel” warning light illuminates when the ignition is on, loosen or unclip the integrated water sensor under the filter assembly and close it when clean fuel appears. Tighten the water sensor securely when you are closing the tap. Otherwise, air may enter the engine, and this may cause fuel leak. WARNING Care that is shown for the cleaning of the fuel filters will contribute the service life of main fuel filter on engine and fuel system of the engine. - 180 - MAINTENANCE AND SERVICE Engine After performing the necessary corrective action, bleeding air from the system is performed by the hand pump on the filter head. Press until hand pump is stiffened, and start the engine when the pump is stiffened. Engine coolant CAUTION Freezing temperature of the 50% distilled water and 50% antifreeze mixture is -37°C. On colder climates, it is possible to achieve protection up to -50°C by adjusting the mixture ratio to 40% distilled water and 60% antifreeze. Maximum antifreeze ratio is 60%, never exceed this ratio. WARNING Do not continue on starting attempts if the vehicle does not start in a few attempt. There may still be air inside the fuel line. Pump fuel with the hand pump, then restart again. CAUTION Fuel that will be taken for the vehicles operating in cold climates shall be cold climate fuel resistant to waxing in cold weather. Otherwise, water inside the fuel will freeze and prevent flow of fuel to the engine; and the engine will not start. Engine coolant contains 50% antifreeze and 50% distilled water. Coolant circulates inside the engine block and cools the engine components. This fluid also cools the intarder oil in vehicles with intarder. CAUTION Antifreeze does not prevent freezing of the engine in winter only. It also lubricates the water pump and extends its service life. Ensure that the antifreeze complies with the Ford specifications when you are purchasing antifreeze. Lime and other chemicals in the non-distilled water cause corrosion in the cast engine block. - 181 - Cover of the engine coolant reservoir must always be tightly closed. Engine coolant reservoir is under the hood. The coolant level should be between the MIN and the MAX marks when the engine is cold, and it shall be inspected daily. If the coolant level is lower than the MIN mark, the x warning shall illuminate on the display. In this case: 5 MAINTENANCE AND SERVICE Engine 5 • Stop the engine considering the road safety. • Check the coolant level in the coolant reservoir under the hood. • If the level is lower than the MIN mark, add 50% distilled water and 50% antifreeze until the level reaches between MIN and MAX marks. In the case of a malfunction in the low temperature circuit, a malfunction in the electrical pump or a water leak; the vehicle will start cutting down the torque. (For vehicles with 12.7 lt engine) CAUTION Risk of Serious Injury: Coolant is pressurized and VERY HOT. Do not open the cover immediately. Wait at least half an hour and open the cover with a thick cloth or protective gloves, if available. Open the cover slowly first to discharge the pressure in the reservoir; then open the cover completely. • Check under the vehicle for any coolant leaks. • Tilt the cab, check the belts for any broken or excessively loosened belt. If the fan cable breaks, fan rotates in maximum rpm; since this will worsen the fuel economy, it is advised you to go to service after the warning light goes on. CAUTION Do not refill with water when the cooling system of a hot engine is empty or its coolant is missing. Add hot water if available, or wait until the engine is cooled. WARNING Air filter shall be replaced in an authorized dealership when light is illuminated. The paper structure is distorted within one year and will not be performing the filtering function. The air filter clogged warning will be illuminated on the digital display when the air filter element is clogged. Contact a Ford Otosan Authorized Dealership for the replacement of the air filter elements after this warning is illuminated. - 182 - WARNING Always tilt the cab completely to replace air filters. Tilting the cab halfway may cause personal injuries. Ensure that the air filter cover is installed so that the dust draining hole faces downward. WARNING Do not operate the vehicle with air filters removed. As the air drawn to the turbocharger and thus the engine shall not be filtrated, this may cause serious and expensive malfunctions on components such as turbocharger and engine. MAINTENANCE AND SERVICE Engine WARNING Clutch fluid damages painted surfaces. Take necessary precautions to prevent spilling over the painted surfaces while adding fluid. Air filter is composed of 2 components: 1- outer filter 2- inner