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Ford E-550 manual

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Table of contents for the manual

  • Page 1

    2002 MARCH 2002 Important Notice[...]

  • Page 2

    REFERENCE INFORMA TION FORD TRUCK BODY BUILDER ADVISOR Y SER VICE The Ford T ruck Body Builder Advisory Service assistance may be consulted regarding information contained in this manual. For assistance:  Call (877) 840-4338  Fax (313) 594-2633  E-Mail bbasqa@ford.com or at the BBAS website - www .fleet.ford.com/truckbbas Include your name[...]

  • Page 3

    INDEX/FEA TURES Index 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric/U.S. Unit Equivalents 2 . . . . . . . . . . . . . . . . . . . . Model Lineup 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Reference SgRP X & Z Locations 4 . . . . . . . . . . . Safety Section Seat Restraint Sy[...]

  • Page 4

    METRIC/U.S. CUST OMAR Y UNIT EQUIV ALENTS BB0689 TYPICAL LONGITUDINAL PLANE GROUND HORIZONT AL PLANE (mm) PLANE VER TICAL TRANSVERSE PLANE MM THREE–DIMENSIONAL REFERENCE SYSTEM X Y Z Z “0 ” click here TO RETURN T O INDEX Page 2 E-550 SUPER DUTY CUT AW A Y Multiply: by: to get: Multiply: by: to get: Multiply: by: to get: Multiply: by: to get: [...]

  • Page 5

    NOTE  [ ] DIMENSIONS ARE INCHES. E-550 SUPER DUTY CUT A W A Y MODEL LINEUP click here TO RETURN T O INDEX Page 3 E-550 SUPER DUTY CUT A W A Y BASE CURB WEIGHT * MODEL SERIES WHEELBASE GVWR ST ANDARD ENGINES BASE CURB WEIGHT* MODEL SERIES CODE WHEELBASE mm/inches GVWR pounds ST ANDARD TRANSMISSION ENGINES liters FRONT pounds REAR pounds TOT AL po[...]

  • Page 6

    THIS INFORMA TION IS PROVIDED TO ASSIST IN THE INST ALLA TION OF SEA TS OTHER THAN FORD INST ALLED SEA TS AND T O HELP PRESERVE THE INTENDED PERFORMANCE OF THE SAFETY AND ERGONOMIC FEA TURES OF THE 2002 E-SERIES. THE MID-TRACK H-POINT LOCA TION MUST BE MAINT AINED IN ORDER TO COMPL Y WITH FMVSS 208 AIRBAG REQUIREMENTS. NOTES  [ ] DIMENSIONS ARE [...]

  • Page 7

    E-550 SUPER DUTY CUT A W A Y OCCUP ANT PROTECTION SYSTEMS SEA T RESTRAINT SYSTEM click here TO RETURN T O INDEX Page 5 E-550 SUPER DUTY CUT A W A Y INFORMA TION The following recommendations are intended to assist in the design of seats and seat belt systems capable of meeting the requirements of the F/CMVSS 207, 208, 209 and 210 except for front s[...]

  • Page 8

    FRONT SEA TS RESTRAINT INST ALLA TION RH P ASSENGER SEA T RESTRAINT SYSTEM INST ALLA TION LH DRIVER SEA T RESTRAINT SYSTEM INST ALLA TION NOTE - [ ] DIMENSIONS ARE FT -LB OR INCHES. E-550 SUPER DUTY CUT A W A Y OCCUP ANT PROTECTION SYSTEMS SEA T RESTRAINT SYSTEM click here TO RETURN T O INDEX Page 6 E-550 SUPER DUTY CUT A W A Y 6.0 MIN. CLEARANCE T[...]

  • Page 9

    LH DRIVER SEA T INST ALLA TION RH P ASSENGER SEA T INST ALLA TION LH DRIVER SEA T DELETE OPTION POWER LH SHOWN SEA T ASY . N802351–S424 STUD 2 REQ’D. M200751 TRACK ASY . FRT . ST . 56912–S58 SCREW 4.2 x 19 T APPING N800937–S424 NUT & WASHER A SY . 2 REQ’D. 55.0 8.3 Nm N620481–S58 NUT M8 x 1.75 HEX FLANGE TORQUE 25.0 3.8 Nm N81 1326?[...]

