auxiliary battery FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual

3.7Exhaust System..........................86
3.7.1Extensions and Optional Exhausts....
86
3.7.2Exhaust Pipes and Supports.............86
3.7.3Exhaust Heat Shields..........................86
3.8Fuel System.................................88
4 Electrical
4.1Communications Network..........90
4.1.1CAN-Bus System Description and
Interface................................................90
4.1.2Central Junction Box (CJB)................91
4.1.3Circuit Diagram....................................93
4.2Module Communications
Network—Specifications.............94
4.2.1Circit Diagram......................................94
4.3Charging System.........................95
4.3.1General Information and Specific
Warnings...............................................95
4.3.2Power Management Settings...........95
4.3.3Electrical Conversions........................95
4.3.4Fitting of Equipment Containing an
Electric Motor.......................................97
4.3.5Vehicle Electrical Capacity -
Alternator..............................................97
4.3.6Charge Balance Guidelines...............97
4.3.7Circuit Diagrams..................................97
4.4Battery and Cables.....................98
4.4.1Battery Information.............................98
4.4.2Generator and Alternator.................103
4.5Climate Control System.............106
4.6Instrument Cluster.....................107
4.7Horn...........................................108
4.8Tachograph................................109
4.8.1Legislation...........................................109
4.8.2Tachograph Mounting.......................110
4.9Information and Entertainment
System - General
Information—Specifications.......112
4.9.1Radio Connector................................112
4.9.2Possible Accessories.........................113
4.10Cellular Phone............................115
4.11Exterior Lighting.........................116
4.11.1Reversing Lamps...............................116
4.11.2Additional External Lamps................116
4.11.3Lamps – Hazard / Direction
Indication..............................................117
4.11.4Lamps – Front and Rear Fog Lights....
117
4.11.5Lamps for Wide Vehicles...................117
4.11.6Electrically operated Door Mirrors....
117
4.12Interior Lighting..........................118
4.12.1Additional Internal Lamps .................118
4.12.2Additional 'Theatre Lighting' for rear
of vehicle interior................................118
4.13Fuses and Relays.......................119
4.13.1Wiring Specification............................119
4.13.2Auxiliary Fuses, Fuse Box and Relays
(Fuses - Standard).............................119
4.13.3Customer Connection Points..........120
4.13.4Special Vehicle Option Auxiliary Fuse
Box........................................................121
4.13.5Additional Ignition, Instrument Panel
Illumination and Air Conditioning On
Signals.................................................124
4.13.6Relays and Switches.........................127
4.13.7Windscreen wipers...........................130
4.14Special Conversions..................131
4.14.1Vehicle Speed Output (Signal).........131
4.14.2Engine Run Signal (D+ Alternative)....
132
4.14.3Connectors.........................................133
4.14.4Installation and Routing Guides.......134
4.14.5Electrics for Tow bar.........................136
4.14.6Ground Points....................................140
4.14.7Special Vehicle Options (SVO) and
Aftermarket Kits.................................146
4.14.8Additional Vehicle Signals / Features..
147
4.14.9Engine RPM (Revs Per Minute) Speed
Controller.............................................157
4.14.10Adding Connectors, Terminals and
Wiring...................................................162
5 Body and Paint
5.1Body...........................................175
5.1.1Body Structures - General
Information..........................................175
5.1.2Back Panel Removal.........................177
5.1.3Integrated Bodies and Conversions...
177
5.1.4Chassis Cab........................................179
5.1.5Cab Van Floor.....................................185
5.1.6Hydraulic Lifting Equipment for Van,
Bus, Kombi and Chassis Cab..........186
5.1.7Partitions (Bulkhead) - Driver and
Front Passenger(s) Protection on Van,
Bus and Kombi..................................192
5.1.8Racking Systems...............................194
5.1.9Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting.............198
5.1.10Tipper Bodies.....................................199
5.1.11Tank and Dry Bulk Carriers...............199
5.2Body System - General
Information—Specifications......200
5.2.1Van Floor - Load Compartment Tie
Downs for Van ,Bus and Kombi.....200
5.3Body Closures..........................203
5.3.1Load Compartment Interior Lining....
203
5.3.2Security, Anti Theft and Locking
System Security ...............................203
5.4Rear View Mirrors.....................208
5.4.1Mirrors for Wide Vehicles.................208
5.5Seats.........................................209
5.5.1Rear Seat Fixings Positions - Kombi...