safety element WARNING Note: Never expose the air filters to compressed air. Compressed air distorts the paper structure of the air filter elements and it may even tear them. 5 Clutch fluid reservoir is placed under the front hood. The level of fluid shall be up to the level mark on the reservoir. Add fluid with proper specifications given if the level is low and close the cover tightly. - 183 - MAINTENANCE AND SERVICE Engine Inspection and Cleaning of the Flyscreen it would be possible to prevent the deformations on the cooling module that may be caused by the flyscreen springs. CAUTION 5 Flyscreen, placed in front of the radiator, is a component that resembles a curtain and it can be cleaned. Its purpose is to prevent objects such as flies, dust, bugs etc.from entering directly to the radiator. Inspect the Flyscreen as per the working conditions and clean it if it is dirty. Cleaning is performed by removing the flyscreen from the radiator and applying pressurized water or air to the flyscreen. Removal of the flyscreen: Pull the flyscreen lower bar downwards from its sides and take it out of the lower seats that connect it to the cooling module. Then, open the upper cover, remove the flyscreen upper connection springs and take it out by pulling it upwards from this area. In this way, Dirty flyscreen prevents air flow to the intercooler, thus to the radiator, and reduces the cooling capacity of the engine. Therefore, the cleaning procedure described above is important. Engine Start/Stop buttons Engine • Operation Conditions • The ignition shall be at position '2'. • The cab shall be overturned • Doors must be closed • Parking brake must be applied • Vehicle speed must be "0". WARNING Note: In an event where one of these conditions are not met, the engine will not be engaged with Start Button. 1-Start 2-Stop - 184 - You can do the following with Two Buttons: • Engine Starting • Engine speed increase • Engine speed reducement • Motor shutdown The System Operation Principle is specified below: The Function consists of 4 basic conditions; 1. When the ignition is in position 2, by pressing the Start button, the engine is engaged. 2. When the engine is engaged, the first long pressing the Start button will increase the engine torque. When the button is released, the engine torque is stabilized at the level. 3. After increasing the engine torque, with the first long press the engine torque will be creased with the same amount and when the button is released, the torque will be stabilized at the level. 4. Stop button is only used to halt the engine that is engaged. In any event, when Stop button is pressed the engine halts. MAINTENANCE AND SERVICE Engine CAUTION You may find more information on the maintenances and contact information for the Ford Trucks authorized dealerships in the Warranty Manual. Distance and engine operating hours to the maintenance are displayed on the displays of your vehicle. Engine total operating hours from the first operation of the engine We advise you to have the periodical maintenance and repair operations on your vehicle performed in Ford Otosan authorized dealerships. - 185 - 5 Your vehicle is suitable for using with a fuel with a bio-diesel ratio of 7% (B7). MAINTENANCE AND SERVICE Steering Steering Fluid For vehicles with 12.7 lt engine Fluid level check: 1- Tilt the cab. 4- The oil level must be between the lines shown in the figure. Add fluid if the fluid level is low. Steering system is very sensitive to foreign material such as dust, dirt etc. Pay maximum attention to cleanliness while checking the fluid level and/or adding fluid. Prevent dirt ingress to the system. 5 Steering uid reservoir is located under the cab on the right side of the vehicle. 1- Cover 2- Wipe the surroundings of the with a clean cloth, open the clip For vehicles with 9 lt engine Adding Fluid 1- Wipe the reservoir cover and surroundings with a cloth 2- Open the reservoir cover and add required amount of fluid. 3- Close the reservoir cover tightly. WARNING Steering uid reservoir is located under the cab on the left side of the vehicle. 3- Take the dipstick out, wipe with a clean cloth, install the dipstick securely and take it out again. - 186 - Steering gear upper area Steering column joint connection area shall be cleaned with non-pressurized water or a brush. The mentioned area shall be protected if it is cleaned with pressurized water. MAINTENANCE AND SERVICE Towing the Vehicle Towing of the vehicle requires specialist knowledge that is not explained in this manual. Make sure that the vehicle is towed by specialist staff. 