  • Page 10

    E-550 SUPER DUTY CUT A W A Y OCCUP ANT PROTECTION SYSTEMS AIRBAG SUPPLEMENT AL RESTRAINT SYSTEM BB0538 AIR BAG SAMPLE XXXXXXXXXXX click here TO RETURN T O INDEX Page 8 E-550 SUPER DUTY CUT A W A Y INFORMA TION Ford urges careful consideration of the recommendations that follow . They are based on analyses of component and vehicle tests, actual serv[...]

  • Page 11

    BB0466 DO NOT INST ALL ADDITIONAL COMPONENTS IN THE SHADED AREAS, OR AL TER OR MODIFY THESE AREAS. ELECTRONIC CRASH SENSOR MODULE AIRBAG INSTRUMENT P ANEL HARNESS STEERING WHEEL AIRBAG READINESS INDICA TOR CONNECTOR A T SAFETY WALL ENGINE COMP ARTMENT HARNESS CRASH SENSOR DO NOT MODIFY OR AL TER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINIT[...]

  • Page 12

    NOTES  [ ] DIMENSIONS ARE INCHES. NOTES  A, B, F, R DIMENSIONS, SEE P AGE 1 1. NOTES  25 MM CLEARANCE IS REQUIRED BETWEEN ALL FUEL T ANK COMPONENTS AND NOTES  SECOND UNIT BODY . CONT ACT BODY BUILDERS ADVISORY SER VICE FOR NOTES  NOT ES INFORMA TION. DIMENSIONS WB OVERHANG OVERALL LENGTH CURB LOADED [159.5] [177.5] [191.5] [209.5] [2[...]

  • Page 13

    DEP AR TURE ANGLE A T GVWR APPROACH ANGLE A T GVWR GROUND LINE 899 [35.4] 1 198 [47.2] MINIMUM GROUND CLEARANCE LINE A T GVWR (LOADED) – COMPONENTS THA T COULD DISABLE A VEHICLE SHOULD BE 30.0 [1.18] ABOVE THE MINIMUM CLEARANCE LINE. BB0684 G J “B” TIRE DIAMETER “A” ST A TIC LOADED RADIUS 162 [6.4] 899 [35.4] 1 198 [47.2] 182 [7.2] 162 [6[...]

  • Page 14

    E-550 SUPER DUTY CUT A W A Y ALL WHEELBASES NOTES  [ ] DIMENSIONS ARE INCHES. NOTES  C, FW , TW, TH DIMENSIONS, SEE P AGE 1 1. TH TW 25.1 FW TW TH 1 1 C FRONT VIEW C L VEHICLE [1.0] CLEARANCE C 25.1 REAR VIEW MAX. RIGHT TURN MAX. LEFT TURN LEFT FRONT TIRE TW L TW R VEHICLE PLAN VIEW C L = DIST ANCE FROM = DIST ANCE FROM T OP OF FRAME C L OF V[...]

  • Page 15

    NOTES  [ ] DIMENSIONS ARE INCHES. NOTES  C, CH, FW DIMENSIONS, SEE P AGE 1 1. E-550 SUPER DUTY CUT A W A Y 159.5  WHEELBASE FRAME DA T A BODY PUCKS BB0679 952 [37.4] 847 [33.3] 613 [24.1] 813 [32.0] 381 [15.0] 1230 [48.4] 1460 [57.5] 47.0 FREE ST A TE 35.7 DIA HOLE IN FRAME [1.4] [1.8] BOL TS & BODY MOUNTS IN DUNNAGE P ACKAGES T ORQUE [...]

