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Exmark 4500-485 Lawn Mower User Manual

1. 0093831 Mem Description Fuel tank 2010 Expedition SSV Modifiers Guide 07 2009 5 10 Reference Information Section 5 Reference Information Fuel Tank Bottom View Long Wheelbase 0106737 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 11 Section 5 Reference Information Hem Description Fuel tank Fuel Tank Top View Short Wheelbase 0093833 2010 Expedition SSV Modifiers Guide 07 2009 5 12 Reference Information Section 5 Reference Information Fuel Tank Top View Long Wheelbase UNT N0106738 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 13 Section 5 Reference Information Fuel Pump Shut Off Switch 0077120 Brake Lines NOTICE When installing equipment it is important to consider the available clearance between the brake lines and the fastener or component Any fasteners or static compone
2. A transceiver location should be selected that provides a solid mounting point which does not interfere with the vehicle operator controls and provides adequate ventilation Before using screws to mount the transceiver equipment be sure to check for vehicle wiring under the carpet or behind the instrument panel which could be pinched cut or otherwise damaged Radio Wiring and Routing Transceiver power connections should be made directly to the battery and appropriately fused as close to the battery as possible A weatherproof fuse holder is recommended Twist the positive and negative power leads together to enhance noise immunity Use caution when routing wires between the passenger and engine compartments to avoid chafing or pinching of wires Use grommets over any exposed sharp edges and strain reliefs to keep wires in place Seal all holes to prevent moisture intrusion Route and secure all underhood wiring away from mechanical hazards such as exhaust manifolds and moving parts steering shaft throttle linkage fans Maintain as great a distance as possible between mobile radio power leads and the vehicle s electronic modules and wiring Avoid running power leads in parallel with vehicle wiring over long distances Note On some Ford vehicles the rear window contains the entertainment radio antennas AM and FM Avoid using the rear window to mount mobile radio antennas in these vehicles Antenna Location and Installatio
3. PC ED Manuals and Owner s Literature In addition a publications order form can be obtained by writing to Ford Publications c o Helm Inc P O Box 07150 Detroit 48207 2010 Expedition SSV Modifiers Guide 07 2009 3 Installation Considerations Contents Section 3 Installation Considerations Mobile Radio Installation Guidelines General Information Spotlight Installation Location Push Bumpers Siren and Grille Lights Partition Installation Guidelines Safety Belt Retractor and Side Impact Sensor Console Design and Installation Restraints Control Module RCM Air Bag Deployment Interference Seat Bolts Driveshaft Clearance Brake Line Clearance Battery Saver 2010 Expedition SSV Modifiers Guide 07 2009 Installation Considerations 3 1 Section 3 Installation Considerations Mobile Radio Installation Guidelines NOTICE This information has been prepared for use by persons installing 2 way radio equipment transmitters and receivers in vehicles It has been prepared in accordance with current engineering principles and generally accepted practices using the best information available at the time of publication These guidelines are intended to supplement but not to be used in place of detailed instructions for such installations which are the sole responsibility of the manufacturer of the land mobile radio Since it is not possible to cover all possible installations of 2 way radio equip
4. object in the power outlet as this will damage the outlet and blow the fuse Do not hang any type of accessory or accessory bracket from the plug Incorrect use of the power outlet can cause damage not covered by the warranty The auxiliary power point is located on the instrument panel Do not use the power point for operating the cigar lighter element if equipped To prevent the fuse from being blown do not use the power point s over the vehicle capacity of 12V DC 180W If the power point or cigar lighter socket is not working a fuse may have blown To prevent the battery from being discharged do not use the power point longer than necessary when the engine is not running Always keep the power point caps closed when not being used General Guidelines Provide circuit protection fuses for all wiring The fuse rating should not exceed either the rated wiring current capacity or the total current requirements for all the add on components on the circuit Install fuses as close to the point of tapped power as possible Document all revisions to the electrical system and place with the vehicle Owner s Literature Color code and or label all revisions or additions to wiring Provide protective covering in all areas that could be damaged during normal equipment installations 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 5 Section 2 Electrical Disconnect the negative battery cable of vehicles stored on site to reduce
5. 530 565 600 635 670 255 270 285 290 310 325 330 340 360 395 425 460 495 530 565 600 635 670 When outside ambient temperature is greater than 21 C 70 F inflate tires to placard pressure Use the table to adjust tire pressure for P metric and LT tires only 0079118 2010 Expedition SSV Modifiers Guide 07 2009 SECTION 2 Electrical Contents Section 2 Electrical Electrical Basics Electrical Systems Management Generator Output Charging Margins Vehicle Component Electrical Loads Typical Police Equipment PCM Red Area Disabling Brake Lights Auxiliary Power Point 12V DC General Guidelines Splices and Repairs How To Change Option Content Rear Power Window Disable Wiring Reference Information 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 1 Section 2 Electrical Electrical Basics Inside a vehicle electricity is supplied through powered wires commonly called hot wires comparable to the pressurized supply pipes of a plumbing system At various points along the wires are outlets in the form of lights switches and receptacles Turning on a light switch is somewhat like opening a faucet to let water run an electric current flows through the hot wire to make the light glow Once the electricity has done its work its potential drops to zero just as water loses pressure after flowing through a sink or laundry tub The electrical system has drains which are the ground wires that re
6. Failure to follow these instructions may result in personal injury Auxiliary Climate Control System Note Expedition EL shown Expedition similar 0076002 The auxiliary heater core and evaporator core housing is located behind the passenger side lower quarter trim panel Do not mount any equipment to the housing Do not mount any equipment in a way that may block the air intake or vents 2010 Expedition SSV Modifiers Guide 07 2009 4 4 Cargo Mounting Considerations Section 4 Cargo Mounting Considerations Cargo Loading AN WARNING Ford recommends that police equipment be both secured and laterally aligned Hard stiff or sharp objects especially when not secured or correctly located pose a risk to the occupants Aftermarket organizers that do not adequately deform in rear impacts can themselves become injury producing objects Failure to follow these instructions may result in personal injury A slogan has been developed to increase police agency awareness of the importance of cargo packing Improve police officer safety by implementing a cargo packing process called LOAD SAFE Lateral Soft Orientation And And Fixed Direction Equipment Equipment Categories and Placement A WARNING Gasoline should not be stored in the cargo area at any time regardless of container Failure to follow this instruction may result in personal injury It is recognized that wide variety of equipment is carried in pol
7. code The second set of letters numbers listed if applicable indicate a 2 tone or accent body color code DX Dark Blue Pearl UG White Platinum UH Tuxedo Black Metallic UJ Sterling Gray Metallic UK Royal Red UX Ingot Silver Metallic YZ Oxford White 4 Wheelbase Code e 119 3 023 mm 119 in wheelbase e 131 3 327 mm 131 in wheelbase 5 Interior Trim Code The interior trim colors are Trim Type 1 Verona leather 2 tone 40 40 Captain s chairs Expedition 2 Verona leather 40 40 Captain s chairs Expedition 3 Verona leather 40 40 Captain s chairs with accent Expedition 4 Verona leather Eddie Bauer Expedition 5 Aniline leather perforated King Ranch Expedition F Cloth Captain s chair Expedition M Cloth 40 60 split bench seat Expedition T Premium Soho leather 40 60 Captain s chairs Navigator Interior Trim Color e C Camel L Medium Light Stone e W Charcoal Black 2010 Expedition SSV Modifiers Guide 07 2009 1 8 General Information Section 1 General Information 7 Radio Type e 1 AM FM stereo with in dash 6 disc CD changer and clock F AM FM stereo CD player navigation system and clock S Premium electric AM FM stereo CD player T Premium AM FM stereo with in dash CD changer and clock U Premium AM FM stereo with in dash 6 disc CD changer and THX speaker system X AM FM
8. mounted or placed in the deployment area of an air bag will reduce the effectiveness of the air bag damage the air bag and potentially damage or dislodge the equipment Some approximate dimensions for air bags at full inflation are provided in Figures 1 through 4 These dimensions are somewhat flexible and represent free form deployments without the loading of occupants All air bag and equipment mounting zone dimensions are approximate due to different air bag deployment characteristics Mount no equipment between the side of the front seat and the door trim that would block deployment of the side air bag 2010 Expedition SSV Modifiers Guide 07 2009 5 2 Reference Information Section 5 Reference Information 0076116 Figure 1 1 250 mm 9 8 in from center of air bag door 2 325 mm 12 8 in from center of air bag door 3 650 mm 25 6 in 0076117 Figure 2 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 3 Section 5 Reference Information 1 500 mm 19 7 in 2 300 mm 11 8 in 3 200 mm 8 in 0077125 Figure 3 No objects should be placed between the air bags due to air bag variability 1 300 mm 11 8 in 2 500 mm 19 7 in 3 260 mm 10 25 in 4 175 mm 7 in AN WARNING The front side impact sens
9. or larger weather resistant connector the very large style since the wire may break during disengagement Use Hypalon XLPE or Elexar insulation in submersible connectors to maintain sealing integrity PVC is not acceptable because it cold flows and allows setting in a deformed pattern therefore compromising the integrity of the seal 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 7 Section 2 Electrical Determine the terminal type Base your decision on wire gauge current carrying capacity connector type and insulation type Use non detent low insertion force terminals whenever possible Do not use low insertion force female terminals in weather resistant connectors Analyze circuit requirements signal levels current voltage to determine the correct plating material such as gold Use of non plated terminals is not recommended Do not use plugs to seal holes in micropin connector grommets It is very easy to forget to insert them during manufacturing and ruin the seal Use a grommet with only the necessary number of holes or use dummy wires at least 600 mm 24 in long Fully align connectors prior to terminal connection terminal cavities should have minimum tolerance to prevent terminals from floating bending or pin push out during mating engagement Make sure connectors of similar type and color are identifiable to the operator to eliminate crossed connections and minimize assembly time Avoid usin
