2006 FORD TRANSIT instrument panel

Heater Jumper for Ignition, Instrument Panel Illumination and Air Conditioning On
Signals - Later Installation
DescriptionItem
Ignition, Instrument Panel Illumination and Air Conditioning On Signals1
C4 - Connection to Heating, Ventilation and Air Conditioning Harness (18B518)2
C5 - Connection to Instrument Panel Harness (14K024)3
4.13.6 Relays and Switches
Relays
Single pole relays must be used under the
conditions:
•Single pole, 2-way (change over) is used to
switch from one circuit to another please refer
to Relay Figures E75017-E75021 for typical
relay circuit diagrams.
•Relays can be installed inside the vehicle or
inside the Special Vehicle Option Auxiliary Fuse
Box.
•The Ford standard relays have a nominal
current of 300mA (max) at 25°C. Relays with
greater loads should not be used.
•For maximum switching currents please refer
to Relay Figures E75017-E75021.
Micro Relay
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Date of Publication: 12/2006
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127E88306123 E750171425312354

Battery Disconnect Switch
Battery Disconnect Switch Relay Parameters
260 ampsNormally open contacts
3.3 A @ 25°CNominal coil current
High Power Bistable relay - Part number: 6C1T-10B728-A_
In addition to the fuses and relays fitted to the
Pre Fuse Box (PFB), Engine Junction Box (EJB)
and Central Junction Box (CJB), depending on
vehicle options, there may be up to 3 relays
mounted directly to the Heating, Ventilation and
Air-conditioning (HVAC) unit. These relays should
not be tampered with as they affect operation
of the associated system.
Heating, Ventilation and Air-conditioning (HVAC)
1 x 82GG-13A025-CAAir-conditioning
2 x 82GG-13A025-CAFuel-fired Heater without Air-conditioning
3 x 82GG-13A025-CAFuel-fired Heater with Air-conditioning*
*In addition to the relays, there is a diode 91AG-10374-B_
These relays have a different terminal
arrangement to those fitted throughout the rest
of the vehicle – if they need to be replaced, only
components with the same Ford part number
should be used.
Switches and their Illumination
The main instrument panel switches work in
conjunction with the Central Junction Box, and
are momentary action (non-latching) types. The
Central Junction Box is responsible for control
operation of the respective systems.
For any additional functions, unless the
interfacing module accommodates momentary
action switches, it is recommended that latching
types are used.
Three switches are available:
DescriptionFord Part Number
Rotary light (beacon)6C1V-13D768-A_
Rear work lamp6C1V-13D756-A_
Water faucet (heater)6C1V-19H218-A_
Search illumination for added switches can be
taken from any of the existing switches, by
connecting to the appropriate feed wire.
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Date of Publication: 12/2006
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129E750211234AB4312BA

harness that provides roof-mounted rear turn
indicators, powered via relays. This should be
used in conjunction with SVO fusebox.
3.Chassis cab LED rear lamp cluster
replacement recommendations, especially
turn indicator relay implications – see lighting
load table. Generally the use of LED equivalent
lighting systems reduces the electrical load on
the vehicle; however, special care needs to
be taken with respect to any change to or
addition of turn indicator lights. Depending on
the current requirements of the LED(s)
compared to the bulb it is replacing, a ballast
resistor may be required, if not already
integrated into the LED lamp assembly.
Without this, bulb outage detection for turn
indicators will be affected, which is a legal
requirement.
Additional turn indicators must be powered
through relays (max 300mA), driven by existing
turn lights. The maximum load that the Central
Junction Box can drive is 3 x 21W per side (front,
rear and CAT 6 turn indicators); but even if the
vehicle is not fitted with the CAT 6 lights, the feeds
for these should not be used as the Central
Junction Box would need reconfiguring, which
could have safety as well as functional
implications.
4.Special Vehicle Option beacon switch: wiring
locations, circuit diagrams and max amperage
– see Special Vehicle Option fuse box
schematic (max current is 15A); there is
provision for the Special Vehicle Option beacon
switch in an empty switch location on the
instrument panel.
