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Body Builder Manual

V1.0, February 2015

Body Builder Manual

Part II - Specific Book LCV

Summary of Contents for Body Builder 2015

Page 1: ...Body Builder Manual V1 0 February 2015 Body Builder Manual Part II Specific Book LCV ...

Page 2: ...TUDIES AND CONSIDERATIONSMAINTENANCE AND DAMAGE PREVENTIONWORK ON BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMSAPPENDIX 2 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 ...

Page 3: ...N WORK ON BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 3 Ammendment Index Body Builder Manual Part II Specific Book LCV Light commercial vehicles Chapter Subject Page No ...

Page 4: ... clearances 39 2 3 8 Wheel clearance 40 2 3 9 Noise insulation 42 2 3 10 Turning diameter 43 2 3 11 Body and chassis clearances 44 3 MAINTENANCE AND DAMAGE PREVENTION 45 4 WORK ON BASIC VEHICLE 46 4 1 Prevention and recommendations 47 4 1 1 General considerations 47 4 1 2 Drilling work 48 4 1 3 Bolted connection work 49 4 1 4 Welding work 50 4 1 5 Corrosion protection 55 4 2 Chassis frame modifica...

Page 5: ...conditioning systems 135 4 12 8 Equipment installed on roof 136 4 12 9 Interior installations for load fixations 137 4 12 10 Retarder 137 4 12 11Other additional equipment 138 4 13 Steering system modifications 139 4 14 Axle and wheel modifications 139 4 15 Electrical and electronic system modifications 141 5 MOUNTING AND CONSTRUCTION OF BODIES 143 5 1 Machinery Directive and CE marking 144 5 1 1 ...

Page 6: ... Wiring process 218 7 2 5 Wiring diagrams 220 7 3 Additional electricity consumers 221 7 3 1 General considerations 221 7 3 2 Possibilities of connection 222 7 3 3 Connection types 229 7 3 4 Earth wire 231 7 3 5 Fuse protection 233 7 4 Handling batteries 234 7 4 1 General considerations 234 7 4 2 Extra batteries 237 7 4 3 Maintenance of batteries 238 7 5 Lighting guidelines 240 7 5 1 General consi...

Page 7: ...ASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 7 1 INTRODUCTION This chapter provides the following information Scope of this manual Content structure Convention of symbols Copyright ...

Page 8: ...odifications and alterations have been made This manual is specifically targeted for professionals assuming they have the basic knowledge needed to understand and manage this manual Likewise HMC recom mends having the construction work carried out by qualified personnel in order to avoid potential hazards or accidents and get the best result in the realisation of the projects undertaken As for pos...

Page 9: ...ical or specific For the correct application of the rules and recommendations of this manual the three books into which it is divided should be considered The content structure is organised as follows Table 1 1 Content of the Body Builder Manual GENERAL BOOK LATEST UPDATES TABLE OF CONTENTS 1 INTRODUCTION 2 GENERAL INFORMATION 3 PRELIMINAR STUDIES AND CONSIDERATIONS 4 MAINTENANCE AND DAMAGE PREVEN...

Page 10: ... 1 Copyright The rights in the designs pictures logos photographs and other contents of this manual including but not limited to hardcopy online CD DVD editions are owned by or licensed to Hyundai Motor Company HMC They are protected by copyright trademarks and other intellectual property rights as acknowledged by the applicable law You may not copy reproduce modify distribute republish display po...

Page 11: ... CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 11 2 PRELIMINARY STUDIES AND CONSIDERATIONS This chapter provides the following information Recommendation for planning work Range of vehicles supplied by HYUNDAI Technical limit values ...

Page 12: ... PTO gearbox etc Possible additional equipment that can be supplied from the factory with the original vehicle and its various settings and features Provide sufficient space to ensure the functioning and operational safety of the additional equipment Appropriate selection of materials to be used Main dimensions of the vehicle after modification Maximum gross weight and height according to laws of ...

Page 13: ... See General Book chapter 4 Maintenance and damage prevention NOTICE Before beginning construction work it is recommended that the vehicle provided should be verified to check whether it satisfies requirements NOTICE The vehicle identification data and the main features of the vehicle can be found on the vehicle identification plates and features See Vehicle identification and feature plates chapt...

Page 14: ...ided into three main groups Table 1 2 Main groups of vehicle designation In order to clarify this system its operation is explained by means of an example Designation system explanation Table 1 3 Example of vehicle designation NOTICE The complete technical documentation for the vehicle can be provided on request Contact the relevant department in each case See General Book chapter 2 4 Contact Poss...

Page 15: ...s Table 1 5 B Acronyms type of vehicle Table 1 6 C Acronyms rear axle configuration Table 1 7 D Acronyms max gross vehicle weight Technical Data specification Table 1 8 B Acronyms wheelbase length TABLE A HYUNDAI TRUCK SERIES Acronym Description H350 Describes vehicles series TABLE B TYPE OF VEHICLE Acronym Description 1 Panel van 2 Passenger van 3 Chassis cab TABLE C REAR AXLE CONFIGURATION Acron...

Page 16: ...C SYSTEMS APPENDIX Table 1 9 C Acronyms roof model Table 1 10 A Acronyms engine model Table 1 11 B Acronyms engine power output Table 1 12 A Acronyms special features TABLE F ROOF MODEL Acronym Description H1 Standard roof H2 High roof TABLE G ENGINE MODEL Acronym Description A A engine TABLE H ENGINE POWER OUTPUT Acronym Description 13 130 HP 15 150 HP 17 170 HP TABLE I SPECIAL FEATURES Acronym D...

Page 17: ...ic Book LCV 17 Range of vehicles The following table shows the range and features of the vehicles to which this man ual refers Table 1 13 SPBTC22_012 Range of vehicles supplied by HMC PANEL VAN Standard roof H1 High roof H2 5M 3 5 t H350 1S 35 L1H1 A13 15 17 H350 1S 35 L1H2 A13 15 17 6M 3 5 t 4 0 t 4 1 t H350 1S 35 L2H1 A13 15 17 H350 1S 35 L2H2 A13 15 17 H350 1S 41 L2H2 A17 7M 3 5 t 4 6 t 5 0 t H...

Page 18: ...F ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX Table 1 14 SPBTC22_012 Range of vehicles supplied by HMC Rear wheel twin is possible for 4 6 ton 1 Front door 2 FR Mid door PASSENGER VAN CHASSIS CAB Standard roof H2 Standard roof H1 5M 3 5 t H350 3S 35 L1H1 A13 15 17 6M 3 5 t 4 0 t 4 1 t H350 2S 40 L2H2 A17 H350 3S 35 L2H1 A13 15 17 7M 3 5 t 4 6 t 5 0 t H350 2D 46 L3H2 A17 H350 3S 35 L3H1 A13 15 17 H350...

Page 19: ...n of the vehicle pro tecting it from theft manipulation and falsification In Hyundai vehicles this number is punched on the engine compartment bulkhead near the lower edge of the windshield This plate must be incorporated by law in all motor vehicles The standard in Europe is regulated by the Standard ISO 3779 Road vehicles Ve hicle Identification Number VIN Fig 2 15 VIN location The VIN is also o...

Page 20: ... number VIN Fig 2 17 Technical characteristics plate Special equipment In addition to the standard equipment vehicles supplied by HMC may include option al equipment always on prior request with the intention of adapting the vehicle as well as possible to the final task The fact that the installation of this special equipment will increase the weight of the vehicle should be taken into account For...

Page 21: ...re REGULATION EU No 1230 2012 of 12 December 2012 implementing Regulation EC No 661 2009 of the European Parliament and of the Council with regard to type approval requirements for masses and dimensions of motor vehicles and their trailers and amending Directive 2007 46 EC of the European Parliament and of the Council REGULATION EC No 661 2009 of 13 July 2009 concerning type approval requirements ...

Page 22: ...ed dimensions in national and international traffic and the maximum authorised weights in international traffic for certain road vehicles circulating within the Community DIRECTIVE 70 157 EEC of 6 February 1970 on the approximation of the laws of the Member States relating to the permissible sound level and the exhaust sys tem of motor vehicles Regulations and legislation in force in each country ...

Page 23: ...cation N1 Vehicles used for the carriage of goods and having a maximum mass not exceeding 3 5 tons N2 Vehicles used for the carriage of goods and having a maximum mass exceeding 3 5 tons but not exceeding 12 tons M1 Vehicles used for the carriage of passengers and comprising not more than eight seats in addition to the driver s seat M2 Vehicles used for the carriage of passengers comprising more t...

Page 24: ...adlamps Type of exterior mirrors installed as standard which should comply with the standard regarding devices for indirect vision ECE Regulation R 46 Table 1 20 LCV_SPBTC23_006 Vehicle width depending on exterior mirrors Because of these restrictions the maximum vehicle width reached is normally 2 190 mm To get more information about optional equipment supplied by HMC such as mirrors with long st...

Page 25: ... of axle weights See chapter 2 3 3 Weight distribution Maximum values of the wheelbase See chapter 2 3 5 Wheelbase Maximum values of the overhang See chapter 2 3 6 Vehicle overhang NOTICE Once the body has been installed the final vehicle shall comply with the dimen sion and visibility values established by law According to this the Body Builder has the final responsibility for ensuring that the v...

Page 26: ...chnical ca pabilities of each vehicle into account The ultimate goal is to achieve the best possible location of the body on the chassis For this purpose the following guidelines should apply Unilateral axle load When the body is planned and designed unilateral load situations should be avoided The maximum load difference between the wheels on the same axle must never ex ceed 4 in order to avoid t...

Page 27: ...y of the vehicle after construction work on the body In all load situations the permissible axle loads should be consid ered The values depend on the type of vehicle PF Minimum front axle load PT Actual axle load WARNING The maximum permissible axle loads should be complied with at all times Failure to meet these requirements can cause the malfunction of the vehicle s systems and lack of stability...

Page 28: ...mum permissible load for the vehicle group and not the maximum authorised loads of each element independently NOTICE In the planning of the superstructure systems for loading and unloading of the goods transported should be taken into account to avoid undue fluctuations of load distribution or producing excessive axle loads They furnish if necessary the respective instructions to the vehicle s use...

Page 29: ...then authorisation must be granted by the competent authorities Proper reinforcement of the vehicle would be also be necessary Weighing the vehicle For correct sizing of the body and its location in the chassis the axle loads must be known before work is started on the vehicle To obtain these loads it is necessary to weigh the vehicle Vehicle weight indicated in the documentation or data sheet is ...

Page 30: ... s centre of gravity should be carefully calculated trying to lo cate it in the most ideal position At all events this calculation will be the responsibility of the Body builder HMC can not issue any opinion NOTICE To get official approval for the vehicle once the conversion work has been finished the calculation of the height of the Centre of Gravity should be credi ted The EC Brakes Directive 71...

Page 31: ...heelbase In this way we ensure not only the stability of the vehicle in unloading conditions or during the tilting process but also the requisite minimum load on the front axle that ensures proper steerability See Chapter 2 3 3 Weight distribution Minimum load on the front axle Fig 2 24 Centre of gravity on the X axis D Distance from CoG to the rear axle WB Wheelbase CAUTION Particular attention s...

Page 32: ...cle load Fig 2 25 CoG in Y axis of the vehicle WARNING The asymmetric distribution of the load on the vehicle due to the carriage of liquid or a hanging load for example particularly when the centre of gravity is in a high position can have an impact on the lateral stability of the vehicle which could cause it to roll over causing injury to the driver or other people In these situations it is advi...

Page 33: ...HL of the Centre of Gravity should not exceed the rec ommended values in this manual for vehicles that incorporate VDC Vehicle Dynamic Control system technology With higher values a malfunction of the system may occur If this is the case it is recommended that the VDC should be disabled HC Height of CoG of the vehicle chassis HL Height of CoG of the vehicle loaded NOTICE To obtain the height of th...

Page 34: ...eries of vehicles offered the wheelbase required to develop the in tended function is not supplied the wheelbase may be modified by means of an intervention on the chassis of the vehicle VEHICLE MODEL MAX COG HEIGHT WITH VDC 3 5 t 1 470 mm 5 0 t NOTICE For information on the calculation of the position of the centre of gravity see Appendix A2 Calculation Centre of Gravity NOTICE Wherever possible ...

