Ford LCF
truck service manuals eBook
2 2 0 0 The New Ford LCF LOW CAB FORWARD 0 0 Body Builders Layout Book 6 Return to Body Builders Layout Books June, 2005 6 Return to Body Builders Layout Books IMPORTANT NOTICE The specifications and designs described herein are believed to be correct as of the time that this book was approved for printing, but accuracy cannot be guaranteed. They are intended only to provide basic data regarding such matters as dimensions and weight ratings of Fordbuilt chassis. The information contained in this book is general and nothing contained herein is to be regarded as providing specific or comprehensive instructions for the completion of a particular vehicle or as authorization by Ford of the specific modifications, alteration or designs of individual vehicles. Regulations such as those issued by the Federal Highway Administration (FHWA) or issued pursuant to the Occupational Safety and Health Act (OSHA), and/or state, provincial, and local laws and regulations may require installation of additional equipment for the particular use intended for the vehicle. It is the responsibility of the subsequent stage manufacturer or completed vehicle alterer and the vehicle purchaser to ascertain how the vehicle will ultimately be used, if FHA, OSHA or state provincial or local regulations apply and how the vehicle as completed will comply with those requirements. Representations regarding the compliance of any Ford-manufactured incomplete vehicle to any rule, regulation or standard issued pursuant to the National Traffic and Motor Vehicle Safety Act or the Canadian Motor Vehicle Safety Act are set forth only in the incomplete vehicle manual which accompanies each incomplete vehicle. Ford reserves the right to discontinue models or change specifications or designs at any time without notice and without incurring any obligation. Nothing contained herein is to be construed as a representation that such equipment required for the particular use intended has been installed on the completed or incomplete vehicle. For the most recent information and updates to this publication refer to www.fleet.ford.com/truckbbas. REFERENCE INFORMATION FORD TRUCK BODY BUILDERS LAYOUT PUBLICATION FORD TRUCK BODY BUILDER ADVISORY SERVICE To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM's please visit our website at www.fleet.ford.com/truckbbas/. Under Publications select Body Builders Order Forms. All dealer requests can be handled online. All other U.S. orders should be faxed to (734) 713-2971. Canadian orders should be faxed to (905) 670-0844. FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to a specific Model Year and vehicle types. The following publications are a few of many manuals which are available from Helm Incorporated; call 1-800-782-4356 or contact Helm, Inc. at their website: www.helminc.com · Ford Truck Shop Manuals · Ford Towing Manuals · Ford Wiring Diagrams · Ford Truck Shop Manuals and Wiring Diagrams on CD-ROM The Ford Truck 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, company and telephone number with all inquiries. If requesting written materials, include your mailing address. © 2005 Ford Motor Company Return to Body Builders Layout Books Link to LCF Chassis Specifications INDEX 2006 MODEL YEAR VEHICLE Page Engineering Data ................................................................................................................. 1 Top of Cab............................................................................................................................ 2 Side View Cab Tilt............................................................................................................. 3 Rear View of Vehicle ............................................................................................................ 4 Top View of Vehicle .............................................................................................................. 5 ENGINE Engine Ports......................................................................................................................... 6 Front Engine Accessory Drive.............................................................................................. 7 Engine Location ................................................................................................................... 