5.Rear loom connector detail location and supply
details for retro-fit loom extension for
example:- when extending a medium wheel
base, long wheel base or extended frame
overhang, what connectors do they use to
make a plug and play loom extension? – for
chassis cab vehicles, there is an Special
Vehicle Option extension loom for rear lamps
(part number 6C1V-14408-A*). There is not, at
present, a similar loom for Van, Bus and
Kombi's, although the appropriate mating
connector is now tooled, so this would be
possible.
Miscellaneous Systems
Handbrake on - Cluster Warning Light -
Unless the vehicle is specified with options that
drive the handbrake warning light (for example
ESP, Australia market), the components making
up this system are not fitted. We do not
recommend installation of this feature as an
aftermarket addition. There are several reasons
for this:
1.Not all circuits carry the requisite wire as a give
away:
•The wires might be part of the main vehicle
harness (14401) even if not used – for example
camper vehicles are normally ordered with
power mirrors, and the wires will be present
as a give-away.
•The seat pedestal harness (14K076), however,
is vehicle specific – if the handbrake is not part
of the specification, it will not be present or
give-away. This harness would need to be
changed to the compatible part that also
includes the handbrake warning light circuit.
2.The handbrake switch (part number
2F2T-15852-A*) together with its short jumper
harness (6C1T-15K857-A*) would need to be
obtained and fitted.
3.The handbrake warning light is in all clusters,
but unless the vehicle config. parameter
“parking brake switch” is set, the Central
Junction Box will not read this input, and hence
NO CAN message sent to the cluster.
Reconfiguration can only be done at a Ford
Dealer.
NOTE: If a vehicle already has a handbrake
warning light in the cluster, or one is installed as
per the Ford design, it is not possible to utilize the
wire from the handbrake switch as part of an
interlock circuit (this is a pull up resistor input that
provides a wetting current of 20mA – anything in
excess of this, for example through additional
circuitry, will almost certainly damage the Central
Junction Box). If there is no handbrake switch
installed, it would be possible to add one and
utilize this as part of a separate circuit, up to a
maximum current of 500mA through the switch.
Reverse Sensors (Rear Park Aid
Module)- The factory-fit option is a CAN-based
system, but for Van, Bus, and Kombi vehicles
only. Stand-alone systems can be installed (for
example for chassis cab conversions), but would
need to utilize the PTA line of the radio if muting
is required.
Fuel Fired Heater (FFH)- Add FFH: wiring is
only present (give-away) in certain harnesses.
There was an aftermarket kit available for this
system on current Transit, which could probably
be “updated” to suit V347/8.
Fuel Fired Heater (FFH) - Programmable
FFH: this utilizes a timer/control module mounted
to the Instrument Panel, which necessitates
having the correct Instrument Panel harness
fitted. Retrofit of this would be a difficult.
For both systems, the appropriate 6C1T-14K132
harness would be required (suffix -A* for
Programmable FFH, and suffix –B* for Add FFH).
Central Locking
Locking is controlled by the Central Junction Box
module. There is current sensing on certain
locking circuit pins as part of the security system
– if these are tampered with, locking cannot be
guaranteed.
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NOTE: A power take off layout can only be
implemented on vehicles fitted with an ABS
braking system. Manual braking systems employ
a transmission speed sensor to determine vehicle
speed & the RPM speed control software
contains vehicle speed restrictions which prohibit
RPM speed control operation if vehicle speed is
detected above very low levels (approx 2.5 mph).
A vehicle fitted with an ABS braking system
derives vehicle speed via the vehicles wheel
speed sensors, so the transmission can operate
normally without effecting RPM speed control
operation.
3 Modes of Operation
There are 3 principle modes in which this feature
can operate, they are:
1.3 speed mode – this provides the end user a
choice of up to 3 preset RPM values to select
from. The end user cannot easily override
these values so there is minimal risk of damage
to ancillary equipment due to it being run at
speeds it was not designed for. Very limited
vehicle speed is allowable while in this mode
(up to 2.5mph approx)
2.Variable speed mode – this provides the end
user with RPM speed ramp up & down
buttons. The end user is free to select RPM
values between 1300-3000rpm in 25rpm
steps. A single press results in a 25 rpm jump.
