Originator: Stephen I. Dains/sdains
Page 11 of 29
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/27/2004
E.
DESIGN andMANUFACTURINGGUIDELINES - GENERALCHASSIS
E0100 HEATMANAGEMENT –Alsosee IndustryUniqueSection
Chassis duty cycles challengemanufacturers toaddress heatmanagement practices. Although
FordMotor Company recognizes that theFinal StageManufacturer has thebest knowledgeof its
customer needs andusageof these specialty vehicles, the followingguidelines areprovided to
assist in that effort. Theguidelines hereinweredevelopedbyFordbasedon testing, field
experience, andgeneral heatmanagement principles andaddress today's demands for heat
protection.
E0101
HeatManagement PerformanceStandards:
•
The topof occupant floor covering is not toexceed140°Funder normal mode testing.
•
Nopermanentmaterial/component degradationor combustion shall occur under either
normal mode testingor any individual failuremode testing (i.e., failedexhaust, engine
malfunction).
•
Heat generatedby the chassis is not toadversely affect thegeneral interior climate
control comfort of thepassengers.
E0102
Floor covering: Typical automotive carpets, vinyl, or rubber floor coverings areacceptable.
Carpetingmust not restrict full throttle, parkingbrake, or servicebrakepedal travel (for the full
master cylinder stroke). Floor coveringsmust not extendunder theFordengine cover seal or
interferewithE-Series engine covermountinghardwareor engine cover removal.
E0103
Donot apply body undercoatingwithin12 inches of theareadirectly above theexhaust, onany
componentswithin12 inches of theexhaust, onany part of theexhaust or relatedheat shields.
Refer toAppendixVI
,
for added information relative to theundercoating zone.
Donot undercoat the fuel tank, fuel filler and vent lines, drive shaft, or shock absorbers.
E0104
THEFINALSTAGEMANUFACTURERMUSTADEQUATELYSEALTHEBODYFROM
UNDERBODYHEAT INFILTRATION.
•
All holes in thebody or floor shouldbe sealed toprevent underbody heat fromentering the
passenger compartment.
•
Theattachment of the secondunit body to the cab cannot allowheat to infiltrate into the
passenger compartment throughbody gaps.
E0105
AIRFLOWRESTRICTIONTHROUGHTHERADIATORTOBEMINIMIZED.
•
Accessories shouldnot be located inany engine coolingair inlet area forwardof the radiator
or air cleaner inlet. Keepall items to the side ormountedout in front of theair inlets, as
described indetail in the
BodyBuildersLayout Book
.
•
Componentsmountedunderhood shouldbeout of the fan blast pattern toprevent radiator air
flow restriction.
•
If components areaddedormodifiedwhichmay impact coolingair flow, ananalysis is
needed toassure coolingperformance is not degraded.
E0106
THEFINALSTAGEMANUFACTURERSHOULDMAKE ITSCUSTOMERANDSERVICE
NETWORKAWAREOFTHEADVERSEAFFECTTHEFOLLOWINGMAYHAVEON
VEHICLEHEATMANAGEMENT
:
•
Poor vehicle serviceand lack ofmaintenance.
•
Deviation froma50/50antifreeze (coolant) -to-water ratio.
•
Exceeding themanufacturer'smaximumGVWorGCW ratings.
•
Failedparts suchas a leakingor bent exhaust pipeor a cloggedair cleaner.
•
Alteringor removing theOEMengine fanor shroud.
•
Anexcessively blocked radiator area (bywarning lights, sirens, pushbars, winches, etc.)