5 Remove the cover on the front grille panel to install draw pin. Remove the draw pin and attach the towing cable. Make sure that the transmission is in neutral and in high range. Draw pin installation location on your vehicle is on the front grille panel. If the transmission cannot be shifted to neutral, you should remove the drive shafts to the axle. Install draw pin by rotating it clockwise as shown in the gure. - 187 - If the vehicle should be transported on a trailer with a deep platform, the speci ed 4m height may be exceeded. Consider the maximum passing heights of the underpasses. You may cause an accident. MAINTENANCE AND SERVICE Towing the Vehicle Engine WARNING Do not tow the vehicle crosswise. 5 Risk of Accident If the vehicle is towed with the engine is not running, the steering assist and air supplies will not be operating. As this would require more steering effort, you may get out of the road or bump the towing vehicle in curves. You may install an emergency steering pump. If you agree on special signs with the driver of the towing vehicle before towing the vehicle, it will prevent occurring of these kind of problems. CAUTION In order to tow the vehicle, the drive shaft connected to the live axle must be removed. For multi-piece drive shafts, it will only be sufficient to remove the rearmost drive shaft. While towing your vehicle CAUTION • The drive shaft needs to be removed first before towing your vehicle. • If the drive shaft is not removed, the movement shall be transmitted from the wheels to the transmission and operate the internal components of the transmission that is not pumping oil. In such a case, you may experience serious transmission malfunctions. This is considered out of warranty cover. CAUTION Have your vehicle towed by specialists only. Improper towing may cause damage to your vehicle and you may experience serious accidents. - 188 - Procedures to be Performed: • If your engine is operating, have your vehicle towed as your engine is operated. If it is not possible to operate your engine, brake air pressure may be reduced after a while and this locks the emergency brakes. • This may cause serious accidents and damages. • To prevent this condition, discharge the emergency brakes before towing your vehicle or connect an air line to the air tubes of your vehicle if the specifications of the towing vehicle allows this. • The drive shaft needs to be removed first before towing your vehicle. • The key should be on the ignition switch and on position (1) as your vehicle has a steering lock. • The vehicle should only be towed with a drawbar. Towing with soft, breakable materials cause a serious risk of accident. • Do not exceed the speed limit specified by traffic law. MAINTENANCE AND SERVICE Electrical Systems Batteries WARNINGS Danger of explosion Explosive gases form when the batteries are charged. Charge the batteries in well ventilated places only. Danger of explosion Avoid sparks! Do not work with open res or lights near bat- teries. Do not smoke. Battery acid may cause burns. Use acid-resistant protective gloves! Neutralize the skin or cloth that the battery acid is spilt on with soapy water or a neutralizing material and rinse with water. Wear protective goggles. Electrolyte may be spilt on the eyes while mix- ing it with water. Wash your eyes with plenty of water and seek medical help immediately. DAMAGES TO THE ENVIRONMENT Batteries contain hazardous material. Do not dispose with household waste. Keep away from children Children cannot decide the risks involved with batteries and acid. Observe the safety warnings, protec- tion precautions and manners described in this manual when you are dealing with the battery. - 189 - Dispose the batteries without harm- ing the environment. Return the batteries to a FORD OTOSAN authorized dealership or a collecting facility for waste batteries. Transport and store the batteries lled with electrolyte in upwards condition. Secure the batteries against turning over when you are carrying them. Battery acid may contaminate the environment by vaporizing from the air discharge holes. 5 MAINTENANCE AND SERVICE Electrical Systems Disconnecting the battery terminals WARNING There is a risk of short circuit when the positive terminals of the battery contact the vehicle parts. This may easily burn the explosive gas mixture. You and other people may get injured in an explosion. 