If a ramp button is held depressed by the end
user then the rate of change is 250rpm/sec.
Very limited vehicle speed is allowable while in
this mode (up to 2.5mph approx)
3.Idle up speed – this mode allows the engines
normal idle to be increased to any value (in 25
rpm steps) in the range 900-1200rpm. There
is not a vehicle speed restriction in this mode
as the intended use is to raise the engine idle
to reduce the likelihood of engine stall when
ancillary equipment is being run from the
engine during normal drive operations. Eg
refrigerator units used to keep the cargo bay
cool.
NOTE: Items 1) & 2) will be available from Nov
2006, while item 3) should be available from Jan
2007. Any latest generation diesel Transit can be
updated to include item 3) Idle up speed with a
simple calibration update once it becomes
available.
System Availability
This feature is built into the latest Powertrain
Control Module (PCM) software on all diesel
engine variants.
By default the feature is not enabled unless the
vehicle is specifically ordered with the feature
from the factory.
Vehicles which have not been ordered with this
feature may have the feature enabled at a dealer
via the IDS diagnostics system. The dealer should
charge for this service.
How to control this feature
A loop of wire (green/white) is provided in the
main electrical loom to permit control of the RPM
Speed Control software. Cutting this loop will
provide two wires to connect a control box to the
PCM.
The control box needs to switch resistors into the
circuit across the two green/white wires which
formally formed the loop prior to being cut. This
sort of circuit is known as a resistance ladder. The
PCM software monitors the green/white wire
circuit & when certain resistances are detected
they are interpreted as various inputs which
control the feature. The switch box can be
located where it’s ideally required for the vehicle
conversion in question, rather than having to be
mounted on the Instrument Panel (IP). If the
converter chooses to locate the switch box in a
location which is subject to an adverse
environment then the converter should design
the switch box to withstand with these conditions.
How to locate the green/white loop
The main electrical loom enters the vehicle cab
from the engine bay on the left hand side of the
vehicle via a large diameter hole in the engine bay
/ cabin bulkhead. This hole is just above the left
hand front suspension turret. See following Figure
E88307
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The software in the PCM responds to the change
of state, so it is recommended that these 3
middle switches be non-latching push button
micro switches. When going from idle to an
elevated RPM the execution of the command
will occur as the button is released. When going
to idle the execution of the command occurs as
the button is pressed.
The final button (the one on the left in Fig. 4) acts
as an ‘emergency’ vehicle engine stop. It is
recommended that this be a red & oversize
non-latching micro switch button. The execution
of this command will occur as the button is
pressed.
All wiring connecting the PCM to the resistance
ladder control box should be shielded & twisted
(33 twists / m) to reduce EMC effects
All resistors should have a tolerance of +/- 5% or
better
Switch contact, connectors & loom (loom
between the green/white wires & the control
box) total resistance must be no greater than 5
ohm max.
The PCM to resister ladder control switch box
loom should not come within 100mm of any other
harness, especially any carrying heavy loads.
Designs which do not require all the button
switches must still have the complete resistor
network with the switches positioned correctly
within the network.
The resistance ladder is acting as a potential
divider
The 220 nF capacitor is used in the circuit to
reduce EMC effects on the system
A suitable two way quality connector should be
used to connect the control box to the two
green/white wires
How to change the default settings
By default, when the feature is first enabled
(either via factory order or via dealer IDS tools),
it will be set to the 3 speed mode of operation
with preset RPM values of 1100, 1600 & 2030rpm
for the 3 speeds.
There are two methods by which these defaults
can be modified:
1.via the IDS diagnostics system at a Ford dealer
(there may be a charge for this)
2.via an inbuilt vehicle ‘learn mode’
Via the IDS system the mode of operation can
freely be changed between any of the 3 modes
of operation, the feature can even be turn off
(disabled). The 3 default RPM speeds can also
be modified.