10. stereo with in dash CD changer and navigation system 8 Axle Ratio Code The axle ratios are e 15 3 31 ratio non limited slip 16 3 73 ratio non limited slip H6 3 73 ratio limited slip 10 Spring Code Front Springs AA 5L14 3C098 AB BB 5L14 3C098 BB CC 3L1J 18B036 AA DD 5L74 3C098 AC FF 3L14 18B036 BA HH 3L14 18B036DA Rear Springs e 11 4L14 18W00 AA 33 5L14 5A965 BB e 44 5L14 5A965 AB 55 4L1J 18W002 AA 66 5L74 5A965 AB 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 9 Section 1 General Information 11 Powertrain Calibration Information Powertrain calibration information is printed in the lower right corner of the VC label Only the base calibration information is printed Revision levels will not appear Powertrain calibration information is limited to a maximum of 5 characters per line on the VC label Calibration identification consisting of more than 5 characters will wrap to the second line on the VC label Good Practices Process and Quality Assurance Systems A formalized Process and Quality Assurance system may be helpful in consistently producing high quality products An overview of some of the key items for such a system are outlined in this section Quality Assurance Completed Unit Sign Off All control items should be inspected with a written sign off All labels should be inspected and signed off includ
11. will come across WARNINGS NOTICES and NOTES Each one is there for a specific purpose WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury NOTICES are given to prevent you from making an error that could damage the vehicle NOTES give you added information that will help you to complete a particular procedure 2010 Expedition SSV Modifiers Guide 07 2009 1 2 General Information Section 1 General Information The following list contains some general warnings that you should follow when you work on a vehicle Z WARNING Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Make sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake when working on the vehicle The gear selector should be set in PARK unless instructed otherwise for a specific operation Place wood blocks 4 in x 4 in or larger against the front and rear surfaces of the tires to help prevent the vehicle from moving Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide poisoning Keep yourself and your clothing away from moving parts when the engine is running especially the drive belts To reduce the risk of serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tailpipe catalytic converter a
12. 1L54 A Cross linked Polyethylene XPLPE or SXL rated at 135 C 275 F is the required insulation for underhood underbody applications Ford Specification ESB M1L123 A GXL can be used as an alternate wire Ford Specification ESB M7L85B as long as the concentricity specifications are met To provide a water resistant seal in conjunction with crimp connectors a Duraseal crimp connector is recommended since it is designed to account for outside wire diameter that is smaller than the present SXL wire Terminals and Connectors Connector Types e Submersible sealed A connector that is capable of being immersed in water Weather resistant A connector that will retain its sealing and connection qualities while being exposed to adverse weather conditions Duraseal crimp A supplier trade name for a sealed wiring repair or splice When a connection is not defined typical situation harness to harness connectors the following suggestions should be implemented Determine the connector type If it will be located in a hostile environment use a submersible sealed connector if not use an open connector A hostile environment is defined as being exposed to water and or salt accumulation and or high temperatures for example underhood exterior panels and footwells Use in line connectors with secondary locks to prevent the terminal from being pushed out Do not use single wires smaller than 14 gauge in a 2 way
13. EXPEDITION EXPEDITION EL SPECIAL SERVICE VEHICLE SSV MODIFIERS GUIDE TABLE OF CONTENTS INTRODUCTION 1 General Information 2 Electrical 3 Installation Considerations 4 Cargo Mounting Considerations 5 Reference Information NOTE The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing Ford Motor Company reserves the right to discontinue models at any time or change specifications or design without notice and without incurring any obligation All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company Copyright 2009 Ford Motor Company SECTION 0 Introduction Contents Introduction 2010 Expedition SSV Modifiers Guide 07 2009 Introduction 0 1 Introduction Ford Motor Company has assembled this Expedition Special Service Vehicle SSV Modifiers Guide to assist vehicle modifiers in producing safe and quality products Ford believes that safety and quality come first This book is divided into topics pertinent to modifiers of vehicles Reference is made to the current Ford Expedition Workshop Manual for appropriate service procedures torque specifications component separation clearances and other standard information t
14. N It also includes the gross vehicle weight rating GVWR and the gross axle weight rating GAWR as well as tire size and pressure ratings The VC label is located on the left hand front door edge 1 2 Standard on EL SSV 2010 Expedition SSV Modifiers Guide 07 2009 1 6 General Information Section 1 General Information Vehicle Certification VC Label Code Positions MFD BY FORD MOTOR CO IN U S A DATE XX XX GVWR XXXXXXXXXXXXXXX FRONT GAWR XXXXXXX REAR GAWR XXXXXXXX XXXXXXXX WITH XXXXXXXX WITH XXXXXXXXXXXX TIRES XXXXXXXXXXXX TIRES XXXXXXXXX RIMS XXXXXXXXX RIMS ATXXXX kPa XXX PSI COLD kPa XXX PSI COLD XXXX THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE XXXXXXXXXXXXXXXXK RES XXXXX EXT PNT 050 INT TRI TP PS TRTAXLE Se Xxx XXX X X XXXXX XKXXX UTC F amp 5B 152 MTA AB 0093380 Position Description Exterior paint code District Special Order DSO WB 1 6 Tape paint pinstripe code pole code OE Pp Transmission code 11 Powertrain calibration information 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 7 Section 1 General Information 1 Exterior Paint Color Code The first set of numbers letters listed indicate the vehicle primary body color
15. Repairs For quality splicing and to reduce potential problems the following guidelines are recommended Stagger the splices within a harness to reduce increased harness diameter Splice only on straight areas as installed not on bends Strip wire ends making sure that individual conductor strands are not damaged When soldering make sure an adequate mechanical joint exists before applying solder Use only resin core solder Acid core solder should not be used since it may result in corrosion For crimp joints use butt type metal barrel fasteners and the correct tool at the appropriate setting for the wire size such as Motorcraft Crimp Tool S 9796 specifically designed for this type of work Make sure splice joints are adequately sealed and insulated In an outside environment use Duraseal butt connectors or equivalent A durable substitute splice joint can be achieved by using a bare metal barrel crimping flow soldering and covering with shrink tubing Quality electrical tape can be used inside the vehicle but is not recommended for an outside environment Be sure that the new wire is not a lesser gauge than its original mating wire CONNECTOR SHRINK TUBING e 4 5 2L A0074039 Splicing Method Solder For 16 AWG and Smaller Diameter Wire nly 1 Disconnect the battery ground cable 2010 Expedition SSV Modifiers Guide 07 2009 Electrical Section 2 Electrical 2 Strip wires to appropriate l
16. a standard patrol car can not SSV Standard Package Deletes Floor console Floor mats Fog lamps Third row seat Standard Equipment Powertrain Functional 5 4L SOHC 3V V8 Engine 6 speed automatic O D transmission Non limited slip axle 3 73 ratio Multi link independent rear suspension P265 70R17 BSW 5 tires 4x2 only P265 70R17 OWL ON OFF road tires 4x4 only Front skid plates only 4x2 Front transfer case and gas tank skid plates 4x4 only Tire pressure monitoring system TPMS Variable assist power rack and pinion steering Exterior 17 in steel wheels Expedition only 17 in aluminum wheels Expedition EL only Autolamps Body color body side cladding front rear fascia and wheel lip moldings Black door handles Fog lamps Black grille Dual beam complex reflector headlamps Keyless entry keypad Black heated power mirrors with security approach lamps Privacy glass Remote keyless entry with 2 key fobs 4 buttons each Black roof rails Step bars 4x2 only Tow hooks 4x4 only Trailer towing integrated class receiver with 4 pin connector Continued 2010 Expedition SSV Modifiers Guide 07 2009 1 4 General Information Section 1 General Information Standard Equipment Interior Second and third row coat hooks Second row map lights Manual A C with auxiliary climate controls AM FM single CD 6 premium speakers 160 watts peak driver adjusted speed compensated volume partitioned audio rear seat control
17. ack Width Front 1 701 mm Track Width Rear 1 706 mm 67 0 in 67 2 in First Row 1 005 mm 39 6 in Expedition or 1 003 mm 39 5 in Expedition EL Second Row 1 010 mm 39 8 in Expedition or 1 008 mm 39 7 in Expedition EL Third Row optional 972 mm 38 3 in Expedition or 965 mm 38 0 in Expedition EL First Row Second Row Third Row optional First Row Second Row Third Row optional 1 318 mm 51 9 in Expedition or 1 704 mm 67 1 in Expedition EL First Row Second Row Third Row optional 1 275 mm 50 2 in Expedition or 1 316 mm 51 8 in Expedition EL 3 06 cu m 108 cu ft Expedition or 3 70 cu m 130 8 cu ft Expedition EL 1 53 cu m 54 cu ft Expedition or 2 42 cu m 85 5 cu ft Expedition EL Continued 2010 Expedition SSV Modifiers Guide 07 2009 5 16 Reference Information Section 5 Reference Information Specification Specification 0 51 18 ft Expedition 1 21 42 6 cu ft Expedition EL Mileage Est km L City 6 8 Highway 9 3 2010 Expedition SSV Modifiers Guide 07 2009
18. and weight of wire bundle Holes with poor accessibility that prevent installation of locators Movement of wires that can result in abrasion squeaks and rattles When wiring is routed between 2 members where relative motion can occur the wiring should be secured to each member with enough wire slack to allow flexing without damaging the wire Wiring exposed to weather must provide a drip loop to prevent moisture from being conducted into the device through the wire connection see figure below eu lt 7 Drip loops should be provided at connectors grommets to direct water away from terminals or inside the vehicle A0073517 Avoid routing wires into areas exposed to wheel splash When such routing cannot be avoided adequate clipping and or protective shields are required to protect the wires from stone and ice damage Allow adequate slack in wiring between the engine and stationary components to compensate for engine roll Avoid routing wires under the frame side members or at points lower than the bottom frame flange Use plastic zip straps for bundling only securing to other wires The wire retainers and grommets installed by the assembly plant are usually designed to accommodate only the Ford installed wires Additional wiring or tubing should be retained by additional clips When added wires or tubes are routed through sheet metal panels new holes with correct wire protection and sealing must be use