209
5.5.2Heated Seats.....................................210
5.6Glass, Frames and Mechanisms...
211
5.6.1Rear Windows....................................211
Table of Contents
4

Electrical circuits associated with Management System
•The base vehicle will be equipped with a single
or dual battery system (with battery disconnect
switch). Additional batteries can be fitted in
conjunction with a battery disconnect switch
(cut-off relay), described in the section Battery
and Cables.
•When auxiliary electrical systems are added
to the vehicle, it is recommended that the
additional circuits are designed to be used with
the Special Vehicle Option Auxiliary Fuse Box
and / or the Link Harnesses, to maintain the
integrity of the electrical system.
Refer to: 4.13 Fuses and Relays (page 119).
•The materials and installation must meet the
quality standards described in this section.
•Any additional equipment or components must
be designed such that they have no Electro
Motive Force effect on the vehicle.
•The alternator and Engine Management
System [EMS, also referred to as Powertrain
Control Module (PCM)] are interdependent.
•The alternator should not be used as a source
for a conventional D+ signal.
Refer to: 4.14 Special Conversions (page 131).
•Take special care with the routing of existing
electrical looms within the vehicle to avoid
damage when fitting additional equipment.
WARNING: The fitting of voltage
boosters or other devices to
enhance alternator output are not
allowed. The fitting of such devices
will not only invalidate vehicle
warranties, but could damage either,
or both, the alternator and Engine
Management System or Powertrain
Control Module (PCM), and possibly
affect vehicle legal compliance.
Check local legislation.
Please see below the note concerning installation
of equipment containing an electric motor.
Where vehicles are equipped with twin battery
system, no additional connections should be
made to the terminal posts of the start relevant
battery. Further connections should only be made
via the customer connection point.
When an additional battery is fitted, this must be
connected to the appropriate battery.
Refer to: 4.4 Battery and Cables (page 98).
Disconnect all batteries, including earth, and the
alternator multi-plug prior to using welding or
cutting equipment and before working on any
electrical installations.
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•Before disconnecting the battery, check
availability of radio key code.
•Fuses – when auxiliary electrical systems are
to be added to the vehicle it is mandatory that
the additional circuit design includes the
necessary fuses.
•The Special Vehicle Option auxiliary fuse box
is recommended.
Refer to: 4.13 Fuses and Relays (page 119).
4.3.4 Fitting of Equipment
Containing an Electric Motor
WARNINGS:
When equipment containing an
electrical motor is connected, it
must be connected via a blocking
diode or relay to prevent “back
Electro Motive Force (EMF)” being
applied to the auxiliary terminal.
When electric motors are to be
fitted, account must be taken of the
potentially high currents that a
motor can draw.
CAUTION: The following must be
observed:
•All motors must be driven via relays with
contacts rated at least 3 times the maximum
rated current of the motor.
•All motor supply circuits must be individually
fused with the proper fuse rating for the
motor.
•All power wiring must be rated for at least 3
times the rating of the motor and installed as
far away as possible from any existing vehicle
wiring.
•All motors fitted should be fully suppressed to
ensure electrical interference does not affect
the vehicle systems.
•Add EMC emissions statement to CE
approval.
4.3.5 Vehicle Electrical Capacity
- Alternator
WARNING: Do not cut into the
alternator wires or use the
alternator as a source to obtain a
'D+ Signal'
An engine run signal is available from the Central
Junction Box by installing a T-piece jumper
harness (Ford Part Number 6C1V-14A411-F_).
Refer to: 4.14 Special Conversions (page 131).
4.3.6 Charge Balance Guidelines
The base vehicle is fitted with a 150A alternator.
It is recommended to conduct a charge balance
calculation in case the conversion comprises a
high number of electrical consumers or high
electrical consumption is expected.
4.3.7 Circuit Diagrams
For circuit diagrams for Auxiliary Fuse Box
Connections and Standard Ford relays.
Refer to: 4.13 Fuses and Relays (page 119).
Full vehicle wiring and circuit diagrams are in the
Ford Workshop Manual.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
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4.4 Battery and Cables
4.4.1 Battery Information
In order to protect the battery system from direct
ground shorts, a special fuse is incorporated into
the battery positive feed, in the pre-fuse box
under the driver’s seat.
This fuse is not repairable – use only a Ford
replacement part.
Where extra batteries are required on vehicles
with a single battery installation, the battery
disconnect switch (split charge relay) and
associated wiring/hardware — fitted as standard
to vehicles equipped with dual batteries — can
be added.
