Iveco DAILY 4x4 2020 Body Builder Instructions Download

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– Printed 692.68.999 – 3 Ed. - Base 08/2020

SECTION 1

GENERAL

INFORMATION

Summary of Contents for DAILY 4x4 2020

Page 1: ...L I G H T R A N G E B O D Y B U I L D E R S I N S T R U C T I O N S I S S U E 0 8 2 0 2 0 4 x 4...

Page 2: ...IVECO S p A TECH PE T H BODY BUILDER SUPPORT Lungo Stura Lazio 49 10156 Torino TO Italy www iveco com Printed 692 68 999 3rd Ed 08 2020 Images and text IVECO S p A 2020 All rights reserved...

Page 3: ...Printed 692 68 999 3 Ed Base 08 2020 UPDATE DATA Section Chapter Description Revision date...

Page 4: ...ich you are about to work ensure that all the safety devices goggles helmet gloves shoes etc as well as the equipment used for work lifting and trans port is available and working ensure that the vehi...

Page 5: ...692 68 999 3 Ed Base 08 2020 GENERAL INFORMATION 1 CHASSIS INTERVENTIONS 2 APPLICATIONS OF SUPERSTRUCTURES 3 POWER TAKE OFFS 4 ELECTRONIC SUB SYSTEMS 5 ADBLUE AND SCRT SYSTEM 6 EXPANSION MODULE 7 Hi...

Page 6: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 7: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 1 GENERAL INFORMATION...

Page 8: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 9: ...ENT ON THE PART OF BODYBUILDER 9 1 12 1 Chassis acceptance 9 1 12 2 Maintenance 9 1 12 3 Delivery of the vehicle to the end customer 9 1 13 VEHICLE NAMES 10 Type approval name 10 1 14 IDENTIFICATIONS...

Page 10: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION Printed 692 68 999 3 Ed Base 08 2020...

Page 11: ...th these Guidelines are not covered by the guarantee on the chassis or relative mechanical units 1 2 TECHNICAL DOCUMENTATION AVAILABLE ELECTRONICALLY The following technical documentation is available...

Page 12: ...iod of at least 10 years from the last fitting of an order 1 6 LEGISLATIVE REQUIREMENTS The bodybuilder must verify that the final product is compliant without exception to all applicable legal requir...

Page 13: ...to a technical service for evaluation appropriate documentation of the changes made in order to give objective evidence of compliance to the aforemen tioned provisions of law e g approval documents t...

Page 14: ...n and with safety regulations required in the individual countries where the vehicles are used All precautions dictated by technical knowledge must be taken to avoid damage and functional defects Comp...

Page 15: ...alibrate its production vehicle and or equipment and verify functionality and safety for items which will be subjected to the intervention carry out the controls set out in the Pre Delivery Inspection...

Page 16: ...CC W DAILY Vehicle name 70 Gross mass GVW no 10 weight in t 35 3 5 t 55 5 5 t 70 7 0 t C Rear wheels S Single rear wheels C Twin rear wheels 18 Engine power no x 10 power in HP 15 146 HP 18 180 HP H...

Page 17: ...litatively in the following figure 222674 Figure 2 1 Front view 2 Side view a Bonnet lower edge For the actual measurements and for the realization of a possible template please consult the design 580...

Page 18: ...of the individual components of the vehicle are shown on the chassis and weight allocation diagram 261809 Figure 3 W Payload plus superstructure W1 Measurement of payload on front axle W2 Measurement...

Page 19: ...s cab version and no load vehicle the value of the height of the centre of gravity is shown on the specific technical documentation for each model chassis cab version diagram For the vehicle complete...

Page 20: ...ways stability of the vehicle Table 1 1 Tyres 225 75 R16 twin wheels 265 70 R19 5 single wheel 255 100 R16 T G W kg 7000 7000 5500 Max mass on front axle kg 2700 2700 2450 Max mass on rear axle kg 500...