19. charged particles called electrons that flows past a given point on a circuit each second It is similar to measuring the amount of water flowing through a pipe at any given point The larger the pipe is the more water that can flow past the point per second Similarly the bigger the wire is the more current that can flow through it at any given point Current that has lost its voltage still has amperage as it completes the circuit and returns to the battery WATT is the unit of power It indicates that rate at which a device converts electric current to another form of energy either heat or motion or to put it another way the rate at which a device consumes energy The relationship of volts amperes and watts to one another is expressed in a simple equation that enables you to make any calculations you may need for correct and safe electrical modifications to the vehicle Volts x amperes watts If the current is at 12 volts and a device requires 4 amperes of current the equation will read 12 volts x 4 amperes 48 watts To figure the current needed for a device rated in watts turn the equation around watts volts amperes For example if you have a piece of equipment such as a communications radio that uses 120 watts 120 watts 12 volts 10 amperes 2010 Expedition SSV Modifiers Guide 07 2009 2 2 Electrical Section 2 Electrical Electrical Systems Management Care must be given in deciding what equipment should be insta
20. cle SSV the generator is controlled by the PCM The Expedition SSV has a 150 amp generator Generator amp output Maximum output for the Expedition SSV is 150 amps Generator drive ratio determined by generator pulley size 2 96 1 Charging Margins Generator output varies with engine speed and ambient temperature The worst case for police vehicles is when the vehicle is idling for long periods of time on a very hot day Lower engine speeds while idling coupled with high underhood temperatures that may approach 93 C 200 F combine to minimize power output from the generator At the same time electrical demand on the vehicle is often at its highest because the A C loads are added to the usual electrical loads experienced in emergency situations Vehicle Component Electrical Loads Vehicle component electrical loads are shown in the table below Not all features are powered all the time so actual vehicle loads on the power supply system will vary 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 3 Section 2 Electrical Amps 16 5 2 2 18 9 134 125 Exterior and Instrument Panel Lamps 7 5 non dimmable Headlamps Low Beam Headlamps High Beam incremental Brake Lights with CHMSL 10 7 Heated Features Heated Rear Windows 21 9 Front Wiper Typical Vehicle Load 80 110 Amps Typical Police Equipment Loads for equipment commonly found on police vehicles a
21. d 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 13 Section 2 Electrical RUBBER Cast ELECTRIC T STEEL BE SATISFACTORY UNSATISFACTORY Cables should not be in contact with sharp edges or pierced holes WHEN PARALLEL 0 4 IN OR MORE TAPING WHEN ACROSS 0 8 IN OR MORE Ne SATISFACTORY S gt UNSATISFACTORY HARNESS Harnesses should not be taped to fuel lines or other lines A sufficient clearence should be maintained between harness and lines 0072291 For retainer screws the following guidelines apply Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components including wiring brake lines fuel tank and lines powertrain components exhaust system and suspension Do not use pointed screws for attachments Also check that screws used in the vicinity of the wiring are blunt ended To minimize the potential for wiring shorts do not use drill point screws Trim components including wiring shields should use pin type attachments instead of screws Always check areas that screws protrude into for verification that an interference condition to other components does not exist Make sure that retainers used are capable of withstanding the environment over the vehicle s life expectancy 2010 Expedition SSV Modifiers Guide 07 2009 2 14 Section 2 Electrical Splices and
22. d Maximum Screw Sizes New Vehicle Storage Tire Pressure Monitoring System TPMS Principles of Operation Ambient Temperature Change and Tire Pressure 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 1 Section 1 General Information Important Safety Notice Note The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing Ford Motor Company reserves the right to discontinue models at any time or change specifications or design without notice and without incurring obligation Appropriate repair methods and procedures are essential for the safe reliable operation of all motor vehicles as well as the personal safety of the individual doing the work This manual provides general directions and guidelines for performing modifications to the Expedition Special Service Vehicle SSV Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for modifying vehicles as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods tools or parts Warnings Notices and Notes As you read through this guide you
23. e side than the other heat shrink insulation will not provide a correct seal Evaluate the use of double terminals instead of splices where practical in these situations Recommended Splicing Method Crimp For 1022 AWG Diameter Wire to Like Wire Diameter 1 Disconnect the battery ground cable 2 Strip wires to appropriate length 3 Install heat shrink tubing 25 4 mm 1 in 6 35 1 4 WIRE STRIP INCORRECT 2 WIRE STRIP 77 0079052 2010 Expedition SSV Modifiers Guide 07 2009 2 18 4 7 Section 2 Electrical Select the appropriate wire slice for the wires to be spliced from Rotunda Wire Splice Kit 164 R5903 Note Rotunda 164 R5901 Pro Crimper supplied with the wire splice kit is the only tool that can be used with these splices Identify the appropriate chamber on the Rotunda Pro Crimper by matching the wire size on the dies with the wire size stamped on the butt splice 1 Cavity 2 Indenter 0053048 Crimp the connector 1 Center one end of the wire splice in the appropriate crimping chamber 2 Insert stripped wire into the barrel 3 Holding the wire in place squeeze the tool handles until ratchet releases gt 1 Lu Repeating Step 6 crimp the other half of the splice 2010 Expedition SSV Modifiers Guide 07 2009 Elec
24. end beyond the shield Failure to do this reduces the effectiveness of the shield Spike suppression in general is accomplished by connecting a diode or resistor diode combination across the terminals of the noisy component The diode should be sufficiently close to the component both electrically and physically so that inductive spikes are clamped off Make sure the diode is connected with the correct polarity Correct routing and retention will reduce the likelihood of chafing or pinching When this ideal routing is unattainable the following additional protection is needed Mechanical Environmental Protection Tape Tape is the most basic means of protection It contains the wires in a loose bundle and provides limited environmental protection It does not protect against chafing and pinching Kendall Polyken Fiberglass Base Tape Ford Specification ESB M3G38 A is used for engine compartment applications This durable tape provides against cut through and abrasion commonly found in underhood applications Polyken 267 is a substitute tape that may be used in lower temperature areas of the engine compartment apron area Convolute Use convolute for all underhood underbody applications or when increased temperature abrasion or pinch resistance is required Convoluted tubing comes in different diameters and materials to accommodate different temperature ranges and harness sizes Use polyethylene convolute when abrasi
25. ength A0075761 Install heat shrink tubing Twist the wires together 2 15 Note Use resin core mildly activated RMA solder Do not use acid core solder Solder wires together A0075762 6 Note Wait for solder to cool before moving wires Bend wire 1 back in a straight line 2010 Expedition SSV Modifiers Guide 07 2009 2 16 Section 2 Electrical A0075763 7 Note Overlap tubing on both wires Evenly position heat shrink tubing over wire repair 25 4mm 49 9 mm 1 in 2 in A0075764 8 Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing A0075765 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 17 Section 2 Electrical 9 Reconnect the battery ground cable Sealed Connectors Ford Part Number E6FZ 14488 A Butt Connector Gauge 18 22 Color Red E6FZ 14488 B Butt Connector Gauge 14 16 Color Blue E6FZ 14488 C Butt Connector Gauge 10 12 Color Yellow Heat Shrinkable Tubing Heat Shrink Ford Specification ESB M99D56 A2 Heat shrinkable tubing is available in various diameters for different splice sizes and configurations When shrunk it forms a small flexible hermetic seal Other methods tape PVC mold do not provide a hermetic seal and are not recommended Splice balancing is critical with heat shrink insulation If the splice is extremely unbalanced more circuits on on
26. erails 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 5 Section 5 Reference Information Fuel Lines Short Wheelbase 0093827 Description 2010 Expedition SSV Modifiers Guide 07 2009 5 6 Reference Information Section 5 Reference Information Fuel Lines Long Wheelbase 7e 7 ARA A CS Hour y N gt mem Description 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 7 Section 5 Reference Information Fuel Tank Cut View Short Wheelbase 0093829 2010 Expedition SSV Modifiers Guide 07 2009 5 8 Reference Information Section 5 Reference Information Fuel Tank Cut View Long Wheelbase 0106736 Mem Description 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 9 Section 5 Reference Information Fuel Tank Bottom View Short Wheelbase
27. g similar types and colors of connectors close together Be sure that connectors have positive locking devices that allow easy installation with a low insertion force and easy removal The connector snap should be easily felt and heard Eliminate the use of edgeboard tang type and molded over connectors The use of blade type weather resistant connectors is restricted to high current applications which cannot be handled by submersible connectors Circuit Protection and Electrical Load Modification to existing vehicle wiring should be done only with caution and careful consideration of effects on the completed vehicle electrical system Anticipated circuitry should be studied to determine the required circuit protection and to avoid feedback loops Added circuitry must be protected either by a base vehicle fuse or circuit breaker or by a similar device supplied by the modifier When adding loads to a base vehicle protected circuit make sure that the total electrical load through the base vehicle fuse or circuit breaker is less than the device s load rating Use 80 of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures 2010 Expedition SSV Modifiers Guide 07 2009 2 8 Electrical Section 2 Electrical Use 135 of the fuse rating when sizing wiring to protect the circuit in the event of an overload Fuses will last for 1 hour at 135 of their rating Total current draw is the su