Batteries – Additional – Heavy Duty
High current consumption may require a
heavy-duty battery or an additional battery.
Factory fitted Special Vehicle Options are available
for heavy-duty and/or extra batteries with the
battery disconnect switch (split charge relay).
The batteries can be retrofitted.
See diagram E74522 - Battery disconnect switch
(split charge relay) circuit.
Deep Cycle Battery (not for use as
primary, start-relevant battery)
A Special Vehicle Option is available. Please
contact your local National Sales Company
representative for availability and details.
•The deep cycle battery is used in conjunction
with the battery disconnect switch (split charge
relay) in applications where power to ancillary
circuits would heavily discharge the main
vehicle battery(s).
•Installation should be under the driver's seat.
When the deep cycle battery is installed, the
battery disconnect switch (split charge relay)
must be used.
•When the Deep Cycle Battery is installed it is
recommended that the Special Vehicle Option
auxiliary fuse box is fed from the customer
connection points.
Battery Part Numbers and Usage
SizeQuantityTypeBattery Part Number
Single Battery Installation Front Wheel Drive
T71680 CCA (70Ah @20 hour rate)98AB-10655-D_ (Turkey)
T71700 CCA (80Ah @20 hour rate)6G9N 10655 P_ (Southampton)
Dual Battery Installation Rear Wheel Drive and Front Wheel Drive with specific options
T62590 CCA (60Ah @20 hour rate)98AB-10655-C_ (Turkey)
T62590 CCA (60Ah @20 hour rate)6G9N 10655 N_ (Southampton)
Dual Battery Installation Rear Wheel Drive -29°C Territories
T72680 CCA (70Ah @20 hour rate)98AB-10655-D_ (Turkey)
T72700 CCA (80Ah @20 hour rate)6G9N 10655 P_ (Southampton)
Deep Cycle Battery
H82(90Ah @20 hour rate;70Ah@5 hour rate)V3C15-10655-A_
Battery Rules:
•Batteries in parallel must be of the same type
and capacity.
•Starter and deep cycle batteries may only be
mixed through an isolator.
•For External charging of batteries ensure that
the maximum voltage of 14.6V is not
exceeded.
NOTE: Deep cycle batteries can be drained but
high loads can damage them. Always observe
circuit set-up outlined in diagram E74522 -
Battery disconnect switch (split charge relay).
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Battery Disconnect Switch (Split Charge Relay) circuit
Battery Disconnect Switch (Split Charge Relay)
Battery Disconnect Switch - Pin 11Central Junction Box (Passenger Junction Box)
- Fuse 77
A
Battery Disconnect Switch - Pin 22Battery Disconnect SwitchB
Battery Disconnect Switch - Pin 33Pre Fuse Box - Fuse 2C
Battery Disconnect Switch - Pin 44Start Relevant BatteryD
Central junction Box - Pin C4-355Non Start Relevant BatteryE
Central junction Box - Pin C4-346Pre Fuse BoxF
Central junction Box - Pin C1-27Central Junction Box (Passenger Junction Box)G
Battery Disconnect Switch (Split
Charge Relay)
Where a vehicle is equipped with a single battery,
a split charge option is available. This allows
auxiliary circuits, which would discharge the main
battery system, to be connected to an auxiliary
battery/batteries.
The battery disconnect switch is driven from the
central junction box and is always used with an
auxiliary battery/batteries, and can be fitted by
the vehicle converter. Reconfiguration of the
central junction box software by the Ford
Dealership is required to support this feature.
Where a vehicle already has a factory-fitted
dual-battery system, there is no provision or
need for a further battery cut-off relay, although
additional batteries can still be added in parallel
to the non start-relevant battery.
Outputs from the Central Junction
Box to the Battery Disconnect
Switch
The Battery Disconnect Switch is a bistable
device, requiring pulsed outputs to change state
(each pulse has duration of 50 ms at battery
voltage):
•C4-34 Pull-in
•C4-35 Pull-out
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Pull-in us actuvated within 70 ms of switching to
key position II
Pull-out is activated when switching to key
position I, or 0, and in key position II when no
engine run signal is sensed within 120 secs.
It is not possible to change state within 500 ms.
Removal of the Battery Disconnect
Switch (on twin battery models) and
wiring of batteries in parallel for high
current applications.