Page 35: ... g propeller shafts compressed air piping etc should be disassembled and the bolted joints renewed so that they are identical to the originals and provide the same torque The guidelines for installation and modification of electrical and electronic sys tems must be taken into consideration if they have been modified See chapter 4 15 Electrical and electronic system modifications Reinforcements sho...

Page 36: ...er 2 3 10 Turning diameter VDC Vehicle Dynamic Control System The VDC might not work properly after the changes In this case a new adjust ment of the parameters will be required See chapter 7 7 3 Electronic control units Propeller shaft It will be necessary to adjust the length of the vehicle transmission The modifi cation must be made by qualified personnel See chapter 4 6 Propeller shaft modific...

Page 37: ...aximum permissible weight on axles Once the modification of the vehicle has been completed the weight on axles must be within the permissible limits Special attention must be paid to the minimum load on the front axle See chapter 2 3 3 Weight distribution Centre of Gravity CoG Modifying the wheelbase can cause displacement of the centre of gravity A check must be carried out to ensure that the new...

Page 38: ...ribution on the axles or the position of the centre of gravity allowed as this avoids the need for the reconfiguration or deac tivation of the VDC system HMC recommends the maximum values for the rear overhang and these must be adhered to The rear overhang U and the wheelbase WB are directly related Table 1 29 SPBTC23_009 Recommended maximum values for the rear overhang Fig 2 30 Wheelbase WB and r...

Page 39: ...S Simple D Double NOTICE The rules in force in each country should be kept in mind These can vary depending on the country in which the vehicle is approved If a non recommended tyre has been fitted to the vehicle the VDC system could suffer a malfunction because the sensors for wheel speed are specifi cally configured to the proper wheel size The suitable size and type of a tyre can be found in th...

Page 40: ...nted This must allow for certain clearances that provide freedom of movement of the wheels Table 1 32 LCV_SPBTC23_007 Minimum distances of the wheel well for panel van NOTICE The space needed for mounting snow chains must be taken into account even where the suspension elements are compressed to the maximum MINIMUM DISTANCES OF THE WHEEL WELL FOR PANEL VAN PERMISSIBLE GROSS WEIGHT TYRES DIMENSION ...

Page 41: ...08 Minimum distances of the wheel well for chassis MINIMUM DISTANCES OF THE WHEEL WELL FOR CHASSIS PERMISSIBLE GROSS WEIGHT TYRES DIMENSIONS mm X1 X2 Y1 Y2 A 3 5 t 235 65 R16 410 410 152 499 247 5 0 t 2 x 195 75 R16 405 405 100 614 238 NOTICE For more info on wheel clearance See chapter 4 3 7 Wheel wells For more info on the distances between the wheels and mudguards See chapter 4 12 4 Mud guards ...

Page 42: ...ne 2007 amending for the purposes of its adap tation to technical progress Council Directive 70 157 EEC concerning the per missible sound level and the exhaust system of motor vehicles DIRECTIVE 70 157 EEC of 6 February 1970 on the approximation of the laws of the Member States relating to the permissible sound level and the exhaust sys tem of motor vehicles REGULATION No R51 Uniform provisions co...

Page 43: ...re be ensured that the turning diameter is within the limits established by standards DIRECTIVE 97 27 EC of 22 July 1997 relating to the masses and dimensions of certain categories of motor vehicles and their trailers and amending Directive 70 156 EEC DIRECTIVE 96 53 EC of 25 July 1996 laying down for certain road vehicles cir culating within the Community the maximum authorised dimensions in nati...

Page 44: ... must be provided to allow for the effective cooling of com ponents or systems that require this for instance brake system radiator etc Sufficient space must be provided to allow the movable elements of the vehicle such as gates platforms cranks wheels etc to move properly Another important distance to be maintained is the distance between cab and body which is there to avoid contact of the two el...

Page 45: ...and its durability To this end a number of important points must be studied Maintenance of batteries and electrical components Welding work prevention Drilling work prevention Bolted connection prevention Corrosion prevention Painted work prevention Fire prevention Storage recommendations Handing over the vehicle NOTICE The accident prevention regulations and laws and regulations of each country s...

Page 46: ...is chapter provides the following information Prevention and recommendations Chassis frame modifications Bodyshell modifications Suspension modifications Interior modifications Propeller shaft modifications Coupling device adaptations Brake system modifications Engine system modifications Exhaust and intake system modifications Fuel system modifications Additional equipment Steering system modific...

Page 47: ...n order to preserve the safety and good performance of the final vehicle it is also recommended that no action should be taken on important vehicle components such as the braking system steering system security systems etc If for some reason work needs to be carried out on any of these components once the work has been completed they must each be returned to their original positions and the same c...

Page 48: ...eams is not allowed neither it the enlargement of holes that are made in the factory as these areas are considered as high stress concentration and the structure might weaken Do not make holes in areas where there are stiffeners or cross members Do not drill in areas subjected to point loads such as spring brackets or where important elements of the vehicle chassis are installed The exception to t...

Page 49: ...hey must have the same properties or superior as the originals screws The type of screws to be used and their main features are shown below Table 1 35 SPBTC Screw types and main features NOTICE The accident prevention standards laws and regulations of each country should be always respected To obtain more detailed information about maintenance and damage prevention See General Book chapter 4 3 Dri...

Page 50: ...ble welding procedure in accordance with specific work and the material used CAUTION Perform welding work on the chassis frame in order to attach the body to it is strictly forbidden This will hinder the movements of flexion and torsion while driving the vehicle which could cause damage to the chassis structure NOTICE Welding work must be performed by qualified personnel at all times being careful...

Page 51: ...ne power train axles etc The A and B pillars of the vehicle The radii of curvature To get a proper weld defects such as undercuts fissure blow holes pits in the weld seam etc should be avoided If the welding bead is not good it will result in stress concentration that will have an effect on fatigue strength Examples of incorrect types of welded connections Fig 4 36 LCV_SPBGC41_007 Faulty weld seam...

Page 52: ...urr sharp edges Preserve cavities with wax preservative HMC offers a few recommendations on resistance spot welding one of the most common welding procedures Resistance Spot Welding is a welding process in which work pieces are welded to gether by holding them together under pressure and apply localised heat generated by a high electric current flowing through the contact area of the weld Fig 4 37...

Page 53: ...imum current is 40 A per mm of electrode diameter Gas shielded welding is permissible Only use welding wires with a thickness of between 1 and 1 2 mm There should be a relation between the thicknesses of the pieces to be welded Fig 4 38 LCV_SPBGC41_003 To avoid melting core damage the specified distances to the sheet edge must be maintained Fig 4 39 LCV_SPBGC41_005 Resistance weld spots allowable ...

Page 54: ... Manual Part II Specific Book LCV V1 0 February 2015 To avoid shunt effects a specified distance between the spot welds must be maintained This depends on the plate thickness Fig 4 40 SPBTC48_002 Distance between spot welds DISTANCE BETWEEN SPOT WELDS Plate thickness x mm 0 60 10 0 70 10 0 775 13 0 875 13 0 975 19 1 10 19 1 20 22 1 40 22 1 575 25 1 80 28 2 00 32 2 20 35 2 50 38 2 80 41 3 00 43 3 1...

Page 55: ...er will protect all parts of the vehicle that have been added or modified against corrosion Protective materials that possess at least the same quality and properties as these used in the original vehicle must be used Corrosion occurs due to the potential difference between two metals with different properties which are in contact in the presence of an electrolyte For this reason the use of insula...

Page 56: ...sing tapes Table 1 41 LCV_SPBTC41_003 Tape method against corrosion TAPE METHOD AGAINST CORROSION Nomenclature P Pieces to connect T Tape B Bolt Nut FEATURES Composition Butyl rubber Colour Black Test items Requirements Penetration Initial 50 10 After heat aging 45 10 Fixing on oily surface mm max 5 Shear strength kg cm2 min 0 5 Thermal flow mm max 2 Contmination of pre treatment no defects Electr...

Page 57: ...same endurance ability as the original The structure must be suitably reinforced in all areas where concentrations of stress occur either due to a peak load or to the addition of a trailer coupling the fixing of equipment to the chassis frame etc After modification work the different groups devices and equipment installed on the vehicle must be accessible for proper maintenance repair or substitu ...

Page 58: ...r rear overhang the materials used in such cases must match the materials and dimensions of the original chassis The different types of material used by HMC to build chassis frames for vehicles given in this manual and their main properties are Table 1 42 LCV_SPBTC42_001 Material type used in chassis frame construction 4 2 3 Main sections The sections of the chassis beams consist of a closed profi...

Page 59: ... GROSS VEHICLE WEIGHT t DIMENSIONS mm TYPE SECTION REF 1 2 3 4 CHASSIS CAB 3 5 CHASSIS CAB a 122 122 122 122 b 119 85 102 119 c 70 72 72 70 d 2 0 2 0 2 0 2 0 e 59 59 59 59 f 72 72 72 72 g 2 0 2 0 2 0 2 0 5 0 CHASSIS CAB a 122 122 122 122 b 120 101 101 120 c 70 72 72 70 PANEL VAN d 3 0 3 0 3 0 3 0 e 78 78 78 78 f 71 71 71 71 g 3 0 3 0 3 0 3 0 3 5 PANEL VAN a 114 114 114 114 b 118 84 101 118 c 70 73...

Page 60: ...3 11 Body and chassis clearances In order to resist bending moments better it is recommended that the support equipment should be installed as close to the chassis cross members as possi ble Additional cross members must not be mounted on the chassis frame because this could affect to the bending capacity of the vehicle However it is possible to reinforce the longitudinal beam web with stiffeners ...

Page 61: ...e materials and di mensions of the original chassis Weight distribution Modifying the frame overhang will result in a displacement of the vehicle s centre of gravity As result a redistribution of the axle loads will occur Therefore before starting modification work the weight distribution on the axles will have to be re calculated to ensure that it is within the allowed limits The minimum load on ...

Page 62: ...attaching it on the chassis frame in the same way as it was installed in the original position At most the end crossbar can be moved forward until it is at a distance of at least 350 mm Umin to the crossbar supporting the rear anchor point of the suspensions Otherwise there would not be enough space for the installation of the coupling de vice This will also prevent the new setting from affecting ...

Page 63: ...t of the vehicle As a general rule allowing the final end of the body or of any other equipment to extend more than 450 mm UB beyond the rear end of the chassis frame is not rec ommended Table 1 45 LCV_SPBGC42_004 Body overhang UB 450 mm The maximum length of the overhang Umax is limited by the exit angle of the ve hicle rear with respect to the limits of the turning diameter according to regulati...

Page 64: ...commended overhang Another variable to consider is the elongation that can be performed on the rear overhang of the vehicle depending on the trailer connection point For this reason the fact that the maximum permitted trailer load will vary depending on the length that exists between the centre of the rear wheel and the point of the trailer hitch must be taken into account Thus when extending the ...

Page 65: ...ng an additional crossbar should be considered to ensure suf ficient torsional stability Additional crossbars should have the same characteristics as originals and must perform the same function Table 1 47 LCV_SPBGC42_006 Additional crossbar Use of end crossbar The end crossbar must always be installed even if there is no intention to tow a trailer If a tow bar is mounted then the necessary reinfo...

Page 66: ...he overhang is more than 100 mm in length reinforcements should be added on beams of the chassis frame The materials used in the reinforcements must match the materials of the original chassis They should be placed symmetrically on either side of the frame The shape of the reinforcements can be as follows Table 1 48 LCV_SPBGC42_012 Reinforcements of the chassis beams The dimensions of the reinforc...

Page 67: ...ey can be seen properly See Chapter 7 ELECTRIC AND ELECTRONIC SYSTEMS Centre of Gravity The maximum values of the centre of gravity must be respected Its position should always be ahead of the rear axle of the vehicle See chapter 2 3 4 Centre of Gravity CoG 4 2 6 Wheelbase modification HMC offers vehicles with different wheelbases trying to adapt them to the maxi mum possible uses See chapter 2 2 ...

Page 68: ...where the vehicle is delivered When making modifications a certain number of restrictions must be respected If any of the elements of the bodyshell have been modified the BB must ensure that the new structure has at least the same load capacity as the structure of the original vehicle The original structure should be strengthened in areas where the changes per formed make this necessary As a gener...