Page 21: ...hind the cab for example cranes or of superstructures with high rigidity for example vans 1 15 7 Observance of the permitted masses All the limits shown on IVECO documentation must be respected It is...

Page 22: ...attery replace ment access to the air suspension compressor and in the case of enclosed superstructures special compartments and doors should be provided the possibility of disassembling the various g...

Page 23: ...tion if fitting in a posi tion other than the original position 257753 Figure 7 1 Isolating shielding Particular attention must be paid to prevent the spillage of hydraulic fluids or inflammable liqui...

Page 24: ...18 DAILY 4x4 GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION Printed 692 68 999 3 Ed Base 08 2020...

Page 25: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 2 CHASSIS INTERVENTIONS...

Page 26: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 27: ...LLING THE TOW HOOK 19 2 6 1 General information 19 2 6 2 Precautions for installation 20 2 6 3 Tow hook for trailers with central axle 22 2 6 4 Observations on payload 24 2 6 5 Increase of towable wei...

Page 28: ...AND ANCHORAGE OF ADDITIONAL UNITS AND EQUIPMENT 41 2 17 1 Horn 41 2 17 2 Wheel mount 41 2 17 3 Fuel tank 41 2 18 TRANSPORT OF HAZARDOUS MATERIALS ADR 42 2 19 INSTALLING A RETARDER 42 2 20 REAR UNDER R...

Page 29: ...M14 may not be used maximum hole diameter of 15 mm unless otherwise specified for cases where unions that require screws are restored the suitability of these screws must be checked before being re us...

Page 30: ...onnection For further details on the connections to ground see the Chapter 5 4 Braking and electrical systems For additional details on the braking and electrical systems see Chapters 2 15 Page 36 and...

Page 31: ...er flaps with exception to what is indic ated in Chapter 3 3 Paragraph Choosing the type of connection When new holes must be made for specific applications installation of shelves corner shelves etc...

Page 32: ...rew treatment allowed is Geomet or zinc coating Geomet treated screws are discouraged when using them in welding opera tions Use flange headed screws and nuts if there is sufficient space Use nuts wit...

Page 33: ...formed nearby avoid touching the spring leafs with the electrodes or pliers Weld operations Cut the side members with a skewed or vertical cut Cuts are not permitted in areas where there are a high co...

Page 34: ...7021 70 80 gloss 2 3 1 Original vehicle components The following tables show respectively the classes of coating and protection required for the original vehicle components the protections required f...

Page 35: ...er materials must not cause the battery effect 2 Coatings free from chromium salts 3 Coatings free of hexavalent chromium Table 2 6 Painted parts IVECO Standard 18 1600 Prospectus III Cycle phase desc...

Page 36: ...nt etc that are add ons or subjected to modifications must be protected against oxidation and corrosion Areas free of protection on ferrous materials are not accepted Tables 2 7 and 2 8 indicate the m...

Page 37: ...aces on the hubs and the contact areas of the locking lugs wheel studs ensure adequate protection of brake discs The electronic components and modules must be removed b On engines and their electric a...

Page 38: ...ened does not differ from a standard side member taken as reference or it differs is lower by just one step of the value see Table 2 2 number type and position of the cross members the existing circui...

Page 39: ...2450 3700 3080 70C Quad Tor 2700 5000 3080 Quad Tor torsion bar 2 4 5 Intervention procedure Proceed as follows to obtain good results position the vehicle so that the chassis is perfectly horizontal...

Page 40: ...es must not be greater than those or the original wheelbase frame assuming an evenly distributed load and considering the frame as a beam positioned in place of the suspension supports When an elongat...

Page 41: ...odifications allowed 2 5 REAR OVERHANG MODIFICATION 2 5 1 General information When modifying the rear overhang it is necessary to note the variations that this modification shall inflict on the payloa...

Page 42: ...e last crossbar must be moved forward when shortening the rear overhang of the frame When the rear crossbar is too close to another crossbar the latter can be eliminated if it plays no role in suspens...