28. go wrong and modify your designs to address any adverse impact Review all connector applications and electrical systems to determine the need for solder grease weather resistant or sealed connectors Make sure components and wire insulation are compatible with greased connectors important for long term durability Make sure that drip loops or other means are provided to prevent water leakage into the vehicle through wiring assemblies that pass through the dash panel 2010 Expedition SSV Modifiers Guide 07 2009 2 9 Section 2 Electrical Use greased or sealed connectors in floor pan troughs which are subject to moisture coming through the carpeting Use XLPE insulation for uncovered runs that exceed 305 mm 12 in Electrical Protection Correctly route wires away from noise generating wires or components However if routing near noisy wires or plugging into noisy components is unavoidable additional protection must be designed into the harness Shielding Electro Magnetic Interference EMI Consider shielding if you must route close to high current or noisy circuits Use shielded wire and ground one side Seal all splices in wire assemblies that use bare coaxial shielding braid or tape for EMI suppression and insulate or tape over all shielding ends that terminate near any open connectors This prevents splice and terminal shorts to the shielding Minimize the length of conductors which ext
29. hat is common with the unmodified vehicle Specifications that are unique to the guide are designated This modifiers guide is not a how to book it should be used as a checklist to help make sure that certain important steps in the modification process are considered While Ford is providing this information to assist modifiers it does not warrant the products methods materials or the workmanship of the modifier Nor does it warrant against failures that result from the modification of a vehicle Following the guidelines contained in this guide does not assure individual modifiers that the products they modify comply with U S Federal or Canadian Motor Vehicle Safety Standards in effect at the time of the modification The guidelines set forth are based on engineering analyses of typical vehicles If followed the modifier s efforts in certifying vehicles to applicable standards should be aided Compliance testing that may be required for certification of specific vehicle configurations or construction is however the sole responsibility of the individual modifier 2010 Expedition SSV Modifiers Guide 07 2009 1 General Information Contents Section 1 General Information Important Safety Notice Warnings Notices and Notes Making Safety Devices and Elements Inoperative Special Service Vehicle SSV Definition Identification Codes Good Practices Process and Quality Assurance Systems Quality Assurance Minimum an
30. ice vehicles as noted above This section addresses the inherent risks of various types of equipment in the event of a high speed rear impact Carrying Not Recommended The following items have been observed in police vehicles should not be transported in the vehicle cargo area containers with gasoline loose ammunition loose flares loose fire extinguisher s loose 4 point lug wrenches loose crowbars loose axes and other loose equipment with potential injury capability in collisions Carry With Caution These items will require special packing or mounting consideration Examples include with proposed orientation fire extinguisher fixed lug wrench 4 point fixed vertical rolotape measuring wheel fixed vertical safety flares lateral orientation in a container stop stick lateral shovel lateral place at rear of cargo area shotgun and rifle lateral store in case baton lateral place at rear of cargo area electronic equipment and ammunition container Flares should be placed in a protective storage container preferably soft sided plastic Flares with spikes attached should be laterally oriented in the cargo area 2010 Expedition SSV Modifiers Guide 07 2009 Cargo Mounting Considerations 4 5 Section 4 Cargo Mounting Considerations Low Risk Items These items are soft in feel and pose a low risk of potential injury capability in collisions Examples are a soft camera case biohazard kit i
31. ilable clearance between the brake lines and the fastener or component Any fasteners or static components should allow a minimum of 15 mm 0 60 in clearance to the brake lines Any dynamic components should allow for a minimum of 19 mm 0 75 in clearance to the brake lines Battery Saver All Expedition vehicles are equipped with a battery saver feature which is a function of the smart junction box SJB The battery saver will disrupt power to the courtesy demand and headlamps off after 10 minutes and chimes after 30 minutes Interior lamps include the dome lamps and the instrument cluster lamps Demand lamps include the front map lamp glove compartment lamp luggage compartment lamp and engine compartment lamp Turning the ignition switch to the RUN or ACC position will terminate the battery saver feature by disabling the interrupt timers reinstating power to the lamps 2010 Expedition SSV Modifiers Guide 07 2009 3 10 Installation Considerations Section 3 Installation Considerations A reset event will set the interior lamps interrupt timer to 0 The reset events for the interior lamps interrupt timer are turning on the interior lamps by using the dome lamp switch or opening any door as detected by the door ajar switches A reset event will set the demand lamps interrupt timer to 0 The reset events for the demand lamps interrupt timer are opening the luggage compartment door or opening any door as detected by the door ajar
32. ing verification that the information on the labels is correct All appropriate systems should be checked for leaks A road test should be performed to verify that all systems are operating correctly All systems and functions that were provided by Ford should be checked to make sure that they function correctly after the build process The modifiers Process and Quality Assurance Systems should also make sure that appropriate training is provided to the employees Minimum and Maximum Screw Sizes When installing aftermarket equipment avoid using fasteners that are too long for the application or are in an area which might damage vehicle components including wiring brake lines fuel tank and lines powertrain components exhaust system and suspension Details for mounting equipment in the trunk as well as appropriate fasteners can be found in Section 4 Cargo Mounting Considerations New Vehicle Storage New Vehicle Storage General Vehicles should be stored in a dry ventilated place and protected from sunlight if possible f vehicles are stored outside maintenance against rust and damage as described below is recommended NOTICE Keep all rubber parts free from oil and solvents Damage to rubber parts can occur 2010 Expedition SSV Modifiers Guide 07 2009 1 10 General Information Section 1 General Information New Vehicle Storage Body Wash vehicle thoroughly to remove dirt grease oil tar or mud from ex
33. ire Pressure Inside Garage for Colder Outside Temperature Do Not Inflate Tire Higher than Maximum Pressure Stamped on Tire Sidewall Table is based Garage Temperature of 70 F Pressure Adjustment is 7 Tire Placard Pressure PSI Outside Temperature F Table 2 Use Table to Adjust Tire Pressure Inside Garage for Colder Outside Temperature Metric Units Do Not Inflate Tire Higher than Maximum Pressure Stamped on Tire Sidewall Table is based on a Garage Temperature of 21 C Max Pressure Adjustment is 50 kPa Tire Placard Pressure kPa 205 220 235 240 260 275 285 290 310 345 380 415 450 485 515 550 585 620 Outside Temperature 205 220 235 240 260 275 285 290 310 345 380 415 450 485 515 550 585 620 215 230 240 250 270 285 290 295 315 350 385 420 460 495 530 565 600 635 220 235 250 255 275 290 295 305 325 365 400 435 470 505 545 580 615 650 230 240 255 260 285 295 305 310 340 370 405 440 485 515 550 595 625 660 235 250 260 270 290 305 315 325 345 380 420 455 495 530 565 600 635 670 240 255 270 275 295 315 325 330 350 395 425 460 495 530 565 600 635 670 250 260 275 285 310 325 330 340 360 395 425 460 495 530 565 600 635 670 255 270 285 290 310 325 330 340 360 395 425 460 495 530 565 600 635 670 255 270 285 290 310 325 330 340 360 395 425 460 495 530 565 600 635 670 255 270 285 290 310 325 330 340 360 395 425 460 495 530 565 600 635 670 255 270 285 290 310 325 330 340 360 395 425 460 495
34. iring Inadequate shielding or loose corroded connectors associated with the antenna feed line Mismatched antenna or high SWR Power feeds not connected directly to the vehicle battery Power feed routing locate as far as possible from vehicle electronics and wiring 2010 Expedition SSV Modifiers Guide 07 2009 3 4 Installation Considerations Section 3 Installation Considerations If any vehicle radio interaction problems exist after following these guidelines contact the radio equipment manufacturer for additional assistance Additional Sources of Information Radio Frequency Interference How to Find It and Fix It ISBN 0 87259 375 4 The American Radio Relay League Inc Newington Connecticut 06111 1494 Phone 203 666 1541 Fax 203 665 7531 Giving 2 Way Radio Its Voice booklet Champion Spark Plug Company Automotive Technical Services Dept P O Box 910 Toledo Ohio 43661 Spotlight Installation Location 0078988 2010 Expedition SSV Modifiers Guide 07 2009 Installation Considerations 3 5 Section 3 Installation Considerations Description Side curtain tether anchor bolt hole A pillar assist handle bracket bolt Spotlight shaft hole Spotlight ma lower bolt 1 Mark a center line between the center of the side curtain tether anchor bolt hole and the A pillar assist handle bracket lower mounting bolt hole Extend the center line past the A pillar assist handle bracket lower mounting b
35. it when disconnected Air bag restraint systems must remain intact as received from Ford Motor Company Before modifications are done to the vehicle the system must be disarmed by following the instructions provided in the current Expedition Workshop Manual Adherence to the above guidelines is not to be construed as approval by Ford Motor Company of any specific revisions or additions to the vehicle s original electrical system Keep Alive Memory KAM Power The electronic engine and transmission control modules require battery power to be supplied at all times to maintain the keep alive memory KAM Keep this in mind when installing load disconnect switches or solenoids 2010 Expedition SSV Modifiers Guide 07 2009 2 6 Electrical Section 2 Electrical Equipment Grounding Guidelines Do not ground the body to the transmission or transmission crossmember Ground accessories to the chassis or the vehicle battery Splicing into circuitry relating to the electronic engine and or transmission control systems is not acceptable because of the adverse effect on the electronic system operation Adequately protect electrical connections exposed to the elements Wire Insulation Polyvinyl Chloride PVC rated at 90 C 194 F is the standard wire insulation that is acceptable for inside body use but is not acceptable for underhood underbody wiring Hypalon insulation should be used on links only Ford Specification ESB M