8 COMPONENTS Battery Box.......................................................................................................................... 9 Exhaust ................................................................................................................................ 10 Fuel Tank Between the Rails (BTR) .................................................................................. 11 Fuel Tank Left Hand Frame-Mounted ................................................................................ 12 Fuel Tanks Dual Frame-Mounted ...................................................................................... 13 Horizontal Fuel Conditioning Module (HFCM)...................................................................... 14 Hydraulic Control Unit .......................................................................................................... 15 Parking Brake ....................................................................................................................... 16 FRAME Page Frame Rail Specifications..................................................................................................... 17 Frame Drilling Restrictions ................................................................................................ 18 Frame Crossmember ........................................................................................................... 19-21 Frame Crossmember Location Frame Ladder .................................................................. 22 Front Bumper & Tow Hooks ................................................................................................. 23 Front Suspension ................................................................................................................ 24 Rear Spring Suspension Installed Position ....................................................................... 25 Rear Spring Suspension Hole Pattern .............................................................................. 26 POWER TAKE-OFF Power Take Off ..................................................................................................................... 27 Required PTO Wiring for Automatic Transmission ............................................................... 28 PTO Wiring for Automatic Transmission............................................................................... 29 APPLICATION INFORMATION Ground Clearance................................................................................................................ 30 Overhang Limits for Pivoting Bodies and Concentrated AF Loadings ................................. 31 LCF CHASSIS SPECIFICATIONS Return to TOC MODEL COMPONENTS GVWR (lbs.) Standard GVWR (lbs.) Optional Max. GCWR (lbs.) Max. Payload (lbs.) WB/AF (in.) Front Axle Capacity (lbs.) Standard Optional Front Axle Track (in.) Front Spring Capacity (lbs.) Standard ` Optional Rear Axle Capacity (lbs.) Rear Suspension Capacity (lbs.) Stabilizer Bar Steering Turning Radius (ft.) Engine Horsepower/Torque Air Cleaner Transmission, Automatic OD Standard Optional Alternator, Visteon, Pad Mounted Battery, Motorcraft, Group 31 Brakes, Hydraulic Frame (psi) RBM (in-lb) Fuel Tank Standard Optional Wheels Standard Optional Tires Standard Optional Body Paint Colors LCF-45 LCF-55 16,000 15,000 22,500 9,720 113/47.5, 113/63, 137/47.5, 137/63, 149/47.5, 149/75, 167/75 19,500 17,950 26,000 13,220 113/47.5, 113/63, 137/47.5, 137/63, 149/47.5, 149/75, 167/75, 185/96 6,000 None 73.4 7,000 6000 73.4 6,000 Taper Leaf None 11,000 11,000 Single variable-rate with 1,500 lbs. rubber auxiliary Front and Rear Ross TAS37 16.5 4.5L V6 Power Stroke Diesel 200 hp/ 440 lb-ft Single Element with Filter Minder Indicator 5-Speed TorqShiftTM with Tow/Haul Feature Less PTO provision With PTO provision 12-volt, 135-amp Two, 12-volt, 1800 CCA Four Wheel Disc, Front and Rear Split System, 3 Channel ABS 50,000 461,000 7,000 Taper Leaf 6,000 Taper Leaf 13,500 13,500 Single variable-rate with 1,500 lbs. rubber auxiliary Front and Rear Ross TAS37 16.5 4.5L V6 Power Stroke Diesel 200 hp/ 440 lb-ft Single Element with Filter Minder Indicator 5-Speed TorqShiftTM with Tow/Haul Feature Less PTO provision With PTO provision 12-volt, 135-amp Two, 12-volt, 1800 CCA Four Wheel Disc, Front and Rear Split System, 3 Channel ABS 50,000 461,000 