Page 43: ...e than 1200 mm apart 2 6 INSTALLING THE TOW HOOK 2 6 1 General information Conversion from non trailer version to type approved trailer version is allowed without requiring specific authorisation from...

Page 44: ...addition to the requirements of the hook manufacturer it is necessary to respect the limitations imposed by the Regulations on clearances required for the coupling of the brakes and electrical system...

Page 45: ...cases where the connection flange of the drawbar coupling does not have holes suitable to those on the existing rear crossbar of the vehicle the latter may be authorised for modification upon applicat...

Page 46: ...a central axle refer to the following formulas DC g T C T C V a C X2 L2 DC representative value of tow hook class kN This is defined as the determination of the theoretical reference value for hori zo...

Page 47: ...08 2020 279565 Figure 11 As original equipment the DAILY 4x4 vehicles may be equipped ball hook or mixed type tow hook i e ball type with safety device These hooks may only be installed on the rear cl...

Page 48: ...load allowed on the rear axle of the vehicle Furthermore the minimum weight on the front axle must be respected as indicated in Chapter 1 15 2 6 5 Increase of towable weight As regards tow vehicles IV...

Page 49: ...on each modified section Given that the driveline is an important part of the vehicle in terms of safety any modifications made must meet the requirements of the maximum safety standards Therefore mod...

Page 50: ...inal intake vacuum and exhaust back pressure values 2 10 1 Intake The air intake must be mounted as to avoid intake of hot air from the engine compartment or dust and water The intake compartment must...

Page 51: ...mise complete filling of the circuit done with a steady flow and without any backflow from the intake until the circuit is filled and regular water flow in addition these modifications must not alter...

Page 52: ...of the vehicle route piping and wiring layout and installation of brackets and flexible fittings in relation to the spaces available and the influ ence of heat on the chassis parts Avoid any exposed p...

Page 53: ...TING CONDITIONING PLANT 29 Printed 692 68 999 3 Ed Base 08 2020 204649 Figure 14 1 Main heater 2 Optional additional heater 3 Solenoid valve 4 Additional heater installed by body builder A Solenoid va...

Page 54: ...th the engine radiator but in a specific and suitably ventilated bay unless a condenser is used that is equivalent in shape and performance to the standard model envisaged by IVECO installation of the...

Page 55: ...er 1 15 As regards operations that entail the removal of internal sound barriers or protective panels panelling cladding be sure to re move only the minimum amount possible restore the protections as...

Page 56: ...s If kits of other origins are fitted follow the specific indications supplied by the manufacturer In any case please note that the possible lack of contact between the superstructure and roof may tri...

Page 57: ...TIONS 2 13 BODYWORK INTERVENTIONS 33 Printed 692 68 999 3 Ed Base 08 2020 228310 Figure 16 1 Roof panel 2 Cutting limit area 3 Side finishing of roof 4 Door support ring 5 Internal rear cross member 6...

Page 58: ...ions to the steering column replacements or installations of seats a different H point compared to the original versions Note Since the configuration of the electronic safety devices of the vehicles m...

Page 59: ...nce speed must be suitable for the maximum performance levels of the vehicle Subsequently if tyres with a lower index than the type approved ones are used the loads permitted on the axles must be redu...

Page 60: ...eel mounting Stud M18x1 5 II 335 410 S Characteristic S safety tightening see IVECO std 19 0405 If using brackets to mount aesthetic studs positioned between the rim lug or stud or if using rims thick...

Page 61: ...n order to avoid imperfections that affect the sealing Permanently mark the section of pipe dimension L in Figure 18 to be inserted into the coupling to ensure secure sealing Mark the pipe to avoid as...

Page 62: ...he plastic pipes it is necessary to take care of the line and the accommodation of the fastening elements rubbing should be avoided with the fixed parts of the vehicle and meet the necessary safety di...

Page 63: ...f the ESP control unit or Body Computer the following parameters are important vehicle configuration van truck camper wheelbase GVW type of suspension type of gearbox transmission wheel circumference...