5 Do not place metal parts or tools on the battery. Batteries should always be charged as required in order to have a long service life. We advise you to use the circuit breaker next to the battery tray to preserve the service life of the battery when the vehicle is not going to be used for a long time. Check the battery voltage level if the vehicle is parked for a long period of time. 12.2 V voltage level measured in a battery indicates that battery charge level is too low. In this case, best method is to leave the vehicle running in the shortest possible time in order to charge the batteries. Disconnect the terminals after 5 minutes minimum when you stop the engine. This is needed to supply power to the Urea system that will operate after a while when the engine is stopped. Otherwise, your Urea system (or vehicle) may be damaged. Disconnect the negative terminal first, and then the positive terminal while disconnecting the terminals. • Remove the key from the ignition switch. • Turn off all consumers. • Open the battery housing cover and remove it. • Disconnect the negative terminals. • Disconnect the positive terminals. Do not loosen or disconnect the terminals when the engine is running. - 190 - Connect the positive terminal first, and the negative terminal then while connecting the terminals. BATTERIES REQUIRE MAINTENANCE MAINTENANCE AND SERVICE Electrical Systems Connecting the battery terminals CAUTION Remove the key from the ignition switch. Turn off all consumers. Connect the positive terminals. Do not confuse terminals! • Connect the negative terminals. • Fit the battery cover. Perform the following when the power is disconnected (e.g.when the terminals are disconnected and connected again). • Set the clock. Removing the battery cover Open the upper connection profile of the step bracket under the battery cover in the direction of the arrow. Checking the electrolyte level 5 Then pull the battery cover to yourself in the arrow direction and remove easily. After the battery replacement; if the replacement is made outside authorized service and parameter update is not performed, “replacement notification” signal is sent for 10 seconds. In this case, the hazard lights button must be pressed 7 times within 14 seconds while the ignition is on. - 191 - CAUTION Battery box is white colored to provide the visibility of the liquid from outside. Pay attention to min./max. sign to understand whether the liquid level is adequate or not. Check the electrolyte level every six months or 40.000 km. Tap water decreases battery power. Only add demineralized or distilled water. Do not use a metal hone when you are filling the batteries. There is a risk of short circuit. • Open the battery housing cover and remove it. • Remove the plugs. • Check the electrolyte level and correct if required. MAINTENANCE AND SERVICE Electrical Systems • Install the plugs. • Fit the battery cover. WARNING 5 Batteries are very heavy. You may drop the battery and injure yourself or others when you are removing or installing a battery. Thus, be careful when you are removing the battery and use the help of a second technician. WARNING Make sure that the battery housing cover is closed. Ensure that the battery surface is always clean. WARNING There is a risk of explosion because of the forming of explosive gases. Avoid sparks! Do not work with open fires or lights near batteries. Do not smoke. Battery Info The blink of the battery status indicator shows that the battery charging level is very low. The best method in this condition is to keep the engine on immediately for batteries to be able to charged Using Jumper Cables If your battery is discharged and you want to start your engine with jumper cables, read the following instructions carefully to prevent damage to the charge system. - The voltage of the spare battery (batteries) should be the same with your battery (your vehicle has a 24V electrical system). Keep the spare batteries in a well-ventilated environment. - Turn off all other consumers. Connect the jumper cables to the spare battery first. Connect the positive (+) terminal of the spare battery to the positive terminal - 192 - of the vehicle battery, and negative (-) terminal of the spare battery to the negative terminal of the vehicle battery. - Start the engine. Run the engine under 1000 rpm. - Disconnect the negative jumper cable from the spare battery first, and then the vehicle battery. Disconnect the positive cable in the same way. - If two vehicles are used, make sure that their bodies or frames do not contact each other. - Do not approach the batteries with sparks or naked flames as the hydrogen will always be available. - Connect the jumper cables as specified above to prevent sparks in the vicinity of the batteries. Always use booster cables with insulated clamps and adequate size cable. Do not disconnect the battery from the vehicle’s electrical system. To start the engine: a- Run the engine of the vehicle with charged battery with a high speed. b- Start the engine of the vehicle with the flat battery. c- Run both vehicles for a minimum of three minutes