36. livered by Ford Motor Company conforms to Standard FMVSS138 Tire Pressure Monitoring Systems This system may not function if any of the following components are removed relocated or modified in any way OEM wheels and tires Tire pressure sensors cradles and bands SJB SJB software and calibrations IC IC software and calibrations Instrument panel wiring Wheel bases greater than originally released Certain modifications could cause reduced system performance including the complete loss of TPMS functionality This may include Non OEM wheels or tires The addition of steel carcass or run flat tires Removal of tire pressure sensors cradles or bands Modification of the recommended tire pressure Modifications to the mounting location of the SJB Modifications or re location of the harness supplying the SJB and IC modules Addition of metallic structures such as prisoner partitions may affect the signal strength of the sensors and could interfere or prevent the SJB from hearing the sensors Addition of intended or unintended transmitters to the vehicle may affect the signal strength of the sensors or interfere SJB internal antenna 2010 Expedition SSV Modifiers Guide 07 2009 1 12 General Information Section 1 General Information The TPMS as delivered from the Ford Motor Company complies with part 15 of the FCC rules and with RS 210 of Industry Canada Operation is subject to the following 2 conditions This device
37. lled into a police vehicle given the power demands of the equipment and the power available from the vehicle A power load strategy should be developed to minimize the risk of running out of power Examine the proposed equipment for vehicle installation Add up the current requirements If the current requirements exceed what the vehicle can reasonably be expected to be able to provide the battery will begin discharging to provide the power to the equipment that the generator is unable to provide After some period of time the vehicle will shut off as the battery voltage decreases to a level that cannot sustain vehicle operation There are alternatives that can be considered to minimize system electrical overload Consider the current requirements of equipment before it is purchased and installed Modern light bars and radios use a fraction of the current than units made as recently as 1996 As the light bar is the most power intensive unit installed on most police vehicles considerable attention should be given to its current requirements Changes in officer habits while in the field can make a difference as well When a vehicle is sitting at an accident scene and no one is in the car the A C can be turned off until the officer is ready to get back into the vehicle The A C is among the largest current users of non police equipment As such it can impact available power for other uses as well Generator Output On the Expedition Special Service Vehi
38. llowing steps should be taken to avoid flat spotting when the vehicles are not used for a period of time Store the vehicles with 44 psi in the tires If the cars are to be driven the air pressure should be reduced to recommended operating pressure and then increased back up to 44 psi when returned to storage e If the vehicle is stored for periods longer than 30 days it should be moved several feet at least once during each 30 day period so that a different portion of the tread contacts the ground 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 11 Section 1 General Information Tire Pressure Monitoring System TPMS Principles of Operation The tire pressure monitoring system TPMS monitors the air pressure of all 4 regular road tires The tire pressure sensors attached to each rim by a metal band located in the drop well transmit via a 315 Mhz radio frequency signal to the internal antenna of the smart junction box SJB These transmissions are sent approximately every 60 seconds when the vehicle speed exceeds 32 km h 20 mph The SJB compares the tire pressure data against a low pressure limit If the module determines that the tire pressure has fallen below this limit the module communicates this on the vehicle network to the instrument cluster IC and illuminates the TPMS indicator solid If there is a system malfunction the TPMS indicator flashes for 70 seconds and then goes solid This vehicle as de
39. m of the base vehicle s circuit current requirement measured with an ammeter and the anticipated add on component current requirements Never increase the rating of a factory installed fuse or circuit breaker If the total electrical load including additional electrical components on any circuit is less than the fuse protection rating or the capacity of some limiting component switch relay the items to be added can be connected directly to that circuit The headlamp switch circuits should never have additional lighting or electrical components directly connected Added devices that exceed the current capabilities of the factory installed system are best controlled through the use of a relay or separate switch The coil of the relay can be fed from the circuit in the factory harness now acting as a signal circuit with added wiring providing feeds to the added electrical device The relay selection is important and depends on current requirements number of cycles expected in the relay lifetime whether the relay is to be operated intermittently or for long periods of time and whether the relay is exposed to weather conditions or is installed in a protected area When the current requirements of a circuit exceed the capacity of an available relay the load should be reduced or divided through the use of additional relays Wire Protection Requirements General Notes Anticipate problems and design accordingly Try to anticipate what could
40. may not cause harmful interference This device must accept any interference received including interference that may cause undesired operation Ambient Temperature Change and Tire Pressure NOTICE Do not inflate tire higher than maximum pressure stamped on tire sidewall Premature tire wear or damage to the tire may result Tire pressures fluctuate with temperature changes For this reason tire pressure must be set to specification when tires are at outdoor ambient temperatures If the vehicle is allowed to warm up to shop temperatures and the outside temperature is less than shop temperature the tire inflation pressure must be adjusted accordingly If the tires are inflated to specification at shop temperatures and the vehicle is moved outdoors when the outdoor ambient temperature is significantly lower the tire pressure may drop enough to be detected by the tire pressure monitoring system TPMS and activate the TPMS warning lamp 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 13 Section 1 General Information As the ambient temperature decreases by 6 C 10 F tire pressure decreases 7 kPa 1 psi Adjust the tire pressure by 7 kPa 1 psi for each 6 C 10 F ambient temperature drop as necessary to keep the tire at the specified vehicle certification VC label pressure Refer to the following tables to adjust the tire pressure indoors for colder outside temperatures Table 1 Use Table to Adjust T
41. ment Ford Motor Company cannot be held responsible for incidental or consequential damages arising from the use of the information contained herein Certain land mobile radios or the way in which they are installed may affect the vehicle operations such as the performance of the engine and driver information entertainment and electrical charging systems Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are not the responsibility of Ford Motor Company General Information Ford Motor Company vehicles are designed and tested for safe operation with correctly installed and used land mobile amateur radio communication equipment with up to 100 watt transmitter power Special design considerations are incorporated into all Ford vehicle electronic systems to provide immunity to radio frequency signals To maintain compatibility with vehicle electronic systems mobile 2 way radio and telephone equipment must be installed correctly by trained personnel observing these general guidelines Power connections should be made directly to the battery and fused as close to the battery as possible Avoid using cigar lighter or power point receptacles as power sources for radio communication equipment Antennas for 2 way radios should be mounted on the roof or the rear area of the vehicle Care should be used in mounting antennas with magnet bases since magnets may affect the accuracy or operation of the compass o
42. n Permanently installed antennas are preferable over magnetic glass or body lip mounts for anything other than for low power or temporary installations Most of these alternate antennas can reflect significant power back at the feedpoint this reflected power could then radiate from the feedline inside the passenger compartment and be picked up by the vehicle wiring However a magnetic mount antenna is a good tool for checking the proposed fixed antenna location for unwanted effects on the vehicle since antenna location is a major factor in these effects 2010 Expedition SSV Modifiers Guide 07 2009 Installation Considerations 3 3 Section 3 Installation Considerations Glass mounted antennas should be kept as high as possible in the center of the rear window or windshield Some vehicles use glass that contains a thin metallic coating for defrosting or to control solar gain glass mount antennas may NOT function correctly when mounted on this type of glass Ford Privacy Glass contains such a coating Also refer to the antenna manufacturer s recommendations If a magnetic mount antenna is used take care to locate the magnetic base in a location which avoids interference to the vehicle s compass mechanism if so equipped Also some Ford vehicles use non metallic body panels decklids etc If metallic backing panels are used do not block the reception paths for factory installed antennas such as Global Position Satellite GPS transcei
43. n SSV Modifiers Guide 07 2009 Reference Information 5 1 Section 5 Reference Information Engineering Drawings Air Bag Deployment Interference AN WARNING Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag dash tunnel or console mounted equipment should be placed within the specified zone Failure to follow these instructions may result in personal injury AS WARNING Dash tunnel or console mounted equipment should not be placed outside of the specified zone Failure to follow these instructions may result in personal injury AN WARNING Do not mount equipment between the side of the front seat to the door trim that would block deployment of the side air bag Failure to follow these instructions may result in personal injury Driver passenger air bags affect the way equipment can be mounted in vehicles Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path Sharp edges corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag Do not mount or place any objects in the deployment path of an air bag Air bags must be allowed to fully deploy without restriction The deployment of air bags is not compatible with any configuration of police equipment mounting that places objects in the air bag deployment path Equipment