Single 40 Gal. Between the Frame Rails Behind the Rear Axle Single 35 Gal. LH Frame Mounted Dual 35 Gal. LH&RH Frame Mounted 70 Gal. Total Capacity with Duals Single 40 Gal. Between the Frame Rails Behind the Rear Axle Single 35 Gal. LH Frame Mounted Dual 35 Gal. LH&RH Frame Mounted 70 Gal. Total Capacity with Duals Six, 19.5 x 6.0 hub piloted, ten lug Six, 19.5 x 6.0 hub piloted, ten lug Steel, Painted White Steel, Painted White Polished Aluminum (Incl. wheel ornamentation) Polished Aluminum (Incl. wheel ornamentation) Goodyear 225/70R19.5 G647RSS Michelin 225/70R19.5 XZE Bright Red (E4), True Blue (L2), Black (UA), Oxford White (YZ), Winter White (W1), Holly Green (GV), Omaha Orange (NJ), Bold Yellow (SY), School Bus Yellow (NY) Goodyear 225/70R19.5 G647RSS Michelin 225/70R19.5 XZE Bright Red (E4), True Blue (L2), Black (UA), Oxford White (YZ), Winter White (W1), Holly Green (GV), Omaha Orange (NJ), Bold Yellow (SY), School Bus Yellow (NY) IV Return to TOC Page 1 LCF ENGINEERING DATA 2006 MODEL YEAR Chassis Weight (lbs)** Dimensions (in.) Wheelbase (in.) Front Rear Effective Useable Total CA CF AF *113 3915 2383 6298 84 131.5 47.5 113 3901 2428 6329 84 147.0 63.0 137 3950 2415 6365 108 155.5 47.5 137 3937 2458 6395 108 171.0 63.0 149 3972 2437 6409 120 167.5 47.5 149 3932 2551 6483 120 195.0 75.0 167 3956 2563 6519 138 213.0 75.0 185 3963 2653 6616 156 252.0 96.0 NOTES: Chart data based on vehicle with standard equipment. Artwork may show some optional equipment. * Dimension data is based on the 113" wheelbase with 47.5" after frame unless otherwise noted. ** Weight includes standard chassis, standard tires, oil and water, but less fuel. 2 = Frame Height at centerline of front axle with standard tires: unloaded - 28.3" 3 = Frame Height at centerline of rear axle with standard suspension and tires: unloaded - 30.0" Note: Due to internal spring friction and manufacturing tolerances, these values may vary up to 0.5 inches. To achieve these normal values directly after loading or unloading a vehicle, it may be necessary to drive the vehicle for a short period. OAL 204.7 220.2 228.7 244.2 240.7 268.2 286.2 325.2 Turning Radius To Curb 16 ft. 7in. 16 ft. 7in. 19 ft. 3in. 19 ft. 3in. 20 ft. 8in. 20 ft. 8in. 22 ft. 5in. 24 ft. 6in. w/Bumper Clearance 18 ft. 4in. 18 ft. 4in. 21 ft. 0in. 21 ft. 0in. 22 ft. 5in. 22 ft. 5in. 24 ft. 2in. 26 ft. 3in. NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 2 LCF TOP OF CAB 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 3 LCF SIDE VIEW -- CAB TILT 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 4 LCF REAR VIEW OF VEHICLE 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 5 LCF TOP VIEW OF VEHICLE 2006 MODEL YEAR Return to TOC Page 6 LCF ENGINE PORTS 2006 MODEL YEAR Return to TOC Page 7 LCF FRONT ENGINE ACCESSORY DRIVE 2006 MODEL YEAR 4.5L V6 DIESEL Return to TOC Page 8 LCF ENGINE LOCATION 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 9 LCF BATTERY BOX 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 10 LCF EXHAUST 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 11 LCF FUEL TANK -- BETWEEN THE RAILS (BTR) 2006 MODEL YEAR Return to TOC Page 12 LCF FUEL TANK -- LEFT HAND FRAME-MOUNTED 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 13 LCF FUEL TANKS -- DUAL FRAME-MOUNTED 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 14 LCF HORIZONTAL FUEL CONDITIONING MODULE (HFCM) 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 15 LCF HYDRAULIC CONTROL UNIT 2006 MODEL YEAR Return to TOC Page 16 LCF PARKING BRAKE 2006 MODEL YEAR NOTE -- WITH HYDRAULIC BRAKES, THE PARK NOTE NOTE -- BRAKE ASSEMBLIES ARE ATTACHED TO THE NOTE -- REAR AXLE INSIDE (BEHIND) THE ROTOR. NOTE -- THEY ARE MECHANICALLY ACTUATED NOTE NOTE -- THROUGH THE USE OF A FIVE-SECTION NOTE -- CABLE. DUE TO THE CONSTRUCTION OF NOTE -- THE CABLES, IT IS NOT POSSIBLE TO ALTER NOTE -- THE LENGTH. Return to TOC Page 17 LCF FRAME RAIL SPECIFICATIONS 2006 MODEL YEAR Side Rail DIMENSIONS (inches) Depth Width Thickness YIELD STRENGTH NOMINAL (psi) MATERIAL # SECTION MODULUS 1 (inches3 ) Maximun Nominal All Frame Rail Straight Channel Side Rail - Kick-up at Rear Suspension Rearward Codes 9.0 3.0 0.25 50,000 B 10.67 9.23 NOTE: # B = High Strength Low Alloy Steel 1 = Section Modulus: Maximum Tolerance: All frame dimensions are at maximum tolerance; used by some competitors as advertised values. Nominal: Calculated using design dimensions - indicates the design load capacity of the frame. 