before disconnecting the Otherwise, you may damage electronic equipment like the engine electronic control unit or the digital instrument cluster. MAINTENANCE AND SERVICE Electrical Systems Fuse and Relay Table 5 - 193 - MAINTENANCE AND SERVICE Electrical Systems 5 No Amp. System No Amp. System F1 5 ABS/EBS F20 7.5 SWITCH RELAY F2 5 ELECTRONIC CONTROLLED AIR SUSPENSION/ STEERING ADDITIONAL AXLE UNIT F21 20 A/C BLOWER F3 3 COMFORT MODULE IGNITION F22 7,5 ACCESSORY GEAR SELECTOR STATE F4 7,5 CAMERA/RADAR F23 10 HEATED SEAT / POWER MIRROR F5 7,5 INT3 F24 20 AIR DRIER / FUEL HEATER F6 10 AUTOMATIC TRANSMISSION IGNITION 9S ZF TRANSMISSION CONTACT F25 20 WIPER MOTOR TRAILER IGNITION F7 5 INSTRUMENT PANEL F26 7,5 F8 5 ECM F27 15 MFS F9 5 TACHOGRAPH F28 30 WINDSHIELD HEATER-1 F10 2/3 TACHOGRAPH F29 30 WINDSHIELD HEATER-2 F11 15 COMFORT MODULE F30 F12 2 TACHOGRAPH BMS CAN SUPPLY F31 5 BCU F13 7,5 INT3 F32 15 EBS/ABS SPARE F14 3 CAMERA F33 15 SUCTION LINE HEATER / ELECTRO HEATER F15 7,5 AIR SUSPENSION F34 20 ECM (Ignition) 10 AUTOMATIC TRANSMISSION 9S ZF TRANSMISSION F35 7.5 WEMA F16 F17 5 INSTRUMENT PANEL F36 15 NOX F18 20 CONVERTER F37 20 24 POWER OUTPUT F19 5 A/C COMPONENTS F38 7.5 INTERIOR LIGHTS - 194 - MAINTENANCE AND SERVICE Electrical Systems No Amp. System No Amp. System F39 3 EROGLONASS SYSTEM F55 5 WEBASTO TIMER F40 10 REAR FOG LIGHT F56 15 COMFORT MODULE F41 10 STOPLAMPS F57 20 WEBASTO PUMP 5 BRAKE LOCK VALVE F42 10 PEAK SIGNAL F58 F43 3 TRAILER AXLE LIFTING F59 F44 10 REVERSE GEAR F60 15 FLASHER /HORN F45 5 HAZARD WARNING F61 20 A/C WET TYPE F46 7.5 RIGHT PARKING LAMPS / DOME LAMPS F62 20 WIPER MOTOR SPARE F47 30 CAB LIFTING F63 2 ALTERNATOR W SIGNAL F48 7.5 LEFT PARKING LAMPS F64 20 BCU1 F49 30 TRAILER 7 PIN SUPPLY F65 20 BCU2 F50 10 TRAILER PARK F66 20 BCU3 F51 5 HEADLIGHT ADJUSTMENT MOTOR F67 20 BCU4 F52 5 WEBASTO TIMER MODULE PARK F58 20 BCU5 F53 15 LIGHTER F69 20 BCU6 SPARE F70 15 IGNITION SWITCH F54 - 195 - 5 MAINTENANCE AND SERVICE Electrical Systems No F71 Amp. 15 F72 5 System No Amp. System VGT/EGR J2 40 LDWS/T ACHOGRAPH/CONVERTOR/ AUTOMATIC TRANSMISSION SPARE J3 40 LAMPS COMFORT MODULE CONVERTOR J4 40 WEBASTO F73 15 F74 20 Radio J5 30 AUTOMATIC TRANSMISSION F75 5 RADIO SUPPLY AND ILLUMINATION / RAIN SENSOR J6 40 CAB LIFTING/TRAILER F76 10 DIAGNOSTIC J7 60 BCU1 F77 5 BCU J8 60 BCU2 F78 2 EROSLONASS SYSTEM IGNITION SUPPLY J9 40 COMFORT MODULE/HORN/HAZARD/WIPERS F79 20 AFTER SALES IGNITION SUPPLY (EXTERNAL) J10 40 ABS/EBS/ECM F80 15 AFTER SALES IGNITION SUPPLY (INTERNAL) J11 40 IGNITION-1 F81 20 AFTER SALES IGNITION SUPPLY (INTERNAL) J12 40 IGNITION-2 F82 2 HEADLAMP SWITCH J13 20 POWER POINT (12 VOLT OUTLET) D1 1 INTARDER J14 40 IGNITION SWITCH / WEMA, VGT&EGR / SUCTION LINE HEATER/ELECTRO HEATER D2 SPARE J15 60 HEATED WINDSCREEN J1 40 INTARDER / COMFORT MODULE / ECAS / CLUSTER J16 40 LIGHTER / AFTER SALES IGNITION SUPPLY - 196 - MAINTENANCE AND SERVICE Electrical Systems No Amp. System No Amp. System R1 40 A IGNITION-1 R16 20 A REVERSE GEAR R2 40 A VGT / EGR / WEMA / NOX R17 20 A PARKING LAMPS R3 40 A IGNITION-2 R18 40 A BRAKING LAMPS -2 R4 40 A WINDSHIELD HEATER 1 R19 20 A BRAKE VALVE R5 40 A WINDSHIELD HEATER 2 R20 20 A BCM TC AVAILABLE R6 40 A CAB TILTING R21 20 A CRUISE CONTROL OFF R7 20 A ROOF SIGNAL R22 20 A WIPER LOW SPEED R8 20 A AUX RELAY R23 20 A HORN R9 20 A TRAILER AXLE LIFTING R24 20 A REAR FOG LIGHT R10 20 A BLOWER1 R11 40 A IGNITION-3 (AFTER-SALE SYSTEMS) R12 20 A ENGINE STOP R13 20 A BLOWER2 R14 20 A WIPER HIGH SPEED R15 20 A BRAKING LAMPS -1 5 Fuse and Relay Table (Battery) F1 F2 F3 No Amp. System No F1 175 PROTECTION BETWEEN THE ENGINE HEATER AND STARTER F2 150 PROTECTION BETWEEN THE ALTERNATOR AND STARTER F3 150 MEGA FUSE - 197 - Amper System F1 N/A F2 100 STEERABLE ADDITIONAL AXLE MAINTENANCE AND SERVICE Changing Bulbs 5 Use the covers on the door steps to replace the low and high beam headlamp bulbs. 1- Pull the rubber part firmly high beam: DTRL-21W low beam :70W - 198 - 2- Open the headlamp rear cover by rotating it counter-clockwise MAINTENANCE AND SERVICE Changing Bulbs Brake Lamp Turn Indicator Lamp (bayonet 21w) Brake Lamp (bayonet 21w) Fog Lamp (bayonet 21w) Reverse Lamp (bayonet 21w) Position Lamp (bayonet 5 w) Licence Plate Lamp (Led) Side Marker Lamp (Led) 5 Rotate the bulb that will be replaced under slight pressure anticlockwise and remove it. Install the new bulb by applying the same procedure backwards. Remove the lens of the lamp by unscrewing its screws. - 199 - MAINTENANCE AND SERVICE Changing Bulbs Dome Lamp CAUTION Do not touch the bulbs with your hands when you are replacing the halogen bulbs, otherwise the bulbs will never work again. Reflector (Led) 5 Remove the Led lamp and renew by applying the procedure backwards. Unscrew the screws of the old reflector and renew it with new one. - 200 - MAINTENANCE AND SERVICE Changing Bulbs Roof Lamp Front Fog Lamp 5 1- Lamp case 3- Bottom plate 2- Top cover 4- Connector and harness Take the upper cover off by removing 2 screws (5) on the lamp. 1- Detach the electrical connector from its socket. 