Page 64: ...patible with the presence of the ESP system In the event of compatibility system management software must be reprogrammed in all other cases Derating is compulsory except as indicated in Attachment XI...

Page 65: ...approval Also in the new position the device must ensure the acoustic performance set by the regulations and must be adequately protected from exposure of weathering and or soiling IVECO reserves the...

Page 66: ...requirements by the additional structures and their connections to incomplete vehicles is the full respons ibility of the bodybuilder 2 19 INSTALLING A RETARDER Application not provided 2 20 REAR UNDE...

Page 67: ...on limit values can be requested via the Support Service the width of the mudguard must be greater than the maximum dimensions occupied by the tyres within the limits set by the regulations the suppo...

Page 68: ...e use the existing holes on the vertical rib of the side member as much as possible in compliance with Chapter 2 2 Page 7 In the construction of the external protective element in accordance with Regu...

Page 69: ...AILY 4x4 GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2 24 REARVIEW MIRRORS 45 Printed 692 68 999 3 Ed Base 08 2020 279568 Figure 21 The distances differ between the left and right rearview mirro...

Page 70: ...46 DAILY 4x4 GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS Printed 692 68 999 3 Ed Base 08 2020...

Page 71: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 3 APPLICATIONS OF SUPERSTRUCTURES...

Page 72: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 73: ...tres of gravity 13 3 4 2 Fixed bodies 13 3 4 3 Creation of van versions 14 3 4 4 Tipping bodies 15 3 5 TRACTOR FOR SEMI TRAILER 16 3 6 TRANSPORT OF INSEPARABLE MATERIALS TRAILER TRUCKS 16 3 7 INSTALLA...

Page 74: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES Printed 692 68 999 3 Ed Base 08 2020...

Page 75: ...assis Following are the characteristics of certain materials which were taken into account in some of the applications stated below Table 3 1 Material to be used for the construction of superstructure...

Page 76: ...flexural hardness and for the quota of the bending moment to be taken depending on the connection used 3 1 3 Aluminium subframe When using materials with different characteristics from those of steel...

Page 77: ...ends of the profile must be tapered in height with an angle not exceeding 30 or another form of equivalent tapering see Figure 2 the front end in contact with the chassis must be properly coupled wit...

Page 78: ...be restored by means of interposition of strips of sheet metal or light alloy If there is to be a rubber undercrawl element we recommend characteristics and thicknesses similar to those used for norma...

Page 79: ...tion suitable gusset plates as in the figure must be used to give adequate resistance to the connection see the fol lowing Figure on the left When you want to achieve greater stiffness in the connecti...

Page 80: ...10 DAILY 4x4 GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3 2 ELEMENTS MAKING UP THE SUBFRAME Printed 692 68 999 3 Ed Base 08 2020 261817 Figure 5 261818 Figure 6...

Page 81: ...approx 250 350 mm from the front end of the subframe especially in the case of su perstructures with concentrated loads behind the cab e g crane body tilting cylinder etc This is to limit the magnitud...

Page 82: ...ville washers 2 or helical springs 3 should be used 256971 Figure 8 1 Rubber block 2 Belleville washers 3 Coil spring Bear closely in mind that the elastic element characteristics should be suited to...

Page 83: ...are shown in Table 3 3 Table 3 3 Models Minimum reinforcing profile Wheelbase mm Section modulus WX cm3 All 3080 3480 3780 4175 21 Note For the dimensions of the profiles see Table 3 2 Fastening is ac...

Page 84: ...rt and connected in such a way as to create a suffi ciently rigid structure self supporting it may not be necessary to use longitudinal profiles The front wall of the van box must have the necessary s...

Page 85: ...ger than normal and additional reinforcement must be applied to the rear 4 Particular attention must be paid to the positioning of the lifting device both in terms of providing supports with adequate...

Page 86: ...228303 Figure 11 1 Subframe 2 Brackets 3 Plates 4 Retainer with hinge Table 3 4 Models Minimum reinforcing profile Section modulus WX cm3 Dimensions mm All 36 100x60x6 Note For the dimensions of the s...