3 = Rail depth given is for base rail . . . kick-up in AF section is 6.37". RESISTING BENDING MOMENT (in.-lbs.) Maximun Design 533,500 461,500 Return to TOC Page 18 LCF FRAME -- DRILLING RESTRICTIONS 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 19 LCF FRAME CROSSMEMBER 2006 MODEL YEAR REAR OF ENGINE TRANSMISSION SUPPORT NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 20 LCF FRAME CROSSMEMBER 2006 MODEL YEAR REAR SUSPENSION/BETWEEN THE RAILS FUEL TANK AFT FRAME NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 21 LCF FRAME CROSSMEMBER 2006 MODEL YEAR INTERMEDIATE DOUBLE FOR REAR SUSPENSION NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 22 LCF FRAME CROSSMEMBER LOCATION -- FRAME LADDER 2006 MODEL YEAR Return to TOC Page 23 LCF FRONT BUMPER & TOW HOOKS 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 24 LCF FRONT SUSPENSION 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 25 LCF REAR SPRING SUSPENSION -- INSTALLED POSITION 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 26 LCF REAR SPRING SUSPENSION -- HOLE PATTERN 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 27 LCF POWER TAKE OFF 2006 MODEL YEAR NOTE -- [ ] DIMENSIONS ARE INCHES. Return to TOC Page 28 LCF REQUIRED PTO WIRING FOR AUTOMATIC TRANSMISSION CAUTION: Installing a transmission-mounted PTO without the required PTO wiring may result in transmission failure. To minimize the risk of transmission damage, PTO controls must be integrated into the vehicle wiring. PTO Request - Applying vehicle battery voltage to the "PTO Request" wire will (1) place the transmission in PTO mode and (2) elevate idle engine idle speed when certain conditions (described below) are met. This wire MUST be part of the PTO control system; failing to do so may result in under capacity PTO clutch wear, resulting in rapid contamination of transmission fluid and internal transmission damage. Remote PTO Enable - One of the two available remote PTO engine wires MUST also be part of the PTO control system. The wire must be connected to the PTO Request circuit. PTO Enable - An output wire is available that indicates when the elevated idle is active. The "PTO Enable" output may be used at the body builder's discretion; for example, to restrict PTO operation to stationary only. PTO Engaged - An input wire is available to control the PTO lamp in the instrument cluster. Applying vehicle battery voltage to the "PTO Engaged" wire will illuminate the PTO lamp. "PTO Request", "PTO Enable", "PTO Engaged", and the remote engine PTO signals are blunt cut wires supplied with the vehicle and are located behind the cab on the left frame rail near the transmission. All other PTO components are to be supplied by the body builder. Elevated Idle Operation - When (1) the "PTO Request" input transistions from open circuit to vehicle battery voltage and (2) the conditions in Table 1 are met, the engine will ramp to 1200 RPM and the "PTO Enable" output will be activated. While in this mode, normal engine speed hand controls are available; however, the engine will maintain an engine speed between 1200 and 2400 RPM. The engine will remain in this mode until either (1) the "PTO Request" input is open circuit or (2) one or more of the conditions in Table 1 are no longer met. NOTE: A "change-of-state" at the "PTO Request" input is required to re-invoke the elevated idle mode. The operator must turn off voltage to the "PTO Request" input, and back on again. Engine Programming - The engine programmable parameter "PTO-CONTROL" must be set to either "1: REMOTE OPERATION ONLY" or "3: REMOTE AND IN-CAB OPERATION" for PTO installations. This parameter is set to "3: REMOTE AND IN-CAB OPERATION" from the factory. 