Via the vehicle ‘learn mode’ the 3 speed mode
& the variable speed mode can be freely
interchanged, however it is not possible to select
the idle up speed mode via the vehicle learn
mode. The 3 default RPM speeds can also be
modified via ‘learn mode’
It is not possible via either method above, to
change the step value of 25rpm per press or the
250 rpm per sec for a held down button, in the
variable rpm speed mode.
Via IDS The RPM Speed Controller menu is under
the tool box tab, then Powertrain, then service
functions, then PCM. The IDS on screen menus
will guide the dealer through the options & setup.
How to enter vehicle ‘Learn mode’
1.Make sure that the RPM Speed controller
switch box is connected but turned off (not
‘armed’)
2.Start the engine (vehicle out of gear & no foot
pedals being pressed, handbrake on)
3.Wait a couple of seconds for the instrument
panel start up diagnostic lights to extinguish
4.Press & release the clutch pedal
5.Press & release the brake pedal
6.Repeat steps 4) & 5) a further four times
(clutch & brake pressed a total of five times
sequentially each)
NOTE: Steps 4) to 6) have to be started within
10 seconds of the engine start
The vehicle should now be in ‘learn mode’
How to Select between modes
1.Enter ‘learn mode’ (see directions above)
2.Arm the RPM speed controller (turn the key
switch to ‘on’)
If the vehicle is already in 3 speed mode (the
initial default):
3.Press & release the brake pedal five times
The vehicle should now be in variable speed
mode. The new settings can be saved & learn
mode exited (see below)
Alternatively
4.Press & release the brake pedal once
The vehicle should now be in 3 speed mode.
The new settings can be saved & learn mode
exited (see below)
Using this method it is easy to change between
these two modes of operation for the RPM
speed controller
NOTE: If the engine stalls out at the initial brake
pedal input then the vehicle was not in, or has
dropped out of ‘learn mode’ & you will have to
restart the procedure.
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How to change the 3 pre-set default
RPM values in the 3 speed mode
1.Enter ‘learn mode’ (see directions above)
2.Arm the RPM speed controller (turn the key
switch to ‘on’)
3.Press & release the brake pedal once
4.Press & release the RPM button that requires
re-programming
5.Use the accelerator pedal to rev the engine to
the new desired RPM speed & hold at this
speed (only speeds between 1200 to 3000
rpm can be selected in 3 speed mode)
6.Press & release the same RPM button to reset
the stored RPM speed to the current engines
RPM
7.Release the accelerator pedal
8.Repeat steps 4) to 7) for the remaining RPM
buttons
The 3 RPM speeds should now be
re-programmed to the new RPM speeds. The
new settings can be saved & learn mode exited
(see below)
NOTE: If the engine RPM responds to the initial
RPM button press, then the vehicle has not
entered ‘learn mode’ correctly & you will have to
restart the procedure. If the engine stalls out at
the brake or accelerator pedal inputs then the
vehicle was not in, or has dropped out of ‘learn
mode’ & you will have to restart the procedure.
How to save new settings & exit
from ‘Learn mode’
1.From within the ‘learn mode’ & with the RPM
Speed Control switch box ‘armed’, press the
clutch pedal repeatedly until the engine stalls.
2.Restart the engine & test the new settings,
repeat above procedures if necessary
NOTE: The engine stalling indicates that the
settings should have been saved & the vehicle
has exited from ‘learn mode’. Learn mode
however is very specific that the exact steps are
taken in the correct order & within certain time
limits otherwise the learn procedure fails & it may
take several attempts to get this order & timing
correct & a successful modification from the
default settings.
Some Reasons why RPM speed
Control operation may stop or fail
The RPM Speed control software monitors
vehicle information during operation in RPM
speed control mode & will drop out of RPM speed
control and / or stall the engine should any
adverse signals be detected. For example:
•If the engine temperature becomes too hot
then RPM speed control will stop in order to
protect the engine.
•If the engine oil light illuminates then RPM
speed control will stop in order to protect the
engine
•If the low fuel level light illuminates then RPM
speed control will stop so that the vehicle can
be driven to a refueling point.