Page 69: ...changes made in the cab must have the authorisation of HMC and a certificate of conformity The guidelines in this manual must likewise be followed Special attention should be paid not to alter any vehicle safety systems such as airbags security bells sensors etc The standards relating to interior fittings for vehicles should be taken into account In this way edges or sharp corners must be avoided ...

Page 70: ...alling air conditioning equipment wind deflector etc See chapter 2 3 3 Weight distribution See chapter 2 3 4 Centre of Gravity CoG The main vehicle dimensions must be respected Care should be taken when installing side wind deflectors or any other equipment that might change the dimensions of the cab See chapter 2 3 2 Vehicle main dimensions If it is necessary to drill or cut the sheet metal or th...

Page 71: ...s The original structure that has been removed should be replaced by a new structure such as a perimeter frame This should ensure strength and rigidity equal to that of the original cab The performance of the safety belts should not be affected by the deformation of the structure 1 Cutting area all dimension in mm NOTICE Keep in mind the requirements and recommendations when performing drilling an...

Page 72: ...hould be replaced by a new structure such as a perimeter frame This should ensure strength and rigidity equal to that of the original roof The performance of the safety belts should not be affected due to excessive deformation of the structure Manipulation of the detection sensors for rain and light must be avoided The vehicle s soundproofing must be checked after the modification work has been ca...

Page 73: ...onsent of HMC See chapter 2 2 Range of vehicles supplied by HYUNDAI When changing the roof height some considerations should be taken into account When increasing the height of the roof the BB should consider installing a sta biliser bar on the front axle to minimise dishing that could occur in the vehicle if it is subjected to centrifugal forces typically in curves When changing the height of the...

Page 74: ...e height of the roof The maximum permissible roof load will be reduced depending on the increment of the roof height The new roof must be securely mounted and sealed on all sides Installation of equipment on the roof Installing a roof hatch A roof hatch might be installed it this will not affect the tightness and strength of the vehicle The cut made through a perimeter frame should be strengthened...

Page 75: ...horisation from HMC is needed before performing the work VEHICLE MODEL ROOF TYPE MAX ROOF LOAD kg PANEL VAN H1 300 H2 150 CHASSIS SIMPLE CAB H1 0 NOTICE If holes are made in the roof the maximum loads provided in this manual are no longer valid Consideration should be given to the maximum permissible axle load and also to the minimum load on the front axle which ensures steerability in any driving...

Page 76: ...must be ensured Authorisation from HMC is needed before performing the work Table 1 52 LCV_SPBGC43_002 Position for subsequent installed windows If the Body Builder wants to modify the existing window panes exchanging them for others with different characteristics care should be taken to ensure that they comply with the standard in force If the Body Builder wants to change the windows panes in the...

Page 77: ...ollowing should be considered The top of the wheels must be covered completely by the wheel wells If the Body Builder wants to lower the wheel wells it must take into account the movements and vibrations of the suspension The wheel wells must be wider than the maximum space occupied by the tyre Care must be taken to ensure that the permissible vehicle main dimensions are not exceeded See chapter 2...

Page 78: ...s vehicle weight Tyres Dimension a mm 3 5 t 235 65R16 238 4 1 t 235 65R16 245 4 6 t 5 0 t 2 x 195 75R16 215 1 Contour of standard panel van wheel well a Minimum distance frame flange to wheel well WARNING Doors that incorporate safety elements such as airbag sensors cannot be modi fied since this could affect the proper performance of these systems during a crash preventing the protection of the o...

Page 79: ...ucture The bearing structure of the panel and passenger vans i e the skeleton of the ve hicle consists mainly in a number of roof beams and lateral pillars connected to the chassis frame They are properly distributed throughout the vehicle to optimise its performance It is important to prevent modification of these elements as this could lead to a loss of stiffness and strength in the vehicle stru...

Page 80: ...eams must be as is shown Table 1 55 LCV_SPBTC43_001 Number and position of roof beams Moreover this bearing structure the floor sheet panel the lateral walls and the roof form a single structural unit For this reason all cuts performed in the body shell such as windows roof hatches etc must be surrounded by a perimeter frame to ensure that this cut forms a continuous structure with the original st...

Page 81: ...fore drilling or welding the floor of the vehicle to install a hardwood floor metal rails or other installations the Body Builder should verify that the various elements installed underneath it such as electrical wiring brake lines or fuel tanks will not be affected A perfect seal against water or dust leaks must be ensured after the work has been completed The floor sheet forms a unit with the su...

Page 82: ... bear the full weight of the vehicle they must be strong enough to ensure that the loads acting on them do not cause permanent deformation In turn they must also be very elastic to allow the wheels to follow the terrain continuously without being separated from it NOTICE Suspension contributes to vehicle safety while driving so no modification of the suspension system is approved To obtain more de...

Page 83: ... side of one and the same axle is not allowed The transformation of mechanical suspension intoa pneumatic suspension is an im portant point because it could affect the vehicle s active safety For example it could impair the performance of the airbag system HMC should therefore be con tactd to ensure that the change is properly managed NOTICE The new suspension must meet all legal requirements and ...

Page 84: ...e noise has a negative effect on both comfort and safety while driving The original vehicles supplied by HMC comply with the European homologation for acoustic insulation 2 3 9 Noise insulation To approve the vehicle and get the Registration Certificate after the modification of elements that are important from the point of view of noise generation e g engine exhaust system tyres etc the noise lev...

Page 85: ...It is advisable to contact a specialised manufac turer in order to choose the most appropriate materials to meet all require ments as well as possible All new equipment and groups installed in the vehicle such as additional batter ies mud guards wind deflectors etc must be properly fixed so as not to cause vibration The original ventilation ducts should not be covered when insulating the inside of...

Page 86: ...insulating materials The roof and the lateral walls can be also protected properly by spraying insu lating foam into the empty holes in the body shell If new windows have been created they must be sealed to prevent the ingress of humidity and noise Apart from reducing the noise that gets into the cab the insulation installed under the hood in factory helps to prevent fire Therefore no manipulation...

Page 87: ...f the airbags It is not possible to cut the cab roof or the supporting elements of the cab in vehicles that incorporate side impact or window airbags Doors or other elements of the body where the airbag sensors are installed must not be modified The control unit of the airbags should not be operated in any way its position changed or fixed by any other means than those used in the standard vehicle...

Page 88: ... II Specific Book LCV V1 0 February 2015 Fig 4 59 LCV_SPBGC45_003 Airbag system components The vehicles supplied by HMC usually incorporate two airbag systems the driver and passenger airbag systems Fig 4 60 SPBTC45_001 Airbag weights 1 Airbag control unit 2 Driver airbag 3 Front passenger airbag Front of the vehicle AIRBAG WEIGHTS Driver airbag 1 1 kg Windowbag Do not apply Front passenger airbag...

Page 89: ...d hinder the proper operation of safety belts Structural elements that have been cut in the vicinity of the anchor points of the seat belts must be suitably reinforced See chapter 4 3 Body shell modifications The rules on safety belts ECE Regulations R14 R16 and R17 must be respected as must Directive 2005 40 EC and Directive 2005 41 EC The regulations and laws of each country should also be consi...

Page 90: ...ats must not be installed in the vehicle without safety belts The standards for safety belts must be considered See chapter 4 5 3 Safety systems The displacement of the seats fitted as standard or the assembly of additional seats is only allowed if seats anchoring systems safety belts etc supplied or approved by HMC are used New seats cannot be installed in vehicles which are supplied from the fac...

Page 91: ...ed as should each of the recommendations in this manual Before mounting the seats the airbags and belt tensioners must be disabled and they must be re activated again afterwards The disassembly and reassembly of the seats must be done with the battery disconnected NOTICE The anchor points for the seats are considered a relevant item for approval of the vehicle It is therefore not possible to chang...

Page 92: ... very important to install the propeller shafts properly in order to prevent the transmission of noise and vibrations When making modifications to the wheelbase use only official parts provided or au thorised by HMC The best option is to choose a standard wheelbase from the range supplied by HMC in order to use an original propeller shaft In any case it should be necessary a certificate of conform...

Page 93: ...ct to the input shaft or primary This defect is called Cardan Error and produces alternate advances and a delays in the rotational speed of the output shaft Fig 4 61 LCV_SPBGC46_001 Cardan Joint To avoid this problem two universal joints are placed in tandem with an intermediate shaft according to different configurations W configuration and Z configuration In these cases the two inner yokes of th...

Page 94: ...t shafts are not contained in the same plane For this reason to compensate the imbalances that are produced the two inner yokes of the joint must be offset by an angle φ while the two working angles remain the same β1 β2 Fig 4 64 LCV_SPBGC46_004 Spatial configuration W Z According to the above if the same working angle φ is always respected config urations with a higher number of shafts may be mad...

Page 95: ...e same The material should also be of the same quality Working angles should be equal in both joints β1 β2 Working angles β should never exceed 3 static condition of inclination or be smaller than 0 5 With different angles vibration would occur and the system would not work properly Shafts must be balanced before assembly Take into account the maximum permissible length of the new shaft which depe...

Page 96: ...reas must be covered with a protector Otherwise there is a risk of an accident occurring which could cause serious injuries to the people CAUTION When the propeller shaft is modified a professional company or manufacturer should be contacted to obtain the information and calculus necessary for the accomplishment of work NOTICE If for structural reasons it is necessary to change the inclination of ...

Page 97: ... the coupling device and its easy and safe maintenance should be taken into account Likewise adequate freedom of movement shall be ensured in brake lines electrical wires etc even when the maximum rotation of the vehicle occurs Proper brackets should be provided to meet this function The size of the coupling device is determined with respect to the value D which rep resents the theoretical horizon...

Page 98: ...ss member supplied by HMC is recommend this incorporates the drills necessary depending on the type of cou pling device installed These drills should not be modified to install any device other than the one planned Fig 4 66 LCV_SPBGC47_001 WARNING When designing the superstructure the possibility of heavy loads on the rear side of the vehicle should be avoided Likewise it is important to reduce th...

Page 99: ...uilder Manual Part II Specific Book LCV 99 Fig 4 67 LCV_SPBGC47_005 The drawbar cross member must be properly attached with screws 4 for each side Fig 4 68 LCV_SPBGC47_002 NOTICE The installation of a drawbar cross member does not allow the installation of a rear underride guard References or manuals from manufacturers of coupling devices must be respected as must the standards in force in the res...

Page 100: ...cording to this legislation certain mounting dimensions must be taken into account depending on the towing hook type Fig 4 69 LCV_SPBGC47_004 Coupling ball type Fig 4 70 LCV_SPBGC47_003 Coupling type open jaw The rigid spear transmits the static vertical loads to the coupling device and to the drawbar and in the braking phase or in the oscillations caused by the road surface the dynamic vertical l...

Page 101: ...or each lighting function or by connecting to the vehicle CAN bus network Semi trailer A semi trailer is a trailer with one axle or group of axles in which the union with the tractor vehicle is performed through a set installed on the tractor vehicle chassis known as fifth wheel In this case the tractor supports much of the load and also the semi trailer weight The Body Builder must check whether ...

Page 102: ...re a ver ification test to be carried out on the brake system In vehicles that incorporate the VDC stability system and ABS braking system the sensors located at the wheels to control their speed should not be manipulated It is not possible to make any modification in the control unit of these systems or change their position After making changes to the braking system it will be necessary to perfo...

Page 103: ...n outer layer of polymer to resist corrosion and cover the whole path from the pump outlet to the vicinity of each wheel The last stretch to the connection with the wheel is made by flexible hoses because in that area a certain amount of movement is required due to the rotation of the steering system Fig 4 71 SPBTC48_001 Brake pipe types CAUTION The use of plastic pipes in brake systems is not aut...

Page 104: ...ipes When installing a hydraulic pipe the following points should be taken into account HMC recommends replacing hydraulic pipes completely instead of making joints between pipes The hydraulic pipes must not be welded If it is not possi ble to use one piece pipe the same type of connections as are used in the original vehicle must be used The pipes must be permanently fixed to the vehicle The fixa...