2- Remove the socket from fog lamp by rotating it counter-clockwise. (H1-70W) Detach the connectors (4) behind the lamp case. Take the lamp body off by removing 2 nuts. Install new lamp case (1) by applying same procedure backwards. - 201 - Remove the bulb and renew by applying the procedure backwards. MAINTENANCE AND SERVICE Changing Bulbs Turn Indicator Lamp Reading Lamp 5 Detach the electrical connector from its socket. Remove the bulb and renew by applying the procedure backwards. (BAYONET21W) Release the lamp covers from the tabs by pressing them from the ends on the direction of the arrow to replace the reading lamp bulbs. Remove the bulbs and renew by applying the procedure backwards. Reverse Buzzer A buzzer is available on your vehicle in addition to the reverse lamp. Buzzer will sound intermittently when the vehicle is shifted to reverse. Remove the socket by rotating it counterclockwise. - 202 - MAINTENANCE AND SERVICE Suspension Systems WARNING t is recommended, for a longer life of the springs, that you have the spring U-bolt nut torques checked between the first range of 2.000 km and 5.000 km (for once). CAUTION Bump stop Bump stop shall be inspected regularly In case of wearing out a bump stop Drive to a workshop. Replace the bump stop. 5 - 203 - MAINTENANCE AND SERVICE Suspension Systems Type 1. Axle 2nd Axle 3rd Axle 4th Axle 35XXD X X 41XXD X X Wear Pad Check 5 Check the grease condition of wear pads every week on X4 vehicles (except mixer vehicles), apply grease from the specified point if required. - 204 - MAINTENANCE AND SERVICE Locations of the Tools in the Vehicle LOCATION PARTS PART NAME LOCATION W SLEEPER CAB W/O SLEEPER CAB UNDER THE BED BEHIND DRIVER'S SEAT TOOLBOX UNDER THE BED BEHIND DRIVER'S SEAT WHEEL NUT WRENCH BEHIND PASSENGER SEAT BEHIND PASSENGER SEAT JACK LEVER BEHIND PASSENGER SEAT BEHIND PASSENGER SEAT - 205 - PARTS W SLEEPER CAB W/O SLEEPER CAB TRAILER CONNECTION WIRE UNDER THE BED BEHIND PASSENGER SEAT TIRE INFLATION HOSE UNDER THE BED BEHIND DRIVER'S SEAT WARNING LAMP IN GLOVE BOX IN GLOVE BOX PART NAME 5 MAINTENANCE AND SERVICE Questions and Remedies 5 FAULT CAUSE AND REMEDY ENGINE IS STALLING Transfer pump does not intake, check the front filter. Check main fuel filter. The hole on the fuel tank cover may be clogged. Open it. There is water in the fuel. Replace if necessary. There is air in the fuel injection system. Check the fuel pipes and hoses. Freezing or air ingress in the fuel settling bottle filter or fuel intake lines; check and clean if required. ENGINE IS RUNNING ROUGHLY There may be air or clogging in the fuel pipes. Bleed air. Incorrect valve adjustment Intake manifold or air filter may be clogged. Clean or replace. There is water in the fuel. Replace if necessary. There may be clogging or damage in the exhaust pipes or the muffler. Have them inspected. Injector pump intake may be insufficient. Contact an authorized dealer. ENGINE IS DIFFICULT TO START Air cleaner is dirty. Clean or replace. Starter is faulty. Have it repaired. Battery discharged. Have it charged. Exhaust system may be clogged. Have them inspected. Pre-heater fault. Have them inspected. Fuel level low. Top up. Air in the fuel system. Bleed air. - 206 - MAINTENANCE AND SERVICE Questions and Remedies FAULT CAUSE AND REMEDY ENGINE IS OVERHEATING Coolant level low. Top up. An object may be blocking the front of the radiator. Check it. Radiator cores may be dirty. Clean the radiator. Water pump belt adjustment is wrong. Have it inspected by an authorized dealership. Exhaust system may be clogged, have it inspected. Thermostat is faulty. Check it (and replace it, if necessary). Water pump is faulty. Have it inspected by an authorized dealership. LOW TRACTION Engine compression level is low. Have them inspected. Air cleaner is dirty. Clean or replace. Incorrect valve adjustment Drive to an authorized dealer. BLACKSMOKE FROM THE EXHAUST Air cleaner is dirty. Clean or replace. Intake manifold or exhaust system may be clogged. Have them inspected. Compression level is low. Cylinder head gasket leaks. Incorrect valve adjustment or valves faulty. Engine worn. Drive to an authorized dealer and have the necessary inspections performed. Turbo unit is faulty. Drive to an authorized dealer. ir leak on the Intercooler and / or hose connections. Inspect the hose and clamps. Diesel particle