2006 MODEL YEAR Return to TOC Page 29 LCF PTO WIRING FOR AUTOMATIC TRANSMISSION 2006 MODEL YEAR CF series - PTO Wiring Circuit Intent Wire Name Input (VPWR) PTO Request Description Blunt cut wire Circuit No. 2335 Wire Color: Purple/Light Green Output PTO Enable Applying vehicle battery voltage to this wire will request the transmission enter PTO mode and will elevate engine speed if conditions are met. Blunt cut wire. Circuit No.2334 Wire Color: Brown/Yellow Input (VPWR) PTO Engaged A low-side driver, changing from "open-circuit" to "ground" indicating elevated idle (PTO) is active. Intended for turning on a relay coil. Maximum current is 1 amp. Blunt cut wire. Circuit No.2336 Wire Color: Red/Orange Input (VPWR) Input (VPWR) ECM Remote Preset PTO Enable ECM Remote Variable PTO Enable Applying vehicle battery voltage to this wire will activate the PTO lamp in the instrument cluster, and removing vehicle battery voltage will deactivate the PTO lamp. Blunt cut wire. Circuit No.2231 Wire Color: Light Blue/Red Applying vehicle battery voltage to this wire will enable the Remote Preset PTO engine operation. This input, or ECM Remote Variable PTO Enable, is required for PTO. Blunt cut wire. Circuit No.2232 Wire Color: Red/Light Blue Applying vehicle battery voltage to this wire will enable the Remote Variable PTO engine operation. This input, or ECM Remote Preset PTO Enable, is required for PTO. Circuit 5 9 14 511 Rear Frame Lighting Circuits Color Gauge Description Orange-Light Blue (OR/LB) 18 RH Turn Light Green-Orange (LG/OR) 18 LH Turn Brown (BR) 16 Market Lights Light Green (LG) 16 Stop Lights Return to TOC Page 30 LCF GROUND CLEARANCE 2006 MODEL YEAR Wheelbase (inches) AF (inches) 113 47.5 113 63 137 47.5 137 63 149 47.5 149 75 167 75 185 96 H106 Bumper 20.6º 20.6º 20.6º 20.6º 20.6º 20.6º 20.6º 20.6º SAE Standard Angles H147 H107 Transmission Oil Pan Aft Fuel Tank 21.7º 21.7º 19.7º 19.7º 19º 19º 18.3º 17.7º 19.9º 19.9º 19.9º 19.9º 19.9º -- -- -- H107 Frame Rail -- 20.3º 20.3º 20.3º 20.3º 16.9º 16.9º 13.2º Return to TOC Page 31 LCF OVERHANG LIMITS FOR PIVOTING BODIES AND CONCENTRATED AF LOADINGS Dump, car carriers, and other pivoting bodies impose a great deal of stress on the frame rails around and aft of the rear suspension area of the frame. In addition, concentrated loads can be applied by the installation and use of equipment such as lift gates, or the placement of heavy objects on a small section of the body. The body installer has the responsibility for determining the magnitude of the pivot pin load or other forces exerted by the body, and for establishing operating guidelines to avoid exceeding the load limits published in the chart. The limits shown in this chart are for equal loading on both sidemembers, i.e. the center of gravity of the raised body is ideally centered and the chassis is on solid, level ground. If the center of gravity is laterally offset due either to uneven loading, uneven ground, or both, the bending moment on one of the rails could increase substantially. For this reason the body installer should derate the overhang limits to account for the lateral shift if either of these factors apply. These limits apply specifically to concentrated or pivoting loads supported only by the bare chassis, and do not factor in the load support provided by any part of the installed body structure. Any load exceeding these limits must be wholly supported by the installed body structure. Static loading refers to the application of loads without shocks to the chassis or significant dynamic accelerations applied to the chassis. Dynamic loading refers to all loading conditions during which the chassis must absorb a shock, stop a load in motion, or support a load during movement of the vehicle. Examples of dynamic loadings would be dumping materials from a dump body, driving the vehicle over uneven surfaces with AF loads, or even operating a loaded liftgate. Because most operations involve dynamic loadings of some kind, the load limits in column "P" should never be exceeded. The load limits in column "D" should be exceeded only when the excess load is supported by rail reinforcement or by the body structure. DUMPBODY PIVOT POINT L 2006 MODEL YEAR P (LBS.) Max. static vertical load (1) both rails combined 3825 4950 6525 9225 Maximum (3) Maximum (3) D (LBS.) Max. dynamic vertical load (2) both rails combined 850 1100 1450 2050 3500 8900 OVERHANG LIMIT, "L" (IN.) Nominal yield strength - 50,000 PSI 96 64 48 32 16 0 (1) Maximum static vertical load defined as maximum load which can be applied in steady state condition without exceeding yield strength of rails. (2) Maximum dynamic vertical load defined as maximum load which can be applied during equipment operation to provide adequate margin for shocks and accelerations (3) Maximum load limited by rear GAWR and vehicle GVWR rather than frame stressesAcrobat Distiller 6.0.1 (Windows)