Page 87: ...icient and gradual flexibility of the chassis in order to avoid high stress areas The use of flexible parts is recommended for the connections between the cistern body and the subframe see Figure 12 i...

Page 88: ...t be authorised by IVECO 208921 Figure 13 The maximum volume the degree of filling of the container and the volumetric mass of the transported goods must be defined in observance of the axle weight li...

Page 89: ...The dimensions of the subframe section modulus refer to the maximum total static moment of the crane MG deduced from the formula shown in Figure 14 If the vehicle outfitting requires the use of a sect...

Page 90: ...g profile 2 Brackets 3 Crane connections 4 Stabilisers In installations of cranes on vehicles with deep cab e g 6 1 the subframe must continue to underneath the cab see Figure 3 otherwise depending on...

Page 91: ...sections must be well fitted as shown in Figure 4 Shear resistant connections a sufficient number of plates spaced at a maximum distance of 400 mm must be used in the box section for fastening to the...

Page 92: ...a trailer all regulations concerning the proper coupling of the vehicle must be observed 3 9 INSTALLATION OF TAIL LIFTS Note The installation of tail lifts must be carried out with due regard for the...

Page 93: ...defined Table 3 9 Installation of tail lifts see Figure 17 Wheelbase mm Tail lift capacity in kN kg 3 300 5 500 7 5 750 10 1000 12 5 1250 15 1500 Minimum value of the section modulus of the subframe...

Page 94: ...ure 17 To compensate for frame flexing which is inevitable when the tail lift is in operation the bodybuilder may use reinforcement struc tures with larger dimensions than those indicated in Table 3 9...

Page 95: ...ad the lifting device is placed forwards of the centre of gravity of the payload body assembly The Bodybuilder must equip the vehicle appropriately to ensure stability during tipping operations All eq...

Page 96: ...ob servance of the maximum permitted axle limits and following the instructions of the winch manufacturer Securing the assembly must be carried out in full compliance with Chapters 2 1 and 2 2 ensurin...

Page 97: ...oviding suitable directions Special attention must be given to the construction of compartments for gas cylinders which must be built in compliance with spe cific regulations in force and adopting the...

Page 98: ...ore Define the type and number of stabilizers provide vehicle lifting lowering speed control on the stabilizers through appropriate flow control valves in the hydraulic sys tem limit as much as possib...

Page 99: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 4 POWER TAKE OFFS...

Page 100: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 101: ...AL INFORMATION 5 4 1 1 Type of use 5 4 1 2 PTO transmissions 6 4 2 POWER TAKE OFF ON THE GEARBOX 7 4 3 POWER TAKE OFF FROM TRANSFER BOX 7 4 4 POWER TAKE OFF FROM DRIVE LINE 8 4 5 POWER TAKE OFF FROM E...

Page 102: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS POWER TAKE OFFS Printed 692 68 999 3 Ed Base 08 2020...

Page 103: ...um torque take off values refer to continuous usage of up to 60 seconds Torque take off values exceeding the maximum values indicated for occasional limited usage less than 30 s must be approved on a...

Page 104: ...to ensure effective kinetic forces the shaft ends must be at the same angle see Figure 1 and this angle must not exceed 7 solution Z is preferred to solution W due to the lower loads on the bearings...

Page 105: ...8 999 3 Ed Base 08 2020 4 2 POWER TAKE OFF ON THE GEARBOX Not applicable on Daily 4x4 4 3 POWER TAKE OFF FROM TRANSFER BOX For the installation of a PTO on the transfer box IVECO provides for the adop...

Page 106: ...he conditions of use NB the user is responsible for carrying out this check Subsequently use of 6th gear is not possible 7th and 8th in the case of automatic gearboxes due to the high multiplication e...

Page 107: ...0 rpm for each second of continuous activation of the lever beyond 2 seconds It is possible to store a new speed with PTO on by pressing and holding the RESUME button for at least 5 seconds With Cruis...