filter breakage (Euro-6 vehicles) - 207 - 5 MAINTENANCE AND SERVICE Questions and Remedies 5 FAULT CAUSE AND REMEDY LOW OIL PRESSURE Oil pressure indicator is blocked or faulty. Have them inspected. Oil filter element is clogged. Replace. Oil strainer is blocked. Clean it. Oil pump is faulty. Check the backlash, drive shaft and operation of safety valve. POWER STEERING Hydraulic oil level is low, top it up and bleed the system. NOISE IN STEERING WHEEL Drive to an authorized dealer and have the necessary inspections performed. STEERING WHEEL IS ROTATING ROUGHLY PLAY IN STEERING WHEEL ENGINE DOESN'T PRODUCE POWER Check the tire pressure. Vehicle maybe overloaded. Check the suitability of load capacity. If load limits are not exceeded, drive to an authorized dealer. Check for looseness in the steering system. Also have the adjustment inspected in an authorized dealership. Check the tire pressure and wheel alignment. Engine is faulty. Drive to an authorized dealer to resolve the fault. Exhaust or intake manifold is loose. Drive to an authorized dealer. Wrapping on turbine shaft bearings. It shall be repaired. Turbo pressure may be lower than necessary. You are recommended to contact nearest FORD OTOSAN authorized dealership. - 208 - TECHNICAL SPECIFICATIONS 6 - 209 - TECHNICAL SPECIFICATIONS Labels Vehicle Identification Plate Over the right chassis arm of the vehicle: Engine label Vehicle identification plate is located under the hood in the front of the cab. Chassis number is placed under the front hood and chassis right side arm, and it has 17 digits. Example: NM0K13TEDFBL12345 Metal label with the engine type and serial number inscribed on it is placed on the lower right side of the turbocharger intake pipe. 6 - 210 - TECHNICAL SPECIFICATIONS Fluid Filling Capacities USAGE AREA ENGINE OIL (INCL. OIL FILTER) DESCRIPTON FORD SPECIFICATION NO. 5W30 WSS-M2C213-A1 WSS-M2C944-A (Cold climate: WSS-M2C212-A1) 26 L 9 LT EURO 6 VEHICLES (CONSTRUCTION TRUCK) 26 L 9 LT EURO 3-5 VEHICLES (ROAD TRUCK) 26 L 9 LT EURO 3-5 VEHICLES (CONSTRUCTION TRUCK) 26 L 10W40 (Cold climate: 5W30) 12.7 LT EURO 6 VEHICLES 46 L 5W30 12.7 LT EURO 3 VEHICLES EATON ESO 14409 ZF 12 TX 2210 TD AMT-INTARDER ZF 12 TX 2210 TD AMT-w/o INTARDER ZF 12 TX 2620 TD AMT-INTARDER TRANSMISSION ZF 12 TX 2620 TD AMT-w/o INTARDER DIFFERENTIAL ZF 16S 2230 TO-with INTARDER ZF 16S 2230 TO-w/o INTARDER ZF 16S 2530 TO-with INTARDER ZF 16S 2530 TO-w/o INTARDER ZF 9S 1310 FORD XSS-470 FORD XSS-470 (Tractor) FORD XSS-510 DIFFERENTIAL FORD XPT-330 FORD XPS-330 DRIVE HUB SAE NO. 9 LT EURO 6 VEHICLES (ROAD TRUCK) 12.7 LT EURO 5 VEHICLES JOURNALHUB CAPACITY X4 AND X2 TRACTION VEHICLES X4 VEHICLES Vehicles with Single Steerable Axle Vehicles with 9lt engine Vehicles with Single Steerable Axle Vehicles with 12.7lt engine STEERING FLUID Vehicles with Dual Steerable Axle Vehicles with 9lt engine Normal climate conditions 40 L 10W40 40 L 10W40 8.5 L 22.5L 12.5 23.5 L 13.5 L 25L 15.4 25L 15.4L 7,5L 12.5 L 12.5 L 18.5 L 23L 17 L 85W140 75W85 85W140 85W140 85W140 85W140 3 L/hub 85W140 75W140 4,7L - 211 - WSS-M2C213-A1 WSS-M2C944-A (Cold Climate: WSS- M2C212-A1) 6 75W80 2 x 0.75 L 3.5 L 4.5 L 9L SPECIFICATION NO. J2360 API GL-5 WSL-M2C192-A WSS-M2C938-A API GL-5 TECHNICAL SPECIFICATIONS Fluid Filling Capacities USAGE AREA ENGINE COOLANT (ANTIFREEZE) DESCRIPTON 40 Lt 12.7 Lt Vehicles (with Intarder) 69 Lt 12.7 Lt Vehicles (without Intarder) CAB LIFTER OIL 6 WHEEL GREASES CAPACITY 9 LT Vehicles FORD SPECIFICATION NO. 50 Lt SLM-6C9100-A Front Disc Brake 650 g/wheel WSS-M1C275-A Front Drum Brake 650 g/wheel WSD-M1C228-A Tax Axle – (Except C6AS) 900 g/wheel WSD-M1C228-A Tax Axle – C6AS 650 g/wheel WSS-M1C275-A Drive Axle (Only 510 Type) 900g/wheel WSD-M1C228-A front axle self steer SPARE WIRE AXLE PIN AXLE LIFTING SHAFT SECOND AXLE STEERING ARM UNDER BODYLEAF SPRING FRICTION PADSLEAF SPRING EYELETBALANCE ARM CENTER PIN BATTERY TERMINALS BRAKE SHOE SLIDERS CAB LOCK BUSHING DOOR STRUT DOOR LOCKS, LATCHES (**) 15 g/pin (**) (**) WSD-M1C228-A Lithium-based Lithium-based Lithium-based Lithium-based WSD-M1C228-A WSD-M1C228-A WSD-M1C228-A WSD-M1C228-A (**) Lithium-based WSD-M1C228-A 20 g Petroleum jelly With Copper Additive WSD-M1C226-A (**) 0.024 g/lock 75 g/door (**) Polyurea NLGI 2 Lithium No. 1 WSD-M1C228-A WSD-M1C238-A SMIC-1021-A (***) Lithium-based WSA-M1C160-D2 SS-M13P12-A DECELERATION -15 °C to -40 °C - 212 - SPECIFICATION NO. WSS-M97B44-D - Factory spec WSS-M97B44-D2 - Service specifications 0.58 L KING PIN GREASES SAE NO. ISO 6743-9 L-XBEHB 2 DIN 51502 KP2P-20 TECHNICAL SPECIFICATIONS Fluid Filling Capacities USAGE AREA DESCRIPTON CLUTCH FLUID A/C SYSTEM REFRIGERANT A/C SYSTEM OIL FUEL 9 LT Engine 12.7 LT