For vehicles equipped with a twin battery system,
wiring of the two batteries in parallel is not
recommended. If higher current is required,
680Ah batteries can be fitted (or a deep cycle
battery in lieu of the non-start relevant battery
only). Where a single passenger seat is fitted,
further batteries (1 or 2) can be installed in the
pedestal and added in parallel to the
non-start-relevant battery, although due
consideration then needs to be given to
increased current availability in the event of a
short circuit. Additional batteries should not be
installed under a passenger bench seat.
if this requirement is imperative, it would be
possible to disconnect the battery disconnect
switch and put the start-relevant and
non-start-relevant batteries in parallel using a
shorting bar (available from the Ford Delerships,
part number 6C1T-14A439-A*). There is one
important consideration when replacing the
battery disconnect switch with a shorting bar:
•Where the vehicle is configured for
twin-battery operation, the Central Junction
Box will detect if the battery disconnect switch
is missing (or has been removed), or the
mating connector short-circuited, and although
the vehicle will be functional, Diagnostic
Trouble Codes will be generated that will
flag-up during service. Hence if a shorting bar
is fitted, the vehicle needs to be reconfigured
(via the Dealership and Dealership Hotline).
Single to Dual Battery Conversion
For vehicles equipped with a single battery, it is
possible to upgrade to a twin battery system -
the connector for the battery disconnect switch
is present on all vehicles. In addition to
reconfiguring the vehicle for twin battery
operation (at a Dealership), the following battery
cables and components are required:
DescriptionPart Number
start relevant battery negative to vehicle ground point cable (right hand)
replaces C_ part
6C1T-14301-A_
start relevant battery negative to vehicle ground point cable (lefthand)
replaces D_ part
6C1T-14301-E_
start relevant battery negative to non-start relevant battery negative cable6C1T-14280-E_
pre-fuse box bus bar to non-start-relevant battery positive cable6C1T-14300-D_
Battery disconnect switch6C1T-10B728-A_
If a requirement exists (camper conversions for
example), it may be viable to order vehicles
installed with a single battery, a battery disconnect
switch, and a kit of harnesses – detailed above –
to be fitted by the installer.
Where required, e.g. for camper conversions,
gas-sealed battery boxes (with exterior venting)
are available. Ford part numbers:
6C1T-10N669-A_ (lefthand); 6C1T-10N669-B_
(right hand); 6C1T-10N725-A_ (lid).
The battery disconnect switch isolates the
auxiliary battery/batteries from the rest of the
base vehicle electrical system when the engine
is stopped.
The battery disconnect switch, together with
associated wiring and hardware, can be fitted as
part of an accessory kit (available from your local
Ford dealer) in the pre-fuse box.
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Dual Battery Installation with Pre-Fuse Box and Customer Connection Points
DescriptionItem
Pre-Fuse Box1
Customer Connection Points (Not M1 or M2 buses)2
Start Relevant Battery - connection to this battery is not permitted3
Battery Access Points
For auxiliary customer loads, only connect to the
customer connection points provided (not on M1
and M2 Buses).
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Connector B
Mono -7Mono +1
Radio Remote Control Ground8Switched Accessory +2
Auxiliary Left -9Auxiliary Left +3
Auxiliary Right -10Auxiliary Right +4
-11Phone Transceiver Active5
-12Radio Remote Control +6
Connector C
-7-1
-8-2
-9-3
-10-4
Auxiliary 2 Right11Auxiliary 2 Left5
-12Audio Ground6
Fuse Relay
no fuse is fitted to the radio1
no fuse is fitted to the radio2
4.9.2 Possible Accessories
Electric Antenna- Activation line, pin B2
(Switched Accessory +) is switched: 0 Volts when
the radio is switched off and +12 Volts when the
radio is switched on.
Auxiliary Input- Accepts a line-out from a
personal stereo or digital media player. This can
be supported by left channel pin C5 (+) and right
channel pin C11 (+) with a common ground, pin
C6, wired to a jack plug socket.
Audio Mute- There is a requirement under the
Health and Safety Machinery Directive to mute
the radio when machinery is in operation - this is
necessary to hear audible alarms and signals.
Pin B5 (C3-5 on the electrical schematic) on the
FAKRA interface should be used for this. In order
to avoid electrical issues due to leakage, and to
ensure connector compatibility, a connector
insert and a pre-crimped wire and terminal are
available as part of a wiring accessory kit, should
be used (Kit Part number KT6C1V-14A411-L*).
NOTE: When this line is pulled low (ground),
radio / CD sound is muted. However, there is no
wire present in the harness as this function is
normally communicated through the CAN bus.