44. n and sealing Be sure that the direction of the hole punch is in the direction of grommet seating and the hole is burr free Make sure the grommet molding compound will adhere to the harness to prevent slippage Make sure the grommet will withstand the environment temperature splash Be sure that holes are large enough to allow the installation of the harness without causing circuit damage Use adhesive tape on main trunks or branches with at least a 5096 overlap to prevent wicking through grommets Be certain to diaper wrap the takeouts Wire Routing AN WARNING Do not place electrical component attachments or ground screws adjacent to vehicle fuel tanks fuel filler pipes fuel lines fuel vapor lines or carbon canisters Failure to follow these instructions may result in personal injury in the event of a collision Wire harness routing should conform to the following Protect wires routed through holes in sheet metal or castings with a grommet whether or not conduit is used see figure below 2010 Expedition SSV Modifiers Guide 07 2009 Electrical 2 11 Section 2 Electrical RUBBER etn a ST wre T STEEL P SATISFACTORY UNSATISFACTORY Cables should not be in contact with sharp edges or pierced holes A0073515 Route wires to avoid metal edges screws trim fasteners and abrasive surfaces When such routing is not possible use protective devices shields caps to protect the wires Cover metal edge
45. n plastic boxes gloves safety rope tow strap traffic cones and sleeves rain gear riot gear soft emergency blankets bullet resistant vests tie straps cloth tape garment bags first responder kit Res Q Flo masks placed in garment bag fuses plastic container briefcases notebooks spray bottles helmets and jumper cables Cargo Area Weight The vehicle s high speed handling and curb height will become increasingly affected as weight is added to the cargo area The more weight that is placed in the cargo area the more it will change the ride and handling characteristics of the vehicle Consider these factors when installing equipment and placing items in the cargo area of the vehicle The vehicle certification VC label on the driver door lists a maximum load of 530 kg 1 170 Ib Expedition or 793 kg 1 750 Ib Expedition EL occupants luggage 2010 Expedition SSV Modifiers Guide 07 2009 5 Reference Information Contents Section 5 Reference Information Engineering Drawings Air Bag Deployment Interference Fuel Lines Short Wheelbase Fuel Lines Long Wheelbase Fuel Tank Cut View Short Wheelbase Fuel Tank Cut View Long Wheelbase Fuel Tank Bottom View Short Wheelbase Fuel Tank Bottom View Long Wheelbase Fuel Tank Top View Short Wheelbase Fuel Tank Top View Long Wheelbase Fuel Pump Shut Off Switch Brake Lines Technical Specifications 2010 Expeditio
46. n vehicles if so equipped The antenna cable should be high quality fully shielded coaxial cable and kept as short as practical Avoid routing the antenna cable in parallel with vehicle wiring over long distances Carefully match the antenna and cable to the radio to achieve a low standing wave ratio SWR and to avoid radio frequency currents on the antenna cable shield All installations should be checked for possible interference between the communications equipment and vehicle electronics Mobile radio equipment with greater than 100 watts output may require special precautionary measures beyond those outlined in this document This pamphlet is provided as a supplement to the radio manufacturer s installation instructions for installing communication equipment in Ford vehicles Additional sources of information are listed on page 3 4 2010 Expedition SSV Modifiers Guide 07 2009 3 2 Installation Considerations Section 3 Installation Considerations Radio transmitters are regulated by the Federal Communications Commission FCC in the United States Compliance with FCC regulations is the responsibility of the manufacturer and or user of transmitter equipment and not Ford Motor Company Installation Guidelines AN WARNING Do not mount any transceiver microphones speakers or any other item in the deployment path of the airbag system Failure to follow these instructions may result in personal injury Transceiver Location
47. nd muffler Do not smoke while working on a vehicle To reduce the risk of injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle When it is necessary to work under the hood keep hands and other objects clear of the radiator fan blades Failure to follow these instructions may result in personal injury Making Safety Devices and Elements Inoperative The vehicle contains many safety features required by Federal or Canadian Motor Vehicle Safety Standards These features which include the key in ignition chime and brake lights should never be disabled or modified Section 30122 of 49 USC states that manufacturer distributor dealer or motor vehicle repair business may not knowingly make inoperative any part of a device or element of design installed on or in a motor vehicle or motor vehicle equipment in compliance with an applicable motor vehicle safety standard prescribed under this chapter unless the manufacturer distributor dealer or repair business reasonably believes the vehicle or equipment will not be used except for testing or a similar purpose during maintenance or repair when the device or element is inoperative 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 3 Section 1 General Information Special Service Vehicle SSV Definition Special Service Vehicles SSV are offered to fill the special needs of police agencies that
48. nt path Equipment mounted or placed in the deployment area of an air bag will reduce the effectiveness of the air bag damage the air bag and potentially damage or dislodge the equipment Air bag deployment drawings are provided in Section 5 Reference Information Consult the drawings before equipment is installed inside the passenger compartment to make sure that the mounted equipment does not interfere with air bag deployment Seat Bolts NOTICE Do not install longer seat bolts if reinstalling seats The vehicle safety belts and seat assemblies are factory installed in their correct location Seat attaching bolts are not to be used as attachment points for any equipment Any added material between the seat bolt and the seat frame could have unpredictable effects on the seat bolt torque If the safety belts are removed for any reason all of the appropriate attaching hardware must be hand started and then tightened to the correct torque specifications as per the workshop manual Correct operation must be verified before returning the vehicle to service Driveshaft Clearance When installing police equipment such as a console or other equipment in the console area it is important to consider the available clearance between the underbody and the driveshaft Never use self tapping screws and never use screws that are longer than necessary in the console area Brake Line Clearance When installing equipment it is important to consider the ava
49. nts should allow a minimum of 15 mm 0 60 in clearance to the brake lines Any dynamic components should allow for a minimum of 19 mm 0 75 in clearance to the brake lines 2010 Expedition SSV Modifiers Guide 07 2009 5 14 Reference Information Section 5 Reference Information 0076017 Description Technical Specifications Specification Specification Make Ford Model Expedition Special Service Sales Code Vehicle SSV Continued 2010 Expedition SSV Modifiers Guide 07 2009 Reference Information 5 15 Section 5 Reference Information Specification Torque Battery Compression Ratio 9 8 1 Transmission Model 6R80 Type 6 speed electronic automatic with lockup torque converter and overdrive Axle Ratio 3 73 1 Gross vehicle weight rating GVWR 3 333 kg 7 350 Ib Expedition or 3 492 kg 7 700 Ib Expedition EL 4x2 GVWR 4 Steering Turning circle curb to curb 12 4 m 40 8 ft Expedition or 15 0 m 43 9 ft Expedition EL Tire Size Load and Speed Rating Suspension Type Front Suspension Type Rear Fuel Capacity Liters 105 9 Expedition or Gallons 28 0 Expedition or 126 8 Expedition EL 33 5 Expedition EL General Measurements Wheelbase 3 022 mm 119 0 in Length 5 245 mm 206 5 in Expedition or 3 327 mm 131 0 in Expedition or 5 621 mm 221 3 in Expedition EL Expedition EL General Measurements Width 2 001 mm 78 8 in General Measurements Tr
50. olt hole by at least 50 mm 1 97 in The spotlight shaft hole is to be located 50 mm 1 97 in above the center of the A pillar assist handle bracket lower mounting bolt hole on the marked center line The spotlight mount lower bolt hole is to be located 14 mm 0 55 in below the center of the spotlight shaft hole and 1 mm 0 04 in forward of the marked centerline Push Bumpers Effect On Air Bag Deployment Different push bumper designs may each have different deformation characteristics in a crash situation that may or may not affect the deployment of air bags Without the benefit of crash tests on vehicles equipped with push bumpers there are a number of different styles available it is the opinion of Ford Motor Company that installation of some push bumpers could affect the timing of the air bag deployment Use of a push bumper that mounts solely to the vehicle s bumper should not have a significant effect upon air bag deployment Effect On Weight Distribution The balance and weight distribution of a vehicle is carefully planned to achieve optimal stability and handling Push bumpers can change this weight distribution by adding excessive weight to the front of the vehicle There are many different styles of push bumpers available Depending on the mounting and weight of the push bumper to be installed it could have an adverse effect on the handling of a vehicle Always verify the vehicle ride height after the addition of a push bumpe
51. on is the only consideration this convolute is adequate up to 96 C 205 F maximum Use nylon convolute when underhood underbody or abrasion and temperature are considerations nylon convolute is adequate up to 177 C 350 maximum On all engine mounted wiring or bend points use vinyl tape on the outside of the convolute to prevent wiring from looping out This tape must be able to withstand temperatures 135 C 275 F or higher Tape convolute junctions with abrasion resistant tape Polyken 267 fiberglass 2010 Expedition SSV Modifiers Guide 07 2009 2 10 Section 2 Electrical Scroll Similar to convolute but without the ridges Scroll is used where harness rigidity is required especially for maintaining critical locator dimensions Use scroll for short lengths only as it is quite inflexible Note This is not meant to be an all inclusive list of methods for physically protecting the wires There are other means of protection available that are not listed Grommets and Sealing Requirements Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and locates the wire s Two piece grommets rubber with plastic inserts are recommended to facilitate installation and retention Locate grommets so they are accessible for correct seating achieved by pulling in sheet metal holes Ramp grommets at the insertion end to facilitate installatio