Engine 9 LT Engine 12.7 LT Engine CAPACITY SAE NO. FORD SPECIFICATION NO. SPECIFICATION NO. 0,37 L FMVSS No.116 WSS-M6C65-A2 SUPERDOT4 J2776 WSH-M17B19-A 940 gr 890 gr 150 -0/+20 cc 175 -0/+10 cc 200L 250L 315L 350L 400L 410L 450L WSH-M1C231-B 6 TSEN590 480L UREA 510L 550L 600L 55L 75L DIN 70070 WSS-M99C130-A ISO 22241-1 (*) Antifreeze ratio in the coolant shall be at least 30% to protect the engine cooling system against corrosion. Engine coolant shall include at least 60% antifreeze to prevent freezing down to -52 °C. (**) This is used as required in maintenances. (***) Instead of lithium based chassis greases in operating conditions from-15°C to-40°C Refer to latest Ford Trucks Periodical Maintenance Sheet or contact a Ford authorized dealership for oil replacement intervals. - 213 - TECHNICAL SPECIFICATIONS Engine Specifications 9 LT 330 PS 6 12.7 LT 420 PS Number of cylinders 6 Number of cylinders 6 Displacement 9000cc Displacement 12700 cc Bore 115mm Bore 130 mm Compression ratio 17,6 ± 0,5:1 Compression ratio 17 ± 0,5:1 Minimum Engine Speed Without Load 600 ± 10 Minimum Engine Speed Without Load 550 ± 10 Maximum Engine Speed With Load: 2200 ± 20 Maximum Engine Speed With Load: 1800 ± 20 Valve Clearance Intake: 0.3 mm . Exhaust: 0,4mm Ignition Sequence 1-5-3-6-2-4 Turbo Euro5: Cummins HE400WG variable geometry Euro6: Borgwarner BV70 variable geometry Valve Clearance DIN 2.1-3bar Exhaust: 2.4 mm. Ignition Sequence 1-5-3-6-2-4 Turbo Borgwarner BV70 variable geometry DIN 0.7-2bar Oil Pressure Intake: 0.4 mm 600 rpm: 0.7 - 2 bar Oil Pressure (100 °C) Max speed: 6 bar 1100 rpm: 2.1 - 3bar Max speed: 6 bar Engine brake 27 kW/lt (2400 rpm) Engine brake 30 kW/lt (2400 rpm) Torque per unit liter 144Nm Torque per unit liter 169 Nm PS per unit liter 37PS PS per unit liter 33 PS - 214 - TECHNICAL SPECIFICATIONS Engine Specifications 12.7 LT 480 PS Number of cylinders 6 Displacement 12700cc Bore 130 mm Compression ratio 17 ± 0,5:1 Minimum Engine Speed Without Load 550 ± 10 Maximum Engine Speed With Load: 1800 ± 20 Valve Clearance 6 Intake: 0.4mm Exhaust: 2.4mm Ignition Sequence 1-5-3-6-2-4 Turbo Borgwarner BV70 variable geometry 600 rpm: 0.7 - 2 bar Oil Pressure (100 °C) 1100 rpm: 2.1 - 3bar Max speed: 6 bar Engine brake 30 kW/lt (2400 rpm) Torque per unit liter 181 Nm PS per unit liter 36 PS - 215 - TECHNICAL SPECIFICATIONS Transmission Specifications Gearbox gear ratios ZF 12 TX 2210 TD AMT 6 LOW HIGH 1ST GEAR 16.69 12.92 2ND GEAR 9.926 3RD GEAR 4TH GEAR ZF16S 2230 LOW HIGH LOW HIGH 5TH GEAR 2.174 1.684 7.688 6TH GEAR 1.291 5.895 4.565 REVERSE GEAR 15.54 3.655 2.831 LOW HIGH 1ST GEAR 13.8 11.54 6TH GEAR 2.08 1.74 1 2ND GEAR 9.49 7.93 7TH GEAR 1.43 1.2 12.03 3RD GEAR 6.53 5.46 8TH GEAR 1 0.84 4TH GEAR 4.57 3.82 REVERSE GEAR 12.92 10.8 5TH GEAR 3.02 2.53 ZF 12 TX 2620 AMT LOW HIGH LOW HIGH 1ST GEAR 16.688 12.924 5TH GEAR 2.174 1.684 2ND GEAR 9.926 7.688 6TH GEAR 1.291 1 3RD GEAR 5.895 4.565 REVERSE GEAR 15.537 12.033 4TH GEAR 3.655 2.831 - 216 - TECHNICAL SPECIFICATIONS Transmission Specifications Gearbox gear ratios ZF 16S 2530 LOW HIGH 1ST GEAR 13.8 11.54 2ND GEAR 9.49 3RD GEAR ZF 16S 1630 LOW HIGH LOW HIGH 6TH GEAR 2.08 1.74 7.93 7TH GEAR 1.43 6.53 5.46 8TH GEAR 4TH GEAR 4.57 3.82 REVERSE GEAR 5TH GEAR 3.02 2.53 LOW HIGH 1ST GEAR 16.41 13.8 6TH GEAR 2.47 2.08 1.2 2ND GEAR 11.28 9.49 7TH GEAR 1.7 1.43 1 0.84 3RD GEAR 7.76 6.53 8TH GEAR 1.19 1 12.92 10.8 4TH GEAR 5.43 4.57 REVERSE GEAR 5TH GEAR 3.59 3.02 Eaton ESO 14409 6 ZF 9AS 1510 TO ECOTRONIC AMT LOW HIGH 1ST GEAR 6.55 6TH GEAR 1.38 2ND GEAR 4.87 7TH GEAR 1 3RD GEAR 3.53 8TH GEAR 0.75 4TH GEAR 2.64 REVERSE GEAR 9.83 5TH GEAR 1.86 C GEAR 9.40 - 217 - 1ST GEAR 9,48 6TH GEAR 1,89 2ND GEAR 6,58 7TH GEAR 1,35 3RD GEAR 4,68 8TH GEAR 1 4TH GEAR 3,48 9TH GEAR 0,75 5TH GEAR 2,62 REVERSE GEAR 8,97 TECHNICAL SPECIFICATIONS Installation of Upper structure 6 You can access the web portal designed to be a guide for Ford Trucks upper structure manufacturers from the following address: http://www.fordtrucks-portal.com. - List of superstructure builders listed as recommended firm as per the inspections of Ford Otosan. Portal requires a membership and provides the following: http://www.fordtrucks-portal.com “Ford Otosan contact information” tab to contact relevant persons for your questions. - Urgent info bulletins - Superstructure forms - Technical bulletins Visit You may send e-mails to qvmhelp@ford. com.tr for your questions on the portal. - Type approvals - 2D and 3D technical drawings and models - Vehicle specification sheets - Electric and air outlet diagrams - Advisory, monitory documents - 218 - MANUFACTURER FIRM Ford Otomotiv Sanayi A.S. Akpınar Mah. Hasan Basri Cad. No: 2 34885 Sancaktepe/Istanbul