Refer to: 4.14 Special Conversions (page 131).
(Adding Connectors, Terminals and Wiring)
After Market Hands Free Telephone Kit
(Non CAN-based)- Power should be supplied
via a fused battery line and activated by the
accessory line, pin A16. The mute line from the
phone is connected to Phone Transceiver Active,
pin B5. The audio output from the phone kit
should be fed into pins B1 (+) and B7 (–). The
phone audio is then amplified and diverted
through vehicle speakers.
Refer to: 4.14 Special Conversions (page 131).
Adding Connectors, Terminals and Wiring (for
Phone Transceiver Active / Speaker Terminals
and Wires).
After Market Audio / Navigation (Non
CAN-based)- Power should be supplied via a
fused battery line and activated by accessory
line, pin A16. Auxiliary input is connected as per
above.
NOTE: Note: Vehicle speed and reverse are
now CAN messages and supplied via the vehicle
multimedia bus, A9 (+) and A10 (-). There is no
hard wired Vehicle Speed Signal or reverse signal
available.
Additional Rear Speakers- Camper
vehicles, typically, are only equipped with
speakers in the front doors, in which case at
end-of-line the vehicle will be programmed for
just the front speakers and the fade function
disabled on the radios. If the radio is set for four
speakers, and those at the rear are absent, a
fault code will be flagged. The vehicle would need
reconfiguring at a Dealer once speakers are
installed. The radio will output 17W per channel
(left and right); a wire size with a CSA of 0.75 is
recommended.
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4.12 Interior Lighting
4.12.1 Additional Internal Lamps
Additional cabin interior lighting may be obtained
by directly accessing the connector inside the
dome lamp in the cab.
Additional load space interior lighting may be
obtained by directly accessing the connector
inside the load space lamps in the load space
area.
CAUTION: The maximum total
internal lamp load must not exceed
5A (75W)
Power for the Interior Lights - cabin and
cargo areas – comes from the battery save
system (Central Junction Box pin C2-31), and for
vehicles with power locking,* the circuit for each
area is controlled by a separate pin on the Central
Junction Box:
•Front (cabin) lights, pin C2-22
•Rear (cargo) lights, pin C2-27 wire not present
on chassis cab and cab-van-floor vehicles
* with manual locking vehicles, control of interior
lighting is done directly through the door contact
switches. All vehicles, however, utilise the battery
saver relay to provide power for internal lighting
for a limited time.
Each of these pins on the Central Junction Box
can take a load of 75W. Lights that are controlled
by the battery save circuit will extinguish 30 to
180 minutes after ignition off (dependent on
vehicle configuration).
4.12.2 Additional 'Theatre
Lighting' for rear of vehicle
interior
For chassis cab or cab-van floor (and camper)
vehicles, rear lighting is not utilised and so there
is no wire to pin C2-27. However, converters can
add their own lights (up to the max. load) via the
battery save or a separate switchable feed, by
adding a pre-crimped wire and terminal to
connector C2. This is located on the Central
Junction Box behind the glove box on the
passenger side (please refer to Figures E84705
and E84712).
Refer to: 4.14 Special Conversions (page 131).
(Adding connectors, Terminals and Wiring)
Where higher wattage installations are required,
these should be taken through the Auxiliary Fuse
Box with a suitable switch and / or relay as
required.
Refer to: 4.13 Fuses and Relays (page 119).
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Fuse Location
Power Feed 2 (Maximum
60A)
Power Feed 1 (Maximum
60A)
Fuse Position
X*1
X*2
X*3
X4
X5
X6
X7
X8
X9
X10
The total sum of fuses marked * is not to exceed 40A
The Special Vehicle Option Auxiliary Fuse Box,
with integrated link harness, will provide the
following connections:
•– Ground
•– Battery +
•– Ignition
•– Engine run
•– Switched interior illumination
The fuse box is connected to the vehicle main
battery(s) but when the deep cycle battery is
installed it is always connected to the deep cycle
battery.
4.13.5 Additional Ignition,
Instrument Panel Illumination and
Air Conditioning On Signals
Access to these feeds can be obtained via a
jumper harness (6C1V-14A411-*) that fits into the
8-pin in-line connector between the instrument
panel (14K024) and heater (18B518) harnesses
located behind the glove-box. This jumper will
provide the following signals through three, single
6.3mm colour-coded connectors, please refer
to Fig. E75089 Heater jumper for illumination,
ignition and air conditioning on access.
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