•If the vehicle speed exceeds approx 2.5 mph
wile in 3 speed or variable speed modes, then
RPM speed control may stop. RPM speed
control should normally be operated with the
hand brake on, but some uses may require a
low level of vehicle ‘creep’ during RPM speed
control operation. Note that there is no sensing
of the park brake on this version of RPM speed
controller to facilitate this type of operation.
•The software monitors for ‘stuck on’ buttons
on the control switch box, this may result in
RPM speed control being halted. A button that
is held down for too long may be registered
by the software as a ‘stuck’ button.
•The software monitors the foot pedals, if
depressed these may stall the engine if in 3
speed mode or variable speed mode (does
not apply to idle up speed)
•If the control switch box circuitry significantly
exceeds 2110 ohms or there is a short circuit
then RPM speed control will not be possible.
•If a PTO conversion has been attempted on a
vehicle with a non ABS braking system then
RPM speed control will fail due to vehicle
speed being registered via a transmission
speed sensor and / or the need to press the
clutch in order to put the vehicle in gear while
in RPM speed control mode.
4.14.10 Adding Connectors,
Terminals and Wiring
Additional Rear Speakers
NOTE: The connectors on the Instrument Panel
harness (14K024) and the main harness (14401)
are reversed between Left Hand Drive (LHD) and
Right Hand Drive (RHD) vehicles, hence different
sets of terminals/wires are required to cover all
the markets.
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162

A
About This Manual................................................6
Accessory Drive..................................................77
Adding Connectors, Terminals and Wiring....
162
Additional 'Theatre Lighting' for rear of vehicle
interior...............................................................118
Additional External Lamps...............................116
Additional Ignition, Instrument Panel Illumination
and Air Conditioning On Signals...................124
Additional Internal Lamps ................................118
Additional Vehicle Signals / Features.............147
Aids for Vehicle Entry and Exit..........................33
Air Bags..............................................................218
Air Bag Supplemental Restraint System (SRS)..
218
Air Flow Restrictions...........................................76
Alternative Type Approval....................................7
Ancillary Equipment - Sub Frame Mounting....
228
Antenna Location...............................................24
Anti-Lock Control - Stability Assist..................65
Auxiliary Fuses, Fuse Box and Relays (Fuses -
Standard)..........................................................119
Auxiliary Heater Installation...............................76
Auxiliary Heater Systems..................................75
B
Back Panel Removal................................177, 214
Battery and Cables............................................98
Battery Information............................................98
Body....................................................................175
Body Closures..................................................203
Body Structures - General Information.........175
Body System - General
Information—Specifications.........................200
Brake Hoses General........................................62
Brake System.....................................................62
C
Cab Roof Removal...........................................214
Cab Van Floor....................................................185
CAN-Bus System Description and Interface....
90
Cellular Phone....................................................115
Center of Gravity ...............................................46
Central Junction Box (CJB)...............................91
Charge Balance Guidelines..............................97
Charging System...............................................95
Chassis Cab.......................................................179
Circit Diagram.....................................................94
Circuit Diagram...................................................93
Circuit Diagrams.................................................97
Climate Control System..................................106
Clutch...................................................................82
Commercial and Legal Aspects.........................7
Communications Network...............................90
Connectors........................................................133
Contact Corrosion............................................221
Contact Information.............................................9
Conversion Affect on Fuel Economy and
Performance.....................................................25
Conversion Affects on Parking Aids................33
Conversion Homologation...............................23
Conversion Type.................................................14
Corrosion Prevention.......................................221
Customer Connection Points.........................120
D
Drilling and Welding..............................................8
Driver's Standing Head Room........................214
Driver Field of View.............................................33
Driver Reach Zones...........................................33
Driveshaft.............................................................61
E
Electrical Conversions.......................................95
Electrically operated Door Mirrors..................117
Electrics for Tow bar........................................136
Electromagnetic Compatibility (EMC)............24
Electronic Engine Controls................................81
End of Life Vehicle (ELV) Directive...................26
Engine Cooling....................................................75
Engine..................................................................66
Engine Power Curves.......................................66
Engine RPM (Revs Per Minute) Speed
Controller..........................................................157
Engine Run Signal (D+ Alternative)................132
Exhaust Heat Shields.........................................86
Exhaust Pipes and Supports............................86
Exhaust System.................................................86
Extended Chassis Frame...............................226
Extensions and Optional Exhausts..................86
Exterior Lighting.................................................116
F
Fitting of Equipment Containing an Electric
Motor..................................................................97
Frame and Body Mounting............................222
Frame Drilling and Tube Reinforcing.............228
Front, Rear and Side Under-run Protection....