52. ors are located in the front doors These are pressure sensors that measure the pressure change in the front door during an impact Do not mount anything on or in the door Do not cut any holes in the door sheet metal trim or water seals Failure to follow these instructions may result in personal injury AN WARNING The rear side impact sensors are located in the C pillars The installation of hardware must not interfere with the correct operation of the rear side impact sensors Failure to follow these instructions may result in personal injury 2010 Expedition SSV Modifiers Guide 07 2009 5 4 Reference Information Section 5 Reference Information 2 j x N S PLD 0079165 Figure 4 curtain airbag extends from the A pillar to the D pillar and from roof rail to Do not mount equipment to the B and D pillars above the beltline Do not mount equipment to the A pillar above the beltline except for spotlights Refer to Section 3 Installation Considerations Spotlight Installation Location Do not mount equipment on the headliner within 200 mm 8 in of the side edges Do not mount equipment above the beltline within 200 mm 8 in of the side glass from the A pillar leading edge to the rear edge of the D pillar Do not mount equipment on the headliner along the sid
53. partition or other equipment to make sure that there is no deployment interference Failure to follow these instructions may result in personal injury AN WARNING The partition and the installation hardware of the partition must not interfere with the correct operation of the safety belt safety belt retractor side impact sensor and the safety belt height adjusters Failure to follow these instructions may result in personal injury AN WARNING Installation of prisoner partitions may increase the risk of injury to front seat occupants if the vehicle is impacted from a high speed rear end collision This risk should be balanced by the law enforcement agency against the risk of injury to the officer associated with prisoner transportation Failure to follow these instructions may result in personal injury 2010 Expedition SSV Modifiers Guide 07 2009 Installation Considerations 3 7 Section 3 Installation Considerations Safety Belt Retractor and Side Impact Sensor Side impact sensor Front safety belt retractor The front safety belt retractors are located in the base of the B pillars The pretensioner located in the buckle is referred to as the safety belt buckle pretensioner In the event of an air bag deployment pretensioners provide improved occupant protection by rapidly removing slack from the safety belt Removing slack from the safety belt helps to correctly position the occupant and allows for maximum effectivenes
54. pment in the cargo area Fuel tank Fuel lines Brake lines Evaporative emissions EVAP canister Electronic modules Wiring harnesses Safety Belt Retractor and Side Impact Sensor if equipped A WARNING The installation of hardware must not interfere with the correct operation of the safety belt safety belt retractor side impact sensor and the safety belt height adjusters Failure to follow these instructions may result in personal injury Note Expedition EL shown Expedition similar 2010 Expedition SSV Modifiers Guide 07 2009 4 2 Cargo Mounting Considerations Section 4 Cargo Mounting Considerations 0076003 Mem Description Side impact sensor 2 Second row safety belt retractor 3 Third row safety belt retractor The second row safety belt retractors are located in the middle of the C pillars The third row safety belt retractors are located in the middle of the D pillars Do not use the safety belt retractor bolts for mounting the partition Do not mount any hardware on the or D pillars Do not mount any hardware that will interfere with the correct sealing of the door 2010 Expedition SSV Modifiers Guide 07 2009 Cargo Mounting Considerations 4 3 Section 4 Cargo Mounting Considerations AN WARNING The rear side impact sensors are located in the C pillars The installation of hardware must not interfere with the correct operation of the rear side impact sensors
55. r For additional information refer to Section 1 General Information in this guide Adjust the ride height if the measurements are not within specifications Airflow The engine cooling system on a vehicle relies on correct airflow through the radiator to keep the engine at its correct operating temperature When adding a push bumper to a vehicle make sure this airflow is not obstructed especially when lights and sirens are mounted on the push bumper Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components During the installation process keep the placement of components away from the grille area of the vehicle 2010 Expedition SSV Modifiers Guide 07 2009 3 6 Installation Considerations Section 3 Installation Considerations Siren and Grille Lights The engine cooling system relies on correct airflow through the radiator to keep the engine at its correct operating temperature When adding sirens and grille lights to a vehicle make sure this airflow is not obstructed Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components During the installation process keep the placement of components away from the grille area of the vehicle Partition Installation Guidelines AN WARNING Side curtain deployment drawing are shown in Section 5 Reference Information Review the deployment drawings before installing a
56. r Second row map lights Illuminated visor vanity mirrors Convenience Package 50C Power adjustable pedals requires XLT Comfort Power rear quarter windows Group Universal garage door opener Reverse sensing system Heavy Duty Trailer Tow Class IV hitch receiver Package 536 Four and 7 pin connectors Heavy duty auxiliary transmission oil cooler and radiator Electronic brake wiring kit Technical Package 17T Auto dimming rearview mirror requires XLT Comfort Keyless enty keypad Group Heated sideview mirrors Continued 2010 Expedition SSV Modifiers Guide 07 2009 General Information 1 5 Section 1 General Information Miscellaneous Options See sales brochure for complete list of available options Description i Exterior Options Daytime running lamps 43D Engine block heater 41H Heated sideview mirrors 54H Running boards 4x4 only 186 Seat Options First row 40 60 split bench cloth with power adjustable driver s seat M Second row 40 20 40 split bench cloth N A with 875 third row seat 21F Second and third row bench cloth requires 574 rear aux A C and heat 21S Third row 60 40 split bench vinyl requires 574 rear aux A C and heat 875 Identification Codes Vehicle Certification VC Label The upper portion of the vehicle certification VC label contains the manufacturer name the month and year of manufacture the certification statement and the vehicle identification number VI
57. re shown in the table below Not all equipment will be operating at the same time so actual loads on the power supply system will vary Component Communications Radio Mobile Data Transmitter Light Bar Light Bar with Internal Accessory Lights Activated Spot Lights each 7 1 Alley Lights each at a Radar Camcorder 0 8 0 5 2010 Expedition SSV Modifiers Guide 07 2009 2 4 Electrical Section 2 Electrical PCM Red Area NOTICE DO NOT make electrical connections to vehicle electrical systems not specifically designed for police equipment installations Damage to the electrical system can occur Do not install any components into the PCM or PCM harness Connecting into this system may affect engine and transmission operation As an example connection of aftermarket electrical equipment into the brake light circuit or any other circuit which is connected to the PCM anti lock brake computer air bag system or any other vehicle system will cause vehicle malfunction Disabling Brake Lights Do not disable the brake light circuits for any reason For additional information refer to Section 1 General Information in this guide Auxiliary Power Point 12V DC NOTICE Do not plug optional accessories into the cigar lighter socket if equipped Incorrect use of the lighter socket can cause damage not covered by the warranty NOTICE Power outlets are designed for accessory plugs only Do not insert any other
58. s and MP3 capability Color keyed assist handles Auxiliary audio input jack in instrument panel Cargo organizer Expedition EL only Column shifter Dome light Vinyl floor covering Vinyl jack stowage cover Electrochromatic day night auto dimming rearview mirror Overhead console with map lights single sunglasses holder and conversation mirror Power door locks and windows with one touch DOWN driver side window First row low back cloth captain s chairs with 2 way adjustable headrests 6 way power driver with power lumbar passenger manual recline Second row vinyl 40 20 40 seats without armrest or cupholder Color keyed leather wrapped steering wheel with tilt and speed control switches Sunvisors with dual auxiliary blades and illuminated mirrors Safety Security AdvanceTrac with Roll Stability Control RSC Driver and passenger passive restraint air bags Rear door child safety locks Lower anchors and tethers for children system in rear outboard seats Power disc brakes with 4 wheel anti lock system and brake assist Personal Safety System Perimeter alarm Safety Canopy Side intrusion door beams Side thorax air bags Securilock passive anti theft system PATS post crash alert Miscellaneous Options See sales brochure for complete list of available options Description 0 25 XLT Comfort Group 52 Overhead console with map lights sunglasses holder front auxiliary climate controls and conversation mirro
59. s of the safety belts and the air bags Do not use the safety belt retractor bolts for mounting the partition Do not mount any partition hardware on the B pillar Do not mount any partition hardware that will interfere with the correct sealing of the door 2010 Expedition SSV Modifiers Guide 07 2009 3 8 Installation Considerations Section 3 Installation Considerations AN WARNING The front side impact sensors are located in the front doors These are pressure sensors that measure the pressure change in the front door during an impact Do not mount anything on or in the door Do not cut any holes in the door sheet metal trim or water seals Failure to follow this instruction may cause personal injury Console Design and Installation Restraints Control Module RCM AN WARNING Do not relocate the restraints control module RCM or modify its installation in any way Failure to follow these instructions may result in personal injury The restraints control module RCM is mounted on the center tunnel under carpet under first row bench seat if equipped The RCM orientation is critical for correct operation of the restraint systems Do not use the RCM mounting bolts for attachment purposes of any equipment Air Bag Deployment Interference AN WARNING Side curtain deployment drawing are shown in Section 5 Reference Information Review the deployment drawings before installing a partition or other equipment to make sure