Page 105: ...o different systems such as the electric or hydraulic systems The hydraulic pipes should be kept away from heat sources such as the exhaust system engine etc If the brake pipes must pass through the chassis frame elements or through the bodyshell precautions should be taken to avoid damage The use of a coupling passing or rubber protection is recommended Fig 4 75 LCV_SPBGC48_002 Rubber protective ...

Page 106: ...dius depends on pipe diameter Particular attention should be paid to not bending the hydraulic tubes as bending would reduce their interior section which would affect the system s performance Fig 4 76 TABLE LCV_SPBTC48_004 Brake pipe bending radius A flared nut type B at should be assembled the end of the brake pipes Fig 4 77 TABLE LCV_SPBTC48_005 Flared nuts for brake lines Type B MINIMUM BENDING...

Page 107: ...n can occur which might cause system failures The homogeneity of the braking system must be checked After each intervention in the brake system carefully carry out an air purge Do not reuse the fluid expelled by the hydraulic circuit during the purging oper ation WARNING The cooling of the disc brakes must not be impaired by attaching spoilers or any kind of cover The overheating of brake system w...

Page 108: ...ot be less than the section on the original vehicle Be careful not to cover the air inlets with posters or other decorative elements Care must be taken to ensure that the air flows through the engine compart ment properly removing the hot air up and taking precautions against stag nation Excessive heat should be dissipated to avoid engine damage The characteristics of the fan must not be altered n...

Page 109: ...In the case of excessive unfavorable climatic zones some changes can be made after a proper study of the new installation always in conformity with HMC NOTICE Additional cooling devices should be provided for when the vehicle is stationary and constant high cooling capacity is required NOTICE More information about HMC conformities in See General Book chapter 2 6 Verification and certification of ...

Page 110: ... General Book chapter 2 6 Verification and certification of superstructures CAUTION Modifications to the exhaust and intake systems might involve the loss of the Registration Certificate of the vehicle and warranty of engine operation ENVIRONMENT If modifications are carried out incorrectly in the exhaust and intake systems this could lead to the leakage of pollutant gases into the atmosphere Oper...

Page 111: ...is not the case it is recommended that the advice given in this manual should be followed Modification of the exhaust system is only permitted in the area located behind the muffler The location of each component of the system is carefully studied to optimise its performance Fig 4 78 LCV_SPBGC410_001 Exhaust system mounting area The same sections and materials must be used as those used in the ori...

Page 112: ...sible bending radius must be respected and narrowing avoided in the section Fig 4 79 LCV_SPBGC41_002 Minimum permissible bending radius The supports to fix the new pipe must be approved or supplied by HMC and the maximum distance between them should be 1000 mm Fig 4 80 LCV_SPBGC41_003 Exhaust pipe support The exhaust pipe must be welded so that the exhaust gas cannot escape See chapter 4 1 4 Weldi...

Page 113: ...exhaust system to ensure that it is within the approved limits CAUTION Increasing the length of the tubes and adding joints can cause or increase the noise level in the exhaust pipe The installer is responsible for checking if there is an increase in the noise level and if there is for solving the problem ENVIRONMENT Specific regulations of each country on air purification systems and vehicle poll...

Page 114: ...onverter The AdBlue product contained in the tank usually heated is injected through a dosing module in the exhaust pipe at the height of the collector through a pipe driv ing Once the AdBlue product is injected into the SCR system this triggers a chemical reaction in the catalytic converter which converts the NOx into a mixture of nitro gen and water vapour both natural substances to the environm...

Page 115: ...e Engine power reduction Increased fuel consumption Reduction of the lifetime of the system components 1 Engine 6 Exhaust gas with oxides of nitrogen NOx 2 AdBlue tank and pump 7 AdBlue product 3 AdBlue tank filler tube 8 Ammonia steam oxide of nitrogen NOx 4 Dosing controller 9 Water nitrogen 5 SCR catalytic converter muffler Front of vehicle CAUTION The changes in the mufflers can cause an incre...

Page 116: ...CR system and therefore reduce the torque speed or even stop the engine Excessive cost and unneces sary downtime can be avoided by using the proper product The AdBlue solu tion must meet the purity requirements defined by ISO 22241 1 This ensures the correct manufacturing processes testing and handling The AdBlue product should not come into contact with other products such as oils coolant liquid ...

Page 117: ...talled in a position where the minimum possible water and dust are absorbed Do not modify or change the air filter Do not change the position of the humidity sensor The air intake must be protected from the emission of hot air from other com ponents that are installed in the vehicle The shield guards to protect against the aspiration of cigarette butts and other sediments must not be replaced or r...

Page 118: ...l vehicles The connections between the different components that make up the fuel sys tem should be made with the same type of connection that is used in the vehi cles from factory The new mass distribution is within permissible limits See chapter 2 3 3 Weight distribution The tightness of the system is guaranteed under all conditions of the vehicle All components of the fuel system should be at a...

Page 119: ...ust not be removed or altered without the consent of HMC Fig 4 83 Fuel level sensor shield 1 Installation of an additional fuel driven heater Depending on the situation some vehicles could require the installation of a fuel driven heater in order to reach the correct temperature in the vehicle interior In this case certain guidelines must be followed A type of heater without any sharp edges should...

Page 120: ...eck For this reason no component that might block the fuel tank filler must be installed Both the fuel gauge and the fuel tank must be protected against shock and friction from the equipment installed in the vehicle or in the body The tank should be in a position where it is protected from collisions rollover or loss of fuel The fluid should pour directly onto the ground and not be stored in the v...

Page 121: ...s and precautions It is very important to ensure that the fuel tanks are inspected and cleaned to re move flammable liquids or vapors before undertaking the modification work It might be necessary to fill the tanks with water or an inert gas CAUTION The fuel system is subjected to high pressures use protection when carrying out work to prevent damage caused by particles that might fly off To preve...

Page 122: ...of gravity as well as the minimum distance between it and the ground or other vehicle components that needs to be respected In order to better resist bending moments it is recommended that the support equipment should be installed as close to the chassis crossbars as possible Additional crossbars must not be mounted on the chassis frame as this could affect the bending capacity of the vehicle Howe...

Page 123: ...otection against vehicles that could hit them from behind This protection is performed by a rear underride device according to Directive 70 221 EEC in vehicles with a high dimension in the rear such as box or tipper bodies Other types of vehicles which are not included in this directive because of their own features such as a panel van or a passenger van offer this protection in the form and desig...

Page 124: ... 550 mm A from the road level The horizontal distance between the last rear end of the vehicle and the rear edge of the underride guard should not be higher than 400 mm B If the wheelbase is modified the underride guard must be relocated using the same method as was used for the original position and resistance and proper per formance must be ensured The height of the cross section of the underrid...

Page 125: ... design of the vehicle e g a panel van or a passenger van are excluded from the requirement for this installa tion According to this the following points should be taken into account Components such as the battery box lights spare wheel and tool boxes etc can be mounted on these protections provided that the prescribed instructions are followed But elements such as brake lines air or hydraulic pip...

Page 126: ...Specific Book LCV V1 0 February 2015 The following measurements must be respected Fig 4 86 LCV_SPBGC412_007 Side underride guard dimensions NOTICE If side underride guards are retrofitted the dimensions specified in the illustration must not be exceeded Underride guards must be fitted in accordance with the EU Directive 89 297 EC The underride guards must extend continuously from the front to the ...

Page 127: ...LCV 127 4 12 3 Spare wheel The spare wheel is normally mounted under the chassis frame in the laterals or in the rear area It must be accessible and easy to dismount so that only one man can remove it rapidly It is desirable to make double sure that it cannot be lost Fig 4 87 LCV_SPBGC412_006 Spare wheel 1 NOTICE The legal requirements in force of each country must be observed To obtain more infor...

Page 128: ... is equipped with standard holes for the installation of the mud guards that allow them to be installed in different positions The following points must be considered The top of the wheels must be completely covered by the mud guards The movements and vibrations of the suspension must be taken into account The wheel must have a normal movement even with the suspension working at maximum capacity T...

Page 129: ...el that is mounted Mud flaps The rear mud flap is a flexible component mounted vertically at the bottom of the chassis frame the body or the mud guards The mud flaps also serve to reduce the risk of the tyres throwing small objects especially gravel towards other road users If mud flaps are fitted they must comply with the standard Fig 4 89 LCV_SPBGC412_004 Mud flap MINIMUM DISTANCES OF THE WHEEL ...

Page 130: ...resistance of the air depends on correct installation and thus the higher or lower fuel con sumption When fitting an air deflectors a strong adhesive must be used Glue must only be applied to the permitted areas Fig 4 90 LCV_SPBGC412_008 Permitted area for gluing a wind deflector 1 CAUTION Additional holes in the cab roof for mounting a wind deflector are not permitted NOTICE When national rules s...

Page 131: ...am age the paint or the bodyshell in any state of use The device must be properly secured so that no vibrations or noise occur No holes must be made in the roof cab to install the wind deflector It must be installed with strong adhesives or another method Both the weight of the element and the pressure exerted on it by the air when the vehicle is in motion should be taken into account See chapter ...

Page 132: ...32 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 To install the undercover there are 4 fixing points in the chassis frame M8X1 25P 4 places Fig 4 92 LCV_SPBGC412_010 Engine undercover bottom view A Fig 4 93 LCV_SPBGC412_011 Engine undercover front view B A Bottom view 2 Chassis frame 1 Undercover Front of vehicle B Front view 2 Chassis frame 1 Undercover Front of vehicle ...

Page 133: ...February 2015 Body Builder Manual Part II Specific Book LCV 133 Fig 4 94 LCV_SPBGC412_012 Engine undercover perspective view C Fig 4 95 LCV_SPBGC412_013 Engine undercover main dimension bottom view A C Perspective view 4 Fixation points 1 Undercover 5 Fixation to frame 4 screws M8 2 Chassis frame Front of vehicle 3 Brackets to be made A Bottom view 2 Chassis frame 1 Undercover Front of vehicle ...

Page 134: ...N BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 134 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 Fig 4 96 LCV_SPBGC412_014 Engine undercover main dimension side view D D Side view 2 Sponge pad 1 Undercover Front of vehicle ...

Page 135: ...equipment to the electrical system of the vehicle See chapter 7 3 Additio nal electricity consumers The guidelines and standards for the installation of electrical cables must be respected See chapter 7 2 Electrical system A leak detector should be used to check the tightness of the refrigerant circuit Leaks can occur in any point in the system such as at the joints the compres sor the filling val...

Page 136: ...s possible that loads are evenly distributed over the entire roof surface The use support legs installed at regular distances is recommended See chapter 4 3 3 Roof In vehicles in which it is necessary to install an escape hatch such as a passen ger vans the installation of any equipment that might prevent entry or exit through this opening if it needs to be used as an emergency exit is forbidden C...

Page 137: ...ad and the vehicle The shelves rails or other elements should be anchored to the strong points of the structure of the vehicle either laterals walls and ceiling or floor Otherwise damage could occur to the body shell of the vehicle Fig 4 97 LCV_SPBGC412_003 Use only approved products to ensure quality and safety inside vehicle They must possess adequate strength and be secured by suitable means Th...

Page 138: ...ng structure For the installation of groups in special vehicles such as fire engines refuse collec tion vehicles etc special settings are needed for the chassis NOTICE A winch must not be installed on the front of the vehicle The freedom of movement of vehicle components must be guaranteed in all driving situations The newly installed equipment must not affect the operation of other vehicle groups...

Page 139: ...s new operating conditions Otherwise it could cause ex cessive wear on rims and suspension besides shortening the life of the tyres 4 14 Axle and wheel modifications Axles The modification of the undercarriage and axles is forbidden The addition of extra axles on the vehicle is not permitted The modification ofcontrol units sensors line routing for VDC and ABS is not per mitted WARNING Modificatio...

Page 140: ...ed this will disrupt the operation of elements such as the braking system undercarriage tyres etc NOTICE The size and type of tyres allowed for each vehicle shall be specified in the Registration Certificate of the vehicle If the type of authorised tyre is changed the vehicle can lose Registration Certificate Therefore an application must be lodged with the competent authorities to certify with th...

Page 141: ...on etc it is also necessary to modify the instal lation of the electrical lines of the vehicle When doing this the instructions in this manual must always be carefully followed WARNING Electrical systems that are added to the chassis wiring must not have an adverse effect on the safety of the vehicle The operation of the electric system of the vehicle should be checked after the operations have be...