38
Front and Rear Brakes......................................64
Front End Accessory Drive 2.2l Diesel............79
Front End Accessory Drive 2.4l Diesel and 2.3l
Petrol...................................................................77
Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting..........................198
Front Suspension...............................................58
Fuel System........................................................88
Fuses and Relays..............................................119
G
General........................................................62, 221
General Component Package Guidelines.....33
General Information and Specific Warnings....
95
General........................................................62, 221
General Product Safety Requirement...............7
Index
230

Generator and Alternator...............................103
Glass, Frames and Mechanisms...................211
Ground Points..................................................140
H
Hardware—Specifications...............................43
Heated Seats...................................................210
Heated Windshield and Heated Rear Window.
213
Horn...................................................................108
How to Use This Manual....................................6
Hydraulic Brake Actuation...............................64
Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab...........................................186
I
Important Safety Instructions............................6
Information and Entertainment System -
General Information—Specifications...........112
Installation and Routing Guides.....................134
Instrument Cluster...........................................107
Integrated Bodies and Conversions.............177
Interior Lighting.................................................118
Introduction..........................................................6
J
Jacking................................................................27
K
Kerb Mass Data.................................................62
L
Lamps for Wide Vehicles.................................117
Lamps – Front and Rear Fog Lights..............117
Lamps – Hazard / Direction Indication..........117
Legal and Vehicle Type Approval......................7
Legal Obligations and Liabilities.........................7
Legislation.........................................................109
Lifting...................................................................29
Load Apportioning Valves................................64
Load Compartment Interior Lining...............203
Load Distribution—Specifications...................44
Load Distribution Calculations - Driver and
Passenger Weight Distribution.....................44
M
Manual Transmission........................................83
Minimum Requirements for Brake system and
Load Apportioning Valves ...............................8
Mirrors for Wide Vehicles...............................208
Module Communications
Network—Specifications................................94
Mounting Points and Tubing.........................222
N
Noise, Vibration and Harshness (NVH)...........31
Non Standard Rear Chassis Frame Extension.
226
P
Package and Ergonomics—Specifications....
34
Package and Ergonomics...............................33
Painting Road Wheels..............................60, 221
Parking Brake....................................................63
Partitions (Bulkhead) - Driver and Front
Passenger(s) Protection on Van, Bus and
Kombi..............................................................192
Possible Accessories.......................................113
Power Management Settings.........................95
Power Take Off...................................................61
Product Liability....................................................8
R
Racking Systems.............................................194
Radio Connector..............................................112
Rear Anti-Roll Bar..............................................59
Rear Seat Fixings Positions - Kombi............209
Rear Suspension...............................................59
Rear View Mirrors...........................................208
Rear Windows..................................................211
Recommended Main Dimensions.................34
Recommended Main Load Area Dimensions
for Bulkhead with Depression Driver Side....
39
Recommended Main Load Area Dimensions
for Bulkhead with Full Depression................40
Recommended Main Load Area Dimensions
for Double Cab In Van Bulkhead...................41
Recommended Nominal Body Lengths for
Chassis Cab models......................................36
Relays and Switches.......................................127
Relocated Parking Brake Lever......................63
Repairing Damaged Paint..............................221
Restraints System...............................................8
Reversing Lamps.............................................116
Road Safety..........................................................8
Roof Opening Panel........................................214
Roof Racks.......................................................216
Roof Ventilation................................................215
S
Safety Belt System.........................................220
Seats.................................................................209
Security, Anti Theft and Locking System
Security ..........................................................203
Self-Supporting Body Structure...................224
Spare Tire Access and Mounting.................229
Spare wheel.......................................................60
Special Conversions........................................131
Special Vehicle Option Auxiliary Fuse Box....
121
Index
231