60. s with a protective shield and fasten the wiring within 76 mm 3 in on each side of the edge see figure below CONVOLUTE OR CLIP PROTECTION EDGE HARNESS DIRECT CONTACT SATISFACTORY UNSATISFACTORY A0073514 Route wires to provide at least 76 mm 3 in of clearance to moving parts in their extreme movement location unless positively fastened and protected by a conduit Avoid wire routing without conduit in areas where temperatures exceed 82 180 F Minimum clearance of 152 mm 6 in should be maintained from exhaust system components Heat insulation and heat shields must be used on the wires routed in high temperature areas Make certain that all underhood or underbody wiring is cross linked polyethylene high temperature insulation wire with a 135 C 275 F minimum rating consistent with SAE specification J1128 Type SXL wire Normal PVC wire must not be used in underhood or underbody applications Make sure all ground locations are readily accessible for installation service and verification Do not place ground attachments in high splash areas Do not route underbody wiring over the exhaust system Underhood underbody wiring must be routed in conduit for protection Minimum conduit rating is 177 C 350 F 2010 Expedition SSV Modifiers Guide 07 2009 2 12 Section 2 Electrical Wire Retention and Routing Use the following criteria to determine the location of retainers Size
61. switches 2010 Expedition SSV Modifiers Guide 07 2009 SECTION 4 Cargo Mounting Considerations Contents Section 4 Cargo Mounting Considerations Cargo Area Equipment Mounting Guide Safety Belt Retractor and Side Impact Sensor if equipped Auxiliary Climate Control System Cargo Loading Cargo Area Weight 2010 Expedition SSV Modifiers Guide 07 2009 Cargo Mounting Considerations 4 1 Section 4 Cargo Mounting Considerations Cargo Area Equipment Mounting Guide NOTICE When installing equipment it is important to consider the available clearance between the brake lines and the fastener or component Any fasteners or static components should allow a minimum of 15 mm 0 60 in clearance to the brake lines Any dynamic components should allow for a minimum of 19 mm 0 75 in clearance to the brake lines NOTICE Inspect behind trim and under the vehicle when determining mounting locations Be sure the drill fasteners will not puncture touch and will leave adequate clearance from the fuel tank fuel lines brake lines wiring harnesses evaporative emissions EVAP canister and the fuel pump shut off switch as well as other vehicle systems Refer to Section 5 Reference Information in this guide for additional illustrations showing the location of the fuel tank fuel lines brake lines and the fuel pump shut off switch Damage to vehicle components may occur Be aware of the following component locations when mounting equi
62. terior surfaces and underside of front fender Periodically wash vehicles stored in exposed locations Touch up exposed raw or primed metal to provide rust protection Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration Rewax as necessary when the vehicle is washed Lubricate all hood door hinges and latches with a light grade oil Cover the interior soft trim to prevent fading New Vehicle Storage Engine Start the engine every 15 days Run it at fast idle until it reaches normal operating temperature With foot on brake pedal and brake applied shift the transmission into all gears while the engine is running New Vehicle Storage Fuel System Regularly move vehicles short distances to mix fuel anti oxidation agents NOTICE During extended periods of vehicle storage 60 days or more gasoline may deteriorate due to oxidation This can damage rubber and other polymers in the fuel system and may clog small orifices A commercially available gasoline fuel stabilizer Sta Bil or equivalent should be added to gasoline powered vehicles whenever actual or expected storage periods exceed 60 days The manufacturer s instructions packaged with the product should be followed The vehicle should then be operated at an idle speed to circulate the additive throughout the fuel system New Vehicle Storage Tires Most high performance tires are made with nylon overlay As such the fo
63. that there is no deployment interference Failure to follow these instructions may result in personal injury WARNING Do not place objects mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag Dash tunnel or console mounted equipment should be placed within the specified zone Dash tunnel or console mounted equipment should not be placed outside of the specified zone Failure to follow these instructions may result in personal injury AN WARNING Do not mount equipment between the side of the front seat and the door trim that would block deployment of the side air bag Failure to follow these instructions may result in personal injury 2010 Expedition SSV Modifiers Guide 07 2009 Installation Considerations 3 9 Section 3 Installation Considerations Driver passenger air bags affect the way police equipment can be mounted in police vehicles Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path Sharp edges corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag Do not mount or place any objects in the deployment path of an air bag Air bags must be allowed to fully deploy without restriction The deployment of air bags is not compatible with any configuration of police equipment mounting that places objects in the air bag deployme
64. the possibility of draining the battery by lights or other equipment Do not allow control panels attached to the instrument panel to protrude into the driver and passenger air bag deployment zones For additional information refer to Section 5 Reference Information in this guide Do not install switches and gauges in the driver or passenger knee impact areas Inspect all Ford gauges lights and switches for correct operation after instrument panel work is performed Correctly secure all wiring relocated or removed while working behind the instrument panel to prevent chafing squeaks and rattles Provide adequate retention for wiring harnesses so that they are clear of bolts corners or edges which could abrade the wires during normal vehicle operation Anticipate misrouted wiring situations and protect all wiring from penetration by screws and raw edges Weather seal all electrical connectors exposed to the elements Do not use quick splice connectors or wire nuts Install the fuse panel so fuses are readily accessible Make sure that connections are easily accessible for assembly and service Make sure submersible connectors do not lose their seals under extreme assembly conditions such as bending wires 90 degrees immediately after the connector Whenever using connectors use a socket female connector on the electrical source side and a plug male connector on the electrical load side to reduce the possibility of a short circu
65. trical 2 19 Section 2 Electrical 8 Check for acceptable crimp 1 Crimp should be centered on each end of the butt splice 2 Wire insulation does not enter butt splice 3 Wire is visible through inspection hole of splices 0053050 9 Evenly position supplied heat shrink tubing over wire repair 10 Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing 0070450 11 Reconnect the battery ground cable How To Change Option Content Courtesy Lamp Disable Dark Mode Move the panel dimmer control to the full down position past detent to prevent the interior lights from illuminating when the doors are opened 2010 Expedition SSV Modifiers Guide 07 2009 2 20 Section 2 Electrical Rear Power Window Disable The rear power windows of the Expedition SSV can be disabled by disconnecting the rear window motor connectors C701 LH and C801 RH These connectors are located inside the door behind the door trim panel While they are disabled the master window control switch will not control the rear windows Refer to Expedition Wiring Diagrams Manual for additional power window wiring information Wiring Reference Information Ordering Information To obtain information about ordering complete copies of Ford or Lincoln Mercury publications call 1 800 782 4356 Available publications include Workshop Manuals Wiring Diagrams
66. turn the current to its source just as a plumbing system has drain pipes through which water runs into the sewer mains or the ground The light or equipment powered by the current technically called the load can be compared to a water wheel that remains motionless until a stream of water causes it to turn A load may be one of 2 kinds The first consists of a resistance a material that permits the passage of electric current but only with difficulty and thereby creates heat The tungsten filament of an incandescent bulb is resistance so is the heating element of an electric heater of a coffee pot A load may also be an inductance typically a motor with windings of copper wire in which the magnetic fields generated by the current create motion At any moment the demand on an electrical system depends on the number of loads in operation and their consumption of energy just as demand on a water system depends on how many faucets are opened and how wide they are opened The mechanics and physical fittings of the system are simple Current moves throughout the vehicle in wires of different sizes according to the current a circuit may have to carry Power is supplied directly to equipment through connectors Electrical Terms VOLT is the unit of electrical potential equal to the difference of electrical potential between 2 points on a circuit AMPERE is the unit used to measure the amount of current that is the number of electrically
67. vers if so equipped Note The installation should be checked periodically for correct SWR and any signs of damage or deterioration to maintain correct operation with your vehicle Antenna Tuning It is important that the antenna be tuned correctly and reflected power be kept to less than 10 VSWR less than 2 1 Antenna Cable Routing Always use a high quality 1 piece coaxial cable at least 9596 shield coverage Connector quality and termination techniques are just as important The ARRL handbook provides excellent guidelines for terminating coaxial cables The antenna cable should be treated in the same way as the control and power cables Avoid sharp edges and pinches and keep the cable as short as possible Also avoid routing the antenna cable in parallel with vehicle wiring over long distances If it is necessary to cross over wiring cross at right angles In some cases additional shielding between the antenna cable and the vehicle wiring may be helpful Additional Information Troubleshooting Should vehicle radio interaction develop following installation the source of the problem should be identified prior to further operation of the vehicle Most interaction problems can be eliminated by following these installation guidelines Possible causes of vehicle radio interaction include e Antenna location move antenna to another position e Antenna feed line routing locate as far as possible from vehicle electronics and w

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