Page 142: ...rmed The connection of additional consumers by splicing to the electrical circuit is not al lowed The connections can only be effected on the points authorised for this pur pose No intervention in the vehicle CAN bus or in the systems connected to it is allowed The maximum transmit power of the communication antennas allowed in each coun try must be taken into account These values must not be exce...

Page 143: ...ON POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 143 5 MOUNTING AND CONSTRUCTION OF BODIES This chapter provides the following information Machinery Directive and CE marking Subframe features and design Subframe attachment Study of different types of bodies ...

Page 144: ...ve maximum customer satisfaction HMC also offers a full warranty on its vehicles The Body Builder must therefore provide its customer with a guarantee for the products manufactured and installed in the chassis and for any equipment or component installed in the basic vehicle that has been modified or altered in any way For all these reasons described here HMC recommends that the Body Builders shou...

Page 145: ...must have the following characteristics The manufacturer must add it conspicuously legibly and indelibly to the product to be supplied according to the format provided by law If due to the appearance and manufacturing method of a product the CE marking cannot be added to it then in this case the marking should be on the packaging and the documents accompanying the product If the Directive requires...

Page 146: ... etc The possibility of fixing additional components or equipment Extra resistance and rigidity of the chassis frame of the vehicle even on the rear overhang which is very useful when this is subjected to heavy loads There are different requirements when designing a subframe and these depend mainly on the type of vehicle the activity during service and the condition of the road According to these ...

Page 147: ... strength limits of each material In cases where the subframe must have the strength and stiffness to withstand high loads for instance with tipper bodies cranes centre axle trailers etc the use of aluminum subframes is not recom mended See chapter 5 2 3 Subframe permissible sections The required resistance of the subframe under the loads to be supported must be estimated by calculation So a mater...

Page 148: ...esistant moment or section modulus Wx required to withstand the stresses to which it will be subjected When several structures are mounted on the chassis frame the moment of greatest resistance between them will be taken as the basis for calculating the dimensions and features of the subframe Ideally it is preferable to have a subframe and a chassis frame with the same flange width HMC recommends ...

Page 149: ...gitudinal beams of the subframe are also manufactured with open U type sections or other similar sections that can properly absorb lateral and bending forces while keeping the subframe joined The subframe crossbars should be distributed over the chassis frame crossbars in order to adapt the two structures each other and so that they can work together properly See chapter 5 2 4 Subframe design requ...

Page 150: ... and behaviour to withstand torsion and flexion forces For example flexible subframes are used for platform or tipper bodies and rigid or very rigid subframes in refrigerated bodies or tank bodies Also the subframes should be designed to absorb lateral forces produced when the vehicle turns or forces produced on the rear overhang due to the trailer Subframe design The following guidelines should b...

Page 151: ...nts forming a box the transition from box beam to U beam should be progressive This is done when the beam section which is obtained by calculation is too high or when there are specific high point loads that can deform the longitudinal beams On the one hand a bigger resistant moment is achieved and on the other hand the subframe structure has greater torsional stiffness Fig 5 106 SPBGC52_005 Progr...

Page 152: ...essively increase the stiffness as needed There are different solutions Fig 5 107 SPBGC52_006 Torsional reinforcement in the subframe 1 Using rectangular section for longitudinal beams on the rear 3 Using cruciform bracings with different sections as needed 2 Using rectangular section for end crossbars NOTICE The stability of the vehicle during operations performed with the superstructures e g the...

Page 153: ...cab roof can be reduced by 70 mm at the most The cutting area must be reinforced and properly adapted to the installation of the roof subframe After modification the cab must be properly painted in the affected areas The original positions of the sun visors or other standard equipment must not be changed but their fixation points can be moved The inner roof lining should also be properly adapted O...

Page 154: ...ich method is most suitable for the situation It should ensure uni form distribution of loads without point loads that could weaken the structure of the cab Another important requirement that must be taken into account is that the upper body must not be fixed by bolting it to the corners of the cab structure Fig 5 109 SPBGC52_007 The maximum permissible loads on the roof must be respected at all t...

Page 155: ...achment consoles distributed along the chassis frame To assemble the body the Body Builder must use all the consoles available in the chas sis In general the number of attachment points must be sufficient to enable them to absorb lateral and braking forces If required more consoles can be added but in no case must fewer attachment points be used than those incorporated in the chassis from factory ...

Page 156: ...rtant to consider these values in order to ensure that they are fixed properly Regardless of the type of console that is used two fixing screws are always used Fig 5 111 SPBGC53_002 SPBGC53_003 Mounting brackets and attachment consoles on the chassis frame In this manual HMC offers a number of ways of attaching the consoles to the sub frame depending on the situation Fig 5 112 SPBGC53_010 Differen...

Page 157: ...h elements to be harmonised with each other making it possible to achieve a good balance between vehicle stability and a high level of comfort while driving According to the freedom of movement provided by the connection and the rigidity offered these will be considered more or less flexible semi flexible i e they pro vide a degree of resistance to higher or lower torsional stresses Therefore HMC ...

Page 158: ...between chassis frame and subframe In these cases the use of a type F_2 connection is recommended Fig 5 114 SPBGC53_006 F_2 type subframe connection In special cases where the upper body is very rigid e g in van bodies refrigerated vehicles tankers etc which are expected to be used on rough roads the use of a connection with a high degree of flexibility is recommended in the area behind the cab e ...

Page 159: ...using type R_1 connections Fig 5 116 SPBGC53_005 R_1 type subframe connection 5 3 4 Combining flexible and rigid connections While driving both the chassis frame and body are subjected to static and dynamic stresses Static forces are generated by the mass the weight of the vehicle and its load They are the only forces acting when the vehicle is stationary Dynamic forces arise when the vehicle is b...

Page 160: ...res Self supporting platforms If on account of its own features the supporting platform of the upper body can assume the function of the subframe then the subframe is not necessary The strength and rigidity required for the subframe must be achieved by this alter native structure See chapter 5 2 Subframe features and design Self supporting bodies If the body has a self supporting structure the ins...

Page 161: ...he vehicle should be easily accessible for maintenance and repairs Avoid twisting the chassis frame when tightening the screws The nuts and bolts of the connections must be re checked and tightened peri odically with the suitable torque HMC recommends not using shackles to attach the chassis frame and subframe These can generate large bending forces on the beam flanges of the chassis frame These c...

Page 162: ...timum strength com fort manoeuverability and cargo handling characteristics When planning the assembly between chassis and body the following points should be considered Choose a chassis frame that harmonises as well as possible with the planned body Check the correct distribution of masses and loads to ensure stability during vehicle operation Choose the right frame size for the chassis and subfr...

Page 163: ...The proper height of the centre of gravity must be achieved to ensure maximum stability as well as to comply with the distribution of weight according to the regu lations in force and to the guidelines contained in this manual See chapter 2 3 Technical limit values Subframe features In this type of body the use of open sections e g U or Z is recommended in the construction of the subframe In this ...

Page 164: ...rom fac tory In this type of vehicle the use of flexible connections with a low degree of flexi bility type F_1 is recommended along the entire length of the chassis frame See chapter 5 3 Subframe attachment Fig 5 120 SPBGC54_001 Positions of flexible connection to be used see chapter 5 3 2 Flexible connection Special points to be considered If peak loads are anticipated due to the transport of ce...

Page 165: ...ight of the centre of gravity must be achieved to ensure maximum stability as well as to comply with the distribution of weight according to the regu lations in force and to the guidelines contained in this manual See chapter 2 3 Technical limit values Subframe features In this type of body the use of open sections e g U or Z is recommended in the construction of the subframe In this way uniform l...

Page 166: ...first fixation point behind the cab is also recommended connection type F_2 or F_3 Sometimes it might even be desirable to use the second points of fixation behind the cab The degree of flexibility of the connections must be chosen according to the particular circum stances of each vehicle for example considering the imperfections of the roads on which the vehicle will be driven the rigidity of th...

Page 167: ...a detailed planning of the work to developed should be carried out In this way it is possible to properly determine the dimensions weights and main features of the upper body to be installed The proper height of the centre of gravity must be achieved to ensure maximum stability as well as to comply with the distribution of weight according to the regu lations in force and to the guidelines contain...

Page 168: ...g an end cross member or cruciform bracings depending on the case See chapter 5 2 Subframe features and design Types of connection At least all the consoles available in the chassis from factory must be used If necessary more consoles can be added but under no circumstances should fewer attachment points be used than those incorporated in the chassis frame from fac tory In this type of vehicle the...

Page 169: ...nd at the rear during unloading Pay special attention not to locate the lifting cylinder behind the centre of gravity of the tipper platform This would make the cylinder lift the rear end of the tipper platform instead of the front when starting the unloading process The cylinder should not be attached to the chassis frame just to the sub frame by rigid connections with the most suitable design ac...

Page 170: ... body of the tanker is considered extra rigid to torsional forces Fig 5 125 SPBGC53_021 Tanker General considerations Before starting conversion work on the vehicle it is recommended that the basic vehicle should be weighed and measured and a detailed planning of the work to developed should be carried out In this way it is possible to properly determine the dimensions weights and main features of...

Page 171: ... the body it is essential to check whether there are vibrations or oth er harmful factors when the vehicle is travelling Vibration can be countered by the proper arrangement of the subframe on the chassis frame and by properly arrang ing the tank supports Type of connections At least all the consoles available in the chassis from factory must be used If necessary more consoles can be added but und...

Page 172: ...Chapter 2 3 4 Centre of Gravity CoG In tankers fluid motion affects the manoeuverability of the vehicle because the centre of gravity of the load can quickly move into the tank The load can be moved laterally during curves and longitudinally during braking For this reason it is rec ommended that transverse and longitudinal deflector plates should be mounted in tanks to reduce the risk of overturni...

Page 173: ...measured and a detailed planning of the work to developed should be carried out In this way it is possible to properly determine the dimensions weights and main features of the upper body to be installed The proper height of the centre of gravity must be achieved to ensure maximum stability as well as to comply with the distribution of weight according to the regu lations in force and to the guide...

Page 174: ...hin the permissible values See chapter 4 5 2 Noise insulation The guidelines and recommendations for Power Take Offs PTOs must also be fol lowed See chapter 6 POWER TAKE OFF The instructions in this manual for the installation of the electrical equipment for cooling the vehicle must be followed See chapter 7 ELECTRIC AND ELECTRONIC SYSTEMS 5 4 7 Tractor for semi trailers General considerations Thi...

Page 175: ...bframe The point of the subframe is to distribute the load falling on the fifth wheel and ensure appro priate behaviour of the chassis frame against torsion and bending forces A steel subframe is recommended This frame should extend along the entire length of the chassis frame to the first anchor point behind the cab The fifth wheel is always mounted on a base plate used to secure the fifth wheel ...

Page 176: ...V_SPBGC54_004 Forces at fifth wheel base plate and subframe The Body Builder is responsible for selecting the required size of the fifth wheel and base plate Fifth wheels must comply with national and international laws and be approved It is recommended that the manufacturer s guidelines should be followed Type of connections At least all the consoles available in the chassis from factory must be ...

Page 177: ... installing wires care should be taken not to rub against moving parts of the body as this could damage them Also enough wire should be provided to allow maximum rotation of the semi trailer The use of brackets for wires is recommended Installing brakes for semi trailer The Body Builder is responsible for performing the installation of the specific brake system for the semi trailer This must be at...

Page 178: ...avity must be achieved to ensure maximum stability as well as to comply with the distribution of weight according to the regu lations in force and to the guidelines contained in this manual See chapter 2 3 Technical limit values There must be no disruption either partial or complete of the functioning of any of the equipment fitted to the vehicle as standard Likewise access should be ensured to re...

Page 179: ...nts be used than those incorporated in the chassis frame from fac tory Special points to be considered The fuel filler cap must not be obstruced in any way The minimum distance between the door and the integrated body must be no less than 20 mm since a shorter distance could cause the door to jam after an accident The use of stabiliser bars is recommended 5 4 9 Loading cranes General consideration...