  • Page 16

    NOTE  [ ] DIMENSIONS ARE INCHES. E-550 SUPER DUTY CUT A W A Y 177.5  - 191.5  WHEELBASE FRAME DA T A 952 [37.4] 847 [33.3] 613 [24.1] 527 [20.7] 743 [29.3] 1231 [48.4] 1460 [57.4] 381 [15.0] BB0681 952 [37.4] 847 [33.3] 462 [18.2] 677 [26.6] 1099 [43.2] 1353 [53.2] 1460 [57.5] 381 [15.0] BB0680 NOTE: SP ACER OPTIONS NOT A V AILABLE ON E–[...]

  • Page 17

    NOTE  [ ] DIMENSIONS ARE INCHES. E-550 SUPER DUTY CUT A W A Y 209.5  - 233.5  WHEELBASE FRAME DA T A 952 [37.4] 847 [33.3] 462 [18.2] 677 [26.6] 822 [32.3] 1353 [53.2] 1460 [57.4] 381 [15.0] 734 [28.9] BB0683 305 [12.0] BB0682 NOTE: SP ACER OPTIONS NOT A V AILABLE ON E–550. CONT ACT BODY BUILDERS ADVISORY SERVICE FOR INFORMA TION REGARDI[...]

  • Page 18

    E-550 SUPER DUTY CUT A W A Y 55 GALLON AFT -OF-AXLE FUEL T ANK NOTE  [ ] DIMENSIONS ARE INCHES. BB0693 822.9 [14.3] [13.0] 40.6 988.0 REAR AXLE C L A A A FUEL FILL C L 374.6 [14.7] 939.8 [37.0] [32.4] [1.6] 363.2 330.2 [38.9] 25mm CLEARANCE IS REQUIRED BETWEEN ALL FUEL T ANK COMPONENTS AND SECOND UNIT BODY . CONT ACT BODY BUILDERS ADVISORY SERVI[...]

  • Page 19

    NOTE  [ ] DIMENSIONS ARE INCHES. E-550 SUPER DUTY CUT A W A Y FUEL FILLER SYSTEMS click here TO RETURN T O INDEX Page 17 E-550 SUPER DUTY CUT A W A Y 1 2 3 4 5 6 FRONT OF VEHICLE TORQUE SEQUENCE C L OF FILLER NECK OUTBOARD SURFACE OF FRAME RAIL FRONT OF VEHICLE FUEL T ANK TO L OF REAR AXLE FOR ALL W .B. C SCREW 3 REQ’D. TORQUE TO 2.1 – 2.9 N[...]

  • Page 20

    E-550 SUPER DUTY CUT A W A Y DIMENSIONAL DA T A E B B E W3 W5 W1 17 C L OUTSIDE FRONT F ASTENER C L OUTSIDE FRONT F ASTENER SEA T BASE POINT A SEA T BASE POINT A P ASSENGER – SEA T DRIVER – SEA T IMPORT ANT : THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE T O BE A T DESIGN POSITION. E–SERIES VEHICLES A T DESIGN POSITION WILL BE LEVEL FRONT[...]

  • Page 21

    NOTE  DIMENSIONS ARE INCHES. E-550 SUPER DUTY CUT A W A Y BODY “ SECTION A ” 51.18 55.12 59.05 63.0 66.93 70.37 74.80 78.74 82.68 39.37 35.43 31.50 0.22 1.97 1.97 1.97 1.97 1.97 1.91 0.53 0.59 0.21 2.30 0.90 1.14 1.26 0.81 2.38 0.87 0.22 1.14 0.40 2.48 2.03 1.61 0.92 1.25 0.65 0.40 BB0671 27.56 23.62 19.68 15.75 1 1.81 7.87 3.94 0 1.97 1.97 [...]

  • Page 22

    CIRCUIT CHART ELECTRICAL WIRING CUST OMER ACCESS CIRCUITS BB0481 UNWRAP T APE FROM HARNESS IN THIS AREA AND REMOVE JUMPER CONNECTION T O EXPOSE FRONT OF VEHICLE T O INST ALL THE “CHMSL CONNECTOR” . “ CHMSL” FIGURE A E-SERIES SUPER DUTY CUT A W A Y click here TO RETURN T O INDEX Page 20 E-550 SUPER DUTY CUT A W A Y Circuit Number Color Code [...]