1 General Information
1.1 About This Manual..............................5
1.1.1 New for this BEMM publication
02/2017............................................................5
1.1.2 Introduction....................................................5
1.1.3 Important Safety Instructions.................5
1.1.4 Warnings, Cautions and Notes in This
Manual.............................................................5
1.1.5 How to Use This Manual...........................6
1.1.6 Low Level and High Level
Vehicles............................................................6
1.2 Commercial and Legal Aspects..........7
1.2.1 Terminology....................................................7
1.2.2 Warranty on Ford Vehicles........................7
1.2.3 Legal and Vehicle Type Approval...........7
1.2.4 Alternative Type Approval.........................7
1.2.5 Legal Obligations and Liabilities.............7
1.2.6 General Product Safety
Requirement...................................................7
1.2.7 Product Liability............................................8
1.2.8 Restraints System........................................8
1.2.9 Drilling and Welding....................................8
1.2.10 Minimum Requirements for Brake
system and Load Apportioning Valves
.............................................................................8
1.2.11 Road Safety....................................................8
1.3 Conversion Homologation..................9
1.4 Electromagnetic Compatibility
(EMC).................................................10
1.4.1 Suggested Antenna Location..................11
1.5 Vehicle Duty Cycle Guidelines...........12
1.5.1 Conversion Effect on Fuel Economy
and Performance........................................12
1.5.2 Vehicle Ride and Handling
Attributes.......................................................12
1.6 Jacking................................................13
1.7 Lifting.................................................14
1.8 Noise, Vibration and Harshness
(NVH).................................................15
1.9 Vehicle Transportation Aids and
Vehicle Storage..................................16
1.10 Package and Ergonomics...................17
1.10.1 General Component Package
Guidelines......................................................17
1.10.2 Driver Reach Zones.....................................17
1.10.3 Driver Field of View.....................................17
1.10.4 Conversion Effects on Parking
Aids...................................................................17
1.10.5 Aids for Vehicle Entry and Exit...............17
1.10.6 Registration Plates.....................................18
1.11 Package and
Ergonomics—Specifications.............19
1.11.1 Recommended Body Dimensions.......19
1.11.2 Chassis Cab Body - Basic Dimensions
and Weights.................................................22
1.11.3 Kerb Mass and Payload...........................23
1.11.4 Front, Rear and Side Under-run
Protection.....................................................23
1.12 Hardware—Specifications................24
1.13 Load
Distribution—Specifications............25
1.13.1 Load Distribution Calculations - Driver
and Passenger Weight
Distribution...................................................25
1.13.2 Center of Gravity.........................................27
1.14 Towing................................................31
1.14.1 Towing Requirements...............................31
1.14.2 Towing.............................................................31
1.14.3 Towing capacities.......................................31
1.14.4 Trailer Towball Download........................31
1.14.5 Towing Specifications...............................31
2 Chassis
2.1 Suspension System...........................32
2.2 Brake System.....................................33
2.2.1 General..........................................................33
2.2.2 Brake Hoses.................................................33
2.2.3 Trailer Brakes (Low Level
Vehicles)........................................................33
2.2.4 Trailer Brakes (High Level
Vehicles).......................................................34
3 Powertrain
3.1 Fuel System.......................................36
3.1.1 Fuel Filler Pipe Shipping Bracket (if
equipped).....................................................36
3.1.2 Fuel Filler Mounting..................................38
3.1.3 Fuel Filler Vent Hose................................40
3.1.4 Axle Breather Vent Hose..........................41
3.1.5 Selective Catalytic Reduction
System............................................................41
3.1.6 Filling the Diesel Exhaust Fluid
Tank................................................................42
4 Electrical
4.1 Battery and Cables............................45
4.1.1 Battery Information..................................45
4.1.2 Auxiliary Battery (XL Plus
Vehicles)........................................................52
4.1.3 Auxiliary Battery Relocation and use
of Electrical Harness Extension (Fly
Lead) (XL Plus Vehicles)........................55
4.1.4 Generator and Alternator.......................55
4.1.5 Authorised Parts........................................55
4.2 Electronic Engine Controls...............56
4.2.1 Vehicle Speed Output (Signal) (Low
Level Vehicles Only).................................56
4.2.2 Vehicle Speed Output (Signal) (High
Level Vehicles )...........................................62
4.3 Exterior Lighting................................63
4.3.1 Rear Combination lamps.......................64
4.3.2 Rear Fog Lamp...........................................64
4.3.3 Rear License Plate Lamp........................65
4.3.4 Reversing Lamps, Rear View Camera,
Reversing Alarm (Manual
Transmission).............................................67
4.3.5 Additional External Lamps - (Low
Level Vehicles Only)..................................67
4.3.6 Trailer Towing..............................................68
4.3.7 Additional External Lamps (Vehicles
with Special Equipment Pack).............70
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