Page 180: ...ne and the upper body This will ensure that the loads will be distributed evenly throughout the chassis frame The chassis frame of the vehicle and the subframe must be suitable for the weight and maximum load moment of the loading crane The maximum permissible crane load moment in HMC vehicles should be less than 25 kNm To ensure stability in crane service the subframe must be constructed with suf...

Page 181: ...platform bodies etc and a subframe is also needed for these A subframe that is able to withstand all the stresses to which the vehicle is subjected during its various operations and also while driving should therefore be considered for the body The subframe also provides the necessary crane height to ensure proper clearance so that the operation of the other components of the vehicle will not be a...

Page 182: ...iating factor is the way the crane is fixed to the chassis The method of attaching the loading crane depends on the position occupied by the crane in the vehicle and the crane type The crane manufacturer s instructions must be followed It is the responsibility of the Body Builder to design and dimension the loading crane attachment to the chassis of the vehicle The number of screws to be used in t...

Page 183: ...by support feet which are laterally extended The use of hydraulic feet is recommended The support feet protruding beyond the vehicle must be properly marked with reflective paint reflectors or any other signalling method approved The crane must be used on flat and stable surfaces During operation of the crane the extendable support feet must be always extend ed and in contact with the ground as th...

Page 184: ...ell as in a chassis cab Before starting the conversion work on the vehicle it is recommended that the free space for mounting should be verified and a complete plan for proper installation of the tail lift made The user of the vehicle is responsible for the security of the tail lift while it is being used It is therefore imperative for the Body Builder to provide clear instructions about the funct...

Page 185: ...ear axle of the vehicle must not be exceeded Likewise care must be taken with the minimum load on the front axle to ensure proper steerability of the vehicle See chapter 2 3 3 Weight distribution The Body Builder must calculate the weight distribution on the axles checking that it remain within permissible limits If after calculating the load distribution on the vehicle the maximum permissible axl...

Page 186: ...f gravity of the load on the tail lift must not exceed 600 mm Fig 5 138 SPBGC54_009 CoG of the load on the tail lift X 600mm HMC recommends mounting a stabiliser bar in both the rear and front axles The maximum permissible lifting loads are showed in the table below Table 1 139 SPBTC54_001 Maximum permissible lifting loads MODEL WHEELBASE mm MAXIMUM LIFTING FORCE kN MINIMUM DIMENSION MOUNTING FRAM...

Page 187: ...ee chapter 4 2 4 Attachment of groups or additional equipment Fig 5 140 LCV_SPBGC54_010 A supporting structure that allows the proper distribution of stresses must be used to attach the tail lift The use of at least two attachment points is recommended for the appropriate absorption of bending moment The factory made fastening points on the chassis frame provided for installing equipment in the re...

Page 188: ...xation point behind the cab connection type F_3 It may also be advisable to use a rigid connection type R_1 in the area above the rear axle See chapter 5 3 Subframe attachment If required the subframe can be reinforced at the rear by fitting a diagonal cross or by making a box section Sometimes it might be necessary to reduce the rear overhang because of the great stresses produced in this area Se...

Page 189: ...imum permissible length of the rear overhang is of par ticular importance See chapter 2 3 6 Vehicle overhang The Body Builder must check that the main dimensions of the final vehicle are within the permissible limits See chapter 2 3 2 Vehicle main dimensions An aerial platform can be mounted in a panel van as well as in a chassis cab Before starting the conversion work on the vehicle it is recomme...

Page 190: ...corporate a subframe which will serve as both a reinforcement and a support for the laerial platform and the upper body if one is installed This will ensure that the loads will be distributed evenly throughout the chassis frame The chassis frame of the vehicle and the subframe must be suitable for the weight and maximum load moment of the aerial platform To ensure stability when using the aerial p...

Page 191: ...ched to the chassis frame at the midpoint between the first two consoles installed from factory in the vehicle In this axis a cross member must be mounted to protect the subframe against torsion forces which occur when operating the platform This cross member is also used to protect against the forc es transmitted by the support feet The installation of another cross member is rec ommended in the ...

Page 192: ...vehicle an additional fixation console must be mounted between the cab and the first console installed from factory This additional console must be lo cated 100 mm from the first console installed in the factory Fig 5 144 LCV_SPBGC54_012 HMC recommends using official parts supplied by HMC for additional consoles If original parts are not chosen a material of at least the same quality as the origin...

Page 193: ... can be type F_1 See chapter 5 3 Subframe attachment Fig 5 145 SPBGC54_013 Special points to be considered Attention must be paid to the asymmetric installation of the aerial platform The maximum load difference between the wheels on the same axle unilateral axle load must not be exceeded See Chapter 2 3 3 Weight distribution Stability must be ensured by support feet which are laterally extended T...

Page 194: ...The operation of a tilt platform body for roadside assistance generally subjects the chassis frame of the vehicle to great stress The vehicle used for this purpose should therefore be specifically indicated for this application Fig 5 146 SPBGC54_029 Vehicle with tilt platform HMC can be contacted for recommendations regarding the choice of a vehicle with the proper features See General Book chapte...

Page 195: ...d and stiff at the rear end of the vehicle and allow the additional structure to contribute more effectively towards the rigidity of the assembly The rear tilt pivot must be installed on the subframe and as close as possible to the anchor point of the rear suspensions It contributes to a better stability of the ve hicle during operation of the platform and protects the rear overhang against heavy ...

Page 196: ...030 People carrier For all modifications tto be performed on this type of vehicle Regulation ECE R 107 Uniform provisions concerning the approval of category M2 or M3 vehicles with regard to their general construction should be considered 5 4 15 Low chassis frame At present there is no information available for vehicles with these characteristics It is the intention of HMC to incorporate this vari...

Page 197: ... integrated bodies This type of vehicles can be used to install different types of bodies which con nected to the vehicle cab form a single unit This includes motor caravans ambu lances partially integrated vans etc Fig 5 148 SPBGC54_031 Sample of a vehicle with integrated body With an integrated body a non positive connection between the cab and the body is required along the entire perimeter of ...

Page 198: ...ts entire length Option B The fixation between the B pillar and the upper body can be effected by means of angle sections by riveting them Table 1 150 SPBTC54_002 The following should also be taken into account A perfect seal must be ensured between cab and body Regulations regarding noise must be complied with See chapter 2 3 9 Noise insulation Parts of the cab involved in the modification must b...

Page 199: ...pecific Book LCV 199 5 4 17 Other type of bodies There are countless types of bodies that can be mounted on the HMC Light Com mercial Vehicles For all types not listed in this manual the guidelines listed for the other type of bodies must be used as deemed appropriate In these cases it is recommended that HMC should be contacted for more informa tion and the appropriate authorisations See General ...

Page 200: ...K ON BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 200 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 6 POWER TAKE OFF This chapter provides the following information General considerations Study of different types of PTOs ...

Page 201: ...so install all the components need ed in the vehicle later However as the subsequent installation of a PTO could be too costly and could seriously disrupt the smooth functioning of the vehicle HMC recommends ordering the installation of the PTO from factory Generally the PTO should be chosen depending on the hours of use and the power to be supplied That is the features of the PTO depend on the ne...

Page 202: ... The transmission ratio can be defined as the relationship between the rotational speeds of two gears connected to each other Because of this relationship different rotation speeds can be achieved between the input and the output of the PTO With a transmission ratio Z 1 the speed is increased at the output Z 1 no speed difference between the input and the output Z 1 the speed is reduced at the out...

Page 203: ...commended 780 rpm should be avoided to prevent irregularities and vibration in vehicle oper ation The power absorption must be within the maximum engine torque Generally the required power output is not constant Depending on the body and its purpose of application the engine power must be minimum constant or maximum Many times it is necessary to meet various power requirements at the same time To ...

Page 204: ...ic actuation system This de vice activates a mechanism that connects the PTO to the engine or gearbox so transmitting the movement to the hydraulic pump or to another working device The PTO can be activated or deactivated by a control device actuated by the driver Fig 6 154 SPBGC61_002 Genuine PTO actuation switch A Out cab B In cab 1 ECU 6 PTO remote acceleration pedal 2 PTO lamp 7 Remote PTO INC...

Page 205: ...trol system is to connect the PTO in a safe way Before activating the PTO the control unit will check if the proper conditions are met such as is there sufficient pressure in the pneumatic system is the vehicle completely stopped etc Peak load at start up The maximum torque of the PTO is referenced to uniform loads This value must not be exceeded as this would lead to damage in the system Lubricat...

Page 206: ...ons If the propeller shafts are assembled at very high angles this can lead to excessive vibration It is therefore recommended that measurements should be taken to en sure the proper functioning of the system A check should be carried out to ensure that the dimensions of the propeller shaft are sufficient to withstand the torque required which the PTO provides to activate the equipment installed i...

Page 207: ... leaks in the system both with the vehicle stationary and with the PTO fully operational In order to prolong the life of the system it is important that the hoses and electrical cables are fixed properly to avoid tem being subjected to unneces sary wear or movements Check for loose screws which could cause damage to the PTO and to the vehi cle Check that screws have the proper torque according to ...

Page 208: ...earbox Its rotational speed and the power sup plied are determined by the engine speed and the transmission ratio of the gearbox In most cases they are activated by a pneumatic system that precludes the PTO connecting with the vehicle in motion This prevents a conflict between the gearbox and the PTO This option is most suitable for operations of the superstructure that do not need to be used duri...

Page 209: ...fic Book LCV 209 PTOs installed from factory HMC can supply different PTO versions installed in the vehicle from factory if re quired The most common positions enabled for the connection of the PTO that HMC incorporates in the vehicles delivered on request are as follows Table 1 155 LCV_SPBTC62_001 PTOs supplied by HMC from factory PTOs SUPPLIED BY HMC FROM FACTORY 1 PTO dependent on the cluch 2 P...

Page 210: ...niform loads without vibrations in which no single axial forces The maximum in itial torques must never exceed twice the value indicated in the specifications of the PTO connected to the gearbox Table 1 156 LCV_SPBTC62_002 Main features PTO dependent of the clutch MAIN FEATURES OF PTO DEPENDENT ON THE CLUTCH Features Permissible torque 20 kgf 196 Nm 1500 rpm PTO ratio 0 697 Rotation direction cloc...

Page 211: ... weight of the pump or any other device which is connected to the coupling flange of the PTO If the device generates a bending moment greater than the maximum allowed an additional fixing bracket must be installed to better withstand these forces Simultaneous operation of more than one PTO When simultaneously operating two or more PTOs that may be connected to the ve hicle at the same time the tor...

Page 212: ...CTRIC AND ELECTRONIC SYSTEMS APPENDIX 212 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 7 ELECTRIC AND ELECTRONIC SYSTEMS This chapter provides the following information Electromagnetic compatibility EMC Electrical system Additional electricity consumers Handling batteries Lighting guidelines Communication systems Electronic system ...

Page 213: ...afterwards it should carry out exactly the same check certifying the correct operation of this equipment by type certificates which will recognise that products are in full com pliance with standards and regulations Electronic systems that are going to be installed in the vehicle must be approved ac cording to Directive 2004 108 EC meet the requirements of the regulation ECE R10 and have the e mar...

Page 214: ...e wire for grounding Only the power points and earth points detailed in this manual must be used See chapter 7 3 2 Possibilities of connection See chapter 7 3 4 Earth wire The new wires should be installed as close as possible to the original wire har ness of the vehicle always trying to place them inside of the chassis to avoid as far as possible radiation emitted by external electromagnetic sour...

Page 215: ...ced in the electrical sys tems must always comply with the guidelines contained in this manual as if this is not the case this can lead to failures which could cause the total stoppage of the vehicle or even cause the driver to lose of control of it and cause an accident Eu ropean specifications and the regulations and laws of each country must also be followed An electrical system that operates a...

Page 216: ...s See chapter 7 2 3 Fuse features The direct connection of auxiliary consumers to the battery terminal is for bidden See chapter 7 3 Additional electricity consumers Elements such as the fuse box batteries control unit etc must not be handled or moved If it is necessary to pass wires through the cabin the areas authorised for this purpose must be used and care taken to ensure that they are complet...

Page 217: ...k the use of components supplied by HMC is recommended The wire section is selected according to current and must be properly protected by means of fuses See chapter 7 2 3 Fuse features Table 1 158 SPBTC72_001 Electrical wire sections 40 C NOTICE The table should only be taken into account for reference The size of each wire should be decided depending on the usage environment temperature vibratio...

Page 218: ...ed on the vehicle it is necessary to modify the electrical lines installed in the vehicle or install new lines In such cases there are rules which must carefully followed Wires with the features recommended by HMC should always be used See chapter 7 2 2 Wire features It is recommend that wires and connections with colours and codes similar to those used in the original vehicle should be used This ...

Page 219: ...h areas where it may be assumed that it damage can occur due to mud accumulation of snow freezing or flying stones Wires should be placed more than 200 mm away from exhaust system elements such as tail pipes and mufflers Otherwise they should be protected by heat insulators When wiring inside the engine compartment wires should pass directly through the same route as the chassis harnesses already ...

Page 220: ... connected Use fuses with the specified capacity for the specific function never use a higher capacity fuse 7 2 5 Wiring diagrams The wiring diagrams for the vehicle are available for Body Builders on request HMC must be contacted See General Book chapter 2 4 Contact possibilities In cases where modifications or new installations in the vehicle are important the Body Builder will develop its own w...

Page 221: ...he earth points which are avail able for the Body Builder The arrangement type and quantity of these connections will vary depending on vehicle model and customer requirements When connecting additional electricity consumers some important aspects must be taken into account No existing connection is disconnected to connect an additional consumer in its place Direct connection of any equipment to t...

Page 222: ...e vehicle s electric system never make electrical connections at points other than those expressly des ignated by HMC this is strictly prohibited The connection points enabled for Body Builders where they can have access to the power supplies are shown in this chap ter The number of connectors depends on the equipment mounted on the vehicle and its features Furthermore as a result of customer requ...

Page 223: ...Junction is located in the driver seat frame left hand drive vehicle It is connected to the auxiliary battery The auxiliary battery is located in the engine compartment For this reason HMC has installed a wire that goes from the auxiliary battery to the Body Builders Block Junction This deviation is always carried out on the additional battery not on the principal battery This avoids any need for ...

Page 224: ... LCV V1 0 February 2015 Option B Auxiliary fuse box The connection of additional electricity consumers can also be carried out using the Auxiliary Fuse Box which is installed in the driver seat frame under the Body Builder Block Junction It is a terminal strip which has three connec tions Fig 7 162 SPBGC73_002 Auxiliary fuse box B Auxiliary fuse box 3 Auxiliary B F Driver seat frame 4 Auxiliary IG...

Page 225: ... CONSUMERS Fuse capacity Maximum Power Remark 1 Terminal 150 A 12 V 105 A B 2 Terminal 10 A 12 V 6 A Engine run 3 Terminal 25 A 12 V 17 A B 4 Terminal 15 A 12 V 10A Ignition 2 A Main battery G Starter B Seat fuse box H DCU C Auxiliary fuse box J Seat fuse box D Auxiliary battery K Engine run relay E Body Builders Block Junction M IG2 relay F Power cut relay NOTICE If the Body Builders block juncti...

Page 226: ...2015 Apart from the connections mentioned there are other possible connection points for lights trailer etc Connection for side mark lamp on chassis cab 6 m only The features of the provision for side marker lamps are Connector KUM NMWP02M B P no PB621 02020 Rated capacity 30W 15W each for left right Korea Union Machinery www ikum kr Fig 7 164 LCV_SPBGC72_004 006 Rear side marker lamps A Side mark...

Page 227: ...BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 227 Electrics for trailer socket trailer option only Fig 7 165 LCV_SPBGC72_007 Adaption to trailer socket C Adaption to trailer socket ...

Page 228: ...ll new switches even if there are blank buttons because the vehicle does not incorporate some of the equipment installed as an option The free places enabled for Body Builders are marked with number 12 in table LCV_SPBTC73_002 Table 1 166 LCV_SPBTC73_002 Location of switches on dash panel NOTICE If available the original Hyundai switches are recommended LOCATION OF SWITCHES ON DASH PANEL 1 Fog lam...

Page 229: ...ring is installed The other part is the counterpart in which the Body Builders must install the terminals Connections to pins and terminals must be of a protected type and resistant to at mospheric agents Components of the same type and properties as those originally used on the vehicle must be used One important connector installed in the vehicle as an option is the trailer socket On request HMC ...

Page 230: ...our 1 Left hand direction indicator light yellow 2 Rear fog lamp blue 3 Earth position 1 8 white 4 Right hand direction indicator light green 5 Right rear light brown 6 Stop lights red 1 mm2 7 Left rear light black 8 Reverse lamps black red 9 Continous power suppply for interior lighting refrigerator etc brown white 10 Switched power supply for charging circuit of caravan battery red 2 5 mm2 11 Ea...

Page 231: ...en equipment connected to the ve hicle and the batteries This achieves a great saving in the number of conductors needed and therefore in the cost of installation This connection to the chassis frame of the vehicle can only be carried out at points designated for this purpose by HMC As poor connection to ground can completely ruin the vehicle s electrical system good planning is required to get th...

Page 232: ...TION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 232 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 Fig 7 169 SPBGC73_012 Earth bolt rear cross member chassis cab Fig 7 170 SPBGC73_011 Earth bolt rear cross member bus panel van chassis cab 1 Earth bolt Front of vehicle 1 Earth bolt Front of vehicle ...

Page 233: ...ent must not be used for equipment belonging to the body The maximum number of terminals allowed to be connected to the same earth point is 4 The torque of the earth bolts and nuts which are M6 is max 10 3 Nm 7 3 5 Fuse protection All connections of the additional electricity consumers to the basic vehicle must be protected by fuses in order to prevent the permissible peak loads accepted by the di...

Page 234: ...cial care should be taken to prevent ac cidents or damage to the vehicle s electrical components HMC recommends follow ing the instructions contained in this manual The vehicles supplied by HMC used to incorporate two batteries The main battery is located on the left hand side of the vehicle under the floor between the driver s seat and the pedals Fig 7 171 SPBGC74_001 Main battery location WARNIN...

Page 235: ...stead of the normal ground cable Care must be taken not to damage this sensor when handling the main bat tery There are two holes in the battery for venting the H2 gas Because the main battery is located in the interior this gas should be passed to the outside of the vehicle To do this stop up the vent hole located near the pole and connect the hose to the vent hole located near the pole The gas f...

Page 236: ...ND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 236 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 Fig 7 173 SPBGC74_004 Main battery connections Fig 7 174 SPBGC74_002 Auxiliary battery Location 1 LIN connection male 2 LIN connection female Front of Vehicle 1 Auxiliary battery ...

Page 237: ...ng and allow the electrolyte to escape The extra battery must be grounded using proper wire section which must be as short as possible The connection should also be made through the appropriate fuse and cut off relay An important point to consider is whether the original alternator of the basic vehicle has enough capacity to provide energy to all the batteries that make up the system The Body Buil...

Page 238: ...gative ter minal The battery must be fully charged and not damaged Slow battery charging is recommended except in cases of necessity WARNING The battery wires or the power switch must not under any circumstances be dis connected from the vehicle with the engine running CAUTION The incorrect polarity of the supply voltage can cause destruction of electrical and electronic elements NOTICE Do not con...

Page 239: ...c review of the charging system of the vehicle should be carried out to ensure that the battery is operating under normal condi tions and that there are no faults in the electrical system which may be affecting the normal life of the battery NOTICE The manufacturer s recommendations for recharging batteries should always be followed WARNING Never open the AGM battery Batteries are filled with high...

Page 240: ...hting system The installation of red lamps on the front and white lamps on the rear must be avo ided except for the reverse light to avoid any possible confusion while the vehicle is being driven The installation of flashing lamps must also be avoided except for the warning flashers Attention must be paid to the new lamps installed as outline marker lamps which must be connected and disconnected i...

Page 241: ... a vehicle can be categorised as Optical signalling systems end outline lamps indicators brake lights lights used by the emergency services and special services etc Illumination system dipped beam headlamps full beam headlamps fog lights interior lamps etc Lights and reflectors which are double and serve the same purpose will correspond in colour and intensity be located symmetrically and if possi...

Page 242: ...eadlamp centres and a horizontal line Horizontal line passing through centre of head lamps on the screen 4 With the headlamp and battery in normal condition aim the headlamps so the brightest portion falls on the horizontal and vertical lines A MFR type 5 1 To aim the low high beam to the left or right turn screw 1 clockwise or counterclockwise To aim the low high beam up or down turn screw 2 cloc...

Page 243: ...ual Part II Specific Book LCV 243 Fig 7 176 LCV_SPBGC75_003 Front fog light Front fog light aiming 1 The front fog light can be aimed in the same manner as the headlamps are 2 With the front fog lights and battery in normal condi tion aim the front fog lights 3 To aim the front fog light up or down turn the bolt clockwise or counterclockwise 1 NOTICE The basic headlamp setting corresponds to 1 10 ...

Page 244: ...nd ground H2 Height between the headlamp high beam the high beam bulb centre and ground H3 Height between the fog light bulb centre and ground W1 Distance between the two headlamp low beam bulb centres W2 Distance between the two headlamp high beam high beam bulb centres W3 Distance between the two fog light bulb centres Vehicle condition Headlamp mm inch Fog light mm inch H1 H2 W1 W2 H3 W3 Projec...

Page 245: ...BEAM BASED ON 10 m SCREEN 1 Ground 5 100 mm 2 Cut off line 6 Car axis 3 Horizontal line of head lamp bulb centre 7 Vertical line of right head lamp bulb centre 4 W1 low beam 8 Vertical line of left head lamp bulb centre DESCRIPTION 1 Turn the low beam on without driver aboard 2 The cut off line should be projected in the cut off line shown in the picture 3 When aiming the low beam vertical aiming ...

Page 246: ...es are being operated situations should be avoided where more than 50 of the rear lamps are hidden If this is not possible the rear lamps must be relocated The new situation of the rear lamps in terms of size and visibility must always comply with the provisions of the regulations in force ADJUSTMENT OF FRONT FOG LIGHT BASED ON 10 m SCREEN 1 Ground 5 Upper limit 180 mm 2 Cut off line 6 Car axis 3 ...

Page 247: ...th a closed body The third brake light is snigle and may be located on either the inside or outside of the vehicle It must be placed in the middle of the longitudinal plane of the rear win dow and higher than the two normal brake lights Marker lamps The side marker lamps are used to indicate the presence of the vehicle when viewed from the side In order to increase security European legislation st...

Page 248: ...mps These are lamps intended for the illumination of the vehicle interior in a manner that it does not cause glare or annoy other road users Their use is mandatory in vehicles for passenger service The illumination should be white NOTICE For an optional configuration from factory to facilitate the installation of these lamps HMC should be contacted See General book chapter 2 4 Contact possibilitie...

Page 249: ...unctions of the vehicle body should not affect the vehicle s functions Existing lines should not be moved or used for additional purposes The installation of new communication devices must not hinder access to other vehicle components that need maintenance or occasional repairs Care should be taken not to mount communication systems in the area of impact of the airbags The communication antenna sh...

Page 250: ...cilitating the work and lowering costs See chapter 7 7 3 Electronic control units WARNING The manipulation of or incorrect intervention in electronic equipment may cause them to malfunction In addition due to the interconnection between the different electronic elements of the vehicle a problem in one of them could affect the per formance of other elements which have not been manipulated Some of t...

Page 251: ...ough two way wires bus The information is not directed to a particular control unit but each control unit rec ognises and analyses any information that it needs transmitting a message back to the network The use of this technology allows a significant reduction in both the number of sen sors used and in the number of wires that make up the electrical installation thus greatly increasing the perfor...

Page 252: ...LES 1 Central Gateway Module C C CAN L1 LIN1 PAS Sensor B B CAN L2 LIN2 Wiper Rain Sensor D D CAN M M CAN Abbreviations EMS ENG Engine Management System WMM Wiper Motor Module ACU Airbag Control Unit PAS Parking Assistant System ADM Assistant Door Module FL Front Left Sensor CCM Climate Control Module FCL Front Centre Left Sensor DDM Driver Door Module FCR Front Centre Right Sensor DTG Digital Tac...

Page 253: ...there are different control units distributed throughout the vehicle Table 1 182 TABLE LCV_SPBTC77_002 Location of the main control units in the vehicle LOCATION OF THE MAIN CONTROL UNITS IN THE VEHICLE A Engine ECU K Heat Seat Control Unit B ABS VDC Unit L Trailer Control Unit C SJB Smart JnctionBox M DDM Driver Door Module D Audio AVN N ADM Assist Door Module E ACU Airbag Control Unit O DTG Digi...

Page 254: ...rgency starts as this could damage the electronics system and especially the control units Do not subject the control units to sources of high heat 80 C Do not install heat producing items or equipment in the vicinity of a control unit If for any reason a control unit has to be disassembled an official Hyundai service centre should be contacted to disassemble and subsequently re assemble the contr...

Page 255: ...m knows immediately what kind of slippage is occurring understeer or oversteer and acts by selectively braking individual wheels to reduce the slip and recover the path All this occurs in tenths of a second When making modifications to vehicles equipped as standard with the VDC system we will have to consider the following recommendations and respect the prompts contained in this manual Otherwise ...

Page 256: ...d the amount of light and actively and automatically adjusts the lamps and windshield wipers according to the requirements of the situation The rain sensor is on the windshield surface near the rear view mirror and the light sensor is on the middle of centre fascia near the windshield It can only be installed with original windshields PARKING ASSISTANCE SYSTEM When the space behind the vehicle is ...

Page 257: ...06 Parking Assistance System B type rear sensors NOTICE If the trailer socket is connected the Rear Parking Assistance System does not work START AND STOP SYSTEM The Start Stop system turns off the engine when the vehicle stops at a red light or in a traffic jam and turns it on again automatically when the driver decides to drive on It is only necessary to push the clutch to engage a gear This red...

Page 258: ... system simultaneously and automatically locks all the doors In addition this system is connected to a safety device that automatically unlocks the doors if a serious shock occurs or locks the doors when the car is moving at a certain speed ELECTRIC WINDOWS If the electric windows are changed for others of a different quality weight or colour they must be connected to the original vehicle electric...

Page 259: ...EVENTION WORK ON BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 259 A APPENDIX This chapter provides the following information Drawings Calculations Technical Data ...

Page 260: ...N POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 260 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 A 1 Drawings NOTICE Drawings can be found in Part III of this manual Body Builder Manual Drawings LCV For more information contact the relevant department See General Book chapter 2 4 Contact Possibilities ...

Page 261: ...rd vehicle model with reference to the main elements to be considered when calculating the axle loads centre of gravity Fig 8 186 SPBGA21_001 Distances and loads general Table 1 187 SPBTA22_001 Terms used in calculations DISTANCES LOADS C Clearance between front axle and body TW Total weight of the vehicle BL Exterior body length RF Reaction load in front axle E Distance between body centre and ce...

Page 262: ... of the front or rear axle O is normally taken as a reference point The calculations are performed on the basis of the formulas of static equilibrium The sum of all the strengths acting on a body is equal to zero The sum of the moments and torques exerted to a body around a point is zero Law of the lever In this case as it said the pivot point is the theoretical centre of the front axle O sometime...

Page 263: ...have a standard for every case a sign and units convention has been adopted for all calculations to facilitate the work The distances refer to the centre of the front axle O Positive from the centre of the front axle to the rear of the vehicle Negative from the centre of the front axle to the front of the vehicle Loads and weights in the vertical plane Positive push down on the vehicle Negative pu...

Page 264: ...n be very useful when checking the effect that new equipment installed in the vehicle such as a snow blade a loading crane an aerial platform etc will have on axle load ensuring that it complies with the permissible limits in the standard and this manual An example is given to make it easier to understand the calculation This example examines the impact on the distribution of axle loads when insta...

Page 265: ...of the crane and the loca tion of its centre of gravity Crane weight NE 1 500 kg Crane CoG distance D 4 400 mm Wheelbase WB 3 670 mm Fig 8 189 SPBGA21_003 Weight distributions on the axles Table 1 190 SPBTA22_002 Terms used in calculations Using the equations of static equilibrium Σ MO 0 NE D RR WB Σ F 0 NE RR RF RF NE RR 1 500 1 798 298 kg DISTANCES LOADS WB Wheelbase NE Total weight of the vehic...

Page 266: ...obtained Once this has been done it should be verified that the values obtained do not exceed the maximum permissible axle loads See chapter 2 3 3 Weight distribution A 2 3 Calculating the Centre of Gravity CoG The height of the centre of gravity of the vehicle should be kept as low as possible once the conversion has been carried out The position of the centre of gravity is measured from a refere...

Page 267: ...ater etc are filled to recommended levels The vehicle must be in a horizontal position and on a flat and even surface The vehicle must be secured with wedges It must check that the weighing scales are in good condition and properly cali brated First each axle must be weighed separately and then the complete vehicle in order to check the values obtained The gearbox is to be in neutral With the data...

Page 268: ...calculation Knowing the value of the wheelbase WB and the axle loads obtained by weighing the vehicle LF and LR it is possible to calculate the position in X of the centre of gravity Σ MO 0 TW a LR WB 2 DISTANCES LOADS WB Wheelbase a b TW Total weight of the vehicle a Distance from the centre of grav ity to the front axle LF Reaction load in front axle b Distance from the centre of grav ity to the...

Page 269: ...tion a vehicle should be weighed with an axle raised to height S This height should be as high as possible according to the longitude of the rear and front over hang S 600mm NOTICE In this manual there is an example of calculation with the front axle of the vehicle raised To improve the precision of the data it is also recommended that the vehicle should be weighed with the rear axle raised After ...

Page 270: ...n this calculation DISTANCES LOADS WB Wheelbase a b TW Total weight of the vehicle a Distance from the centre of grav ity to the front axle LF Reaction load in front axle b Distance from the centre of grav ity to the rear axle LR Reaction load in rear axle c Horizontal distance from the front axle to the reference point d Horizontal distance from the centre of gravity to the reference point r Whee...

Page 271: ...f the elevation angle α can easily be obtained as the wheelbase WB is also known Subsequently using the equations of static equilibrium See chapter A 2 1 General concepts and formulas Σ MO 0 LF c TW d 2 Σ MO 0 LF a b TW b cos α hsen α It is also known that 5 α arcsine S WB 6 h TW b LF a b TW tan α 7 H h r NOTICE It is necessary to verify that the data obtained by calculation is within the limits a...

Page 272: ...ription Units D Value of the theoretical horizontal force between the drive vehicle and the trailer kN DC Reduce value of D for rigid drawbar and central axle trailers kN T Technically permissible maximum mass of the drive vehicle ton R Technically permissible maximum mass of the trailer ton C Sum of the axle loads of the centre axle trailer ton U Fifth wheel imposed vertical load ton g Accelerati...

Page 273: ...be calculated Fig 8 196 SPBGA22_006 Calculating the position of the 5th wheel Table 1 197 SPBTA22_005 Terms used in this calculation Using the equations of static equilibrium See chapter A 2 1 General concepts and formulas Σ MO 0 U F LR WB 2 The value U can be obtained using the formula 11 11 D g 0 6 T R kN T R U DISTANCES LOADS WB Wheelbase a b U Max 5th wheel vertical load F Distance from the fr...

Page 274: ... passenger Driver passenger twin compressor Driver Refrigerant Weight of volume 700 1 15 2 100 700 1400 700 Classification R134a Compressor lubricant Weight of volume 130 270 Driver 130 Passenger 270 130 Classification PAG oil LIGHT BULB WATTAGE W MFR Projection Headlights low high 55 Front fog lights 35 Front turn signal lights 21 21 Front position lights 5 LED DLR lights 21 LED Side repeater LED...

Page 275: ...5 C above SAE 10W 30 40 20 C above SAE 5W 30 40 25 C above Engine oil consumption Normal driving condition max 1 0 l 1 500 km _ _ Severe driving condition max 1 0 l 1 000 km _ _ Manual transmission oil with PTO 3 5 l 3 7 US qt API GL 4 SAE 75W85 synthetic w o PTO 3 2 l 3 38 US qt Rear axle oil Tropical zone 2 5 0 25 l 2 64 0 26 US qt API GL 5 SAE 140 Temperate frigid zone 2 5 0 25 l 2 64 0 26 US q...

Page 276: ...ual Part II Specific Book LCV V1 0 February 2015 Table 1 201 LCV_SPBTA3_005 Recommended engine oil Europe Table 1 202 LCV_SPBTA3_006 Temperature range for SAE viscosity AVAILABLE ENGINE OIL EUROPE Engine Supplier Product Diesel Shell HELIX ULTRA AP 5W 30 TEMPERATURE RANGE FOR SAE VISCOSITY Temperature C 30 20 10 0 10 20 30 40 50 F 10 0 20 40 60 80 100 120 Diesel Engine Oil 15W 40 10W 30 40 5W 30 4...

Page 277: ... II Specific Book LCV 277 A 3 4 Engine features Table 1 203 LCV_SPBTA3_007 Engine specification Engine full load graph 170 hp engine full load graph VGT Euro 6 Fig 8 204 SPBGA33_001 150 hp engine full load graph VGT Euro 6 Fig 8 205 SPBGA33_002 ENGINE SPECIFICATIONS Item D4CB Note Displacement cm3 in3 2 493 152 38 TCI EEGR Common rail 2 000 bar bore x stroke mm in 91 x 96 3 58 x 3 77 Firing order ...

Page 278: ...IC SYSTEMS APPENDIX 278 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 Power and torque graphics Table 1 206 LCV_SPBTA3_008 Power and torque 150 hp engine D4CB E5 Table 1 207 LCV_SPBTA3_009 Power and torque 170hp engine D4CB E5 VAN TRUCK 150 HP ENGINE SPECIFICATION Power and torque D4CB E5 VAN TRUCK 170 HP ENGINE SPECIFICATION Power and torque D4CB E5 ...

Page 279: ... ON BASIC VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX V1 0 February 2015 Body Builder Manual Part II Specific Book LCV 279 Table 1 208 LCV_SPBTA3_010 Power and torque 170 hp engine D4CB E6 BUS 170 HP ENGINE SPECIFICATION Power and torque D4CB E6 ...

Page 280: ...C VEHICLE MOUNTING AND CONSTRUCTION POWER TAKE OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX 280 Body Builder Manual Part II Specific Book LCV V1 0 February 2015 A 3 5 PTO information NOTICE More information about PTO can be found by contacting HMC see General Book chapter 2 4 Contact Possibilities ...

Page 281: ...49 brake fluid 275 brake lamps 247 brake system modifications 102 C cab modification 69 cutting areas 71 cable cross section 217 calculation axle load 264 centre of gravity 266 centre of gravity x coordinate 268 centre of gravity z coordinate 269 centre of the front rear axle 262 convention of units 263 coupling device 272 general concepts and formulas 261 position of the 5th wheel 273 CAN bus 142...

Page 282: ...89 297 EC 125 126 91 226 EEC 128 94 20 EC 97 100 96 53 EC 22 43 97 27 EC 43 exhaust system 110 F fifth wheel 175 floor 81 front axle minimum load 27 fuel capacity 275 fuel system fuel level sensor 119 fuel system alternative 121 fuel sytem fuel tank 120 fuel driven heater 119 fuse 217 218 fuse box 224 fuse capacity 217 fuse size 218 fuses protection 233 H headlamp 241 headlamp adjustment 241 hydra...

Page 283: ...y belts 89 SCR technology 114 seats additional 90 Selective Catalytic Reduction SCR 114 semi trailer tractor 174 signalling lamps 241 snow plough device 138 soundproofing 109 spare wheel 127 special equipment 20 standard CISPR 12 213 CISPR 21 213 CISPR 25 213 DIN EN 55012 213 DIN EN 55025 213 DIN ISO 11446 229 EN 1756 1 184 ISO 10605 213 ISO 11451 213 ISO 11452 213 ISO 16750 250 ISO 22241 1 116 IS...

Page 284: ...e dynamic control system 33 vehicle identification number 19 vehicle main dimensions 23 vehicle overhang 37 ventilation system 89 W weighing 29 weight distribution 61 weld works correct distances between weld spots 54 correct distances of weld spots to edges and holes 53 faulty weld seams 51 plate thickness 53 welding work 50 wheel clearance 40 wheel dimensions 39 wheel well 40 41 77 clearances 78...

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