Page 108: ...10 DAILY 4x4 GUIDELINES FOR BODYBUILDERS POWER TAKE OFFS Printed 692 68 999 3 Ed Base 08 2020...

Page 109: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 5 ELECTRONIC SUB SYSTEMS...

Page 110: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 111: ...ne start up 19 5 4 5 Ground points 19 5 4 6 Electromagnetic compatibility 26 5 5 RECEIVER TRANSMISSION SYSTEMS 28 General instructions 28 5 5 1 Amateur equipment for CB 27 MHz and 2 m band 144 MHz 29...

Page 112: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB SYSTEMS Printed 692 68 999 3 Ed Base 08 2020...

Page 113: ...ed to connect devices or electrical circuits directly to the control units Only the connectors listed in Chapter 5 2 may be used 5 1 1 Location of control units 262151 Figure 1 A Instrument panel B St...

Page 114: ...validity of the warranty to be preserved As standard there is a connector 72105A interfaced with the dashboard cable of the cab and accessible after having removed the panel of the passenger side stor...

Page 115: ...om 1 50 2 00 2 50 mm 41200697 EZ Male contact for cable 2 50 4 00 mm 5802291206 EZ Male contact for 0 35 mm cable from 5 to 18 5802290575 EZ Male contact for 0 50 to 0 75 mm cable 5802290577 EZ Male c...

Page 116: ...Max 100 mA use a decoupling diode BCM C 17 12 V reverse gear engaged 4 11 Positive with key 8879 Output Max 200 mA BCM G 12 Positive with key protected by fuse on Body Computer F49 12 Cruise Control...

Page 117: ...r no current draw is possible 2 Vehicle equipped with Hi Matic gearbox without trailer maximum current draw 7 5 A 3 Vehicle equipped with manual gearbox with trailer maximum current draw 7 5 A 4 Vehic...

Page 118: ...n the Hi MATIC version refer to the indications provided in Annex C Page 8 5 Only supported with Cruise Control option The resistors must be connected between pin 12 and pin 13 Different functions may...

Page 119: ...r to OFF otherwise the external controls will be ignored Table 5 3 Function Short cut necessary CC Resume Pin 2 Pin 6 CC Set Pin 2 Pin 8 CC Set Pin 2 Pin 5 CC ON Pin 2 Pin 4 6 Should you wish to chang...

Page 120: ...r The resistor must be inserted between 72105A Pin 16 and 72105A Pin 11 Without the pull up resistor no B7 signal is available 262159 Figure 8 1 Outfitting 2 Connector 72105A The B7 output supplies th...

Page 121: ...al is a square wave The characteristics of the rpm signal are 4 pulses for each revolution of the crankshaft frequency field 0 400 Hz corresponding to 0 6000 rpm duty cycle fixed at 50 Table 5 5 Chara...

Page 122: ...age LOW level R_ON output resistor ON E_Clamp energy at the output terminals V_Out_Clamp voltage at the output terminals R_Load Diag Maximum diagnosable load resistance t_Fall signal fall time from 90...

Page 123: ...n the steering wheel lever The Cruise Control option must be configured on both the ECM and BCM systems Please note that the driver must position the Cruise Control switch on the steering wheel lever...

Page 124: ...ronic systems par ticularly the control units that manage the ignition and power supply functions do not supply current to components served by electronic modules with jumper cables connect the contro...

Page 125: ...o the original one i e suitable bracket The device must not be rotated in relation to the chassis so as to avoid potential malfunctions e g infiltration of water Therefore the original positioning mus...

Page 126: ...g for the type of load and the position of the load in the vehicle The power cables direct must be individually intubated in conduits of suitable diameter and not together with other different cables...

Page 127: ...inal system after any operations 5 4 4 Engine start up If the engine fails to start because of the battery and not because of problems with the electrical system do not try to start the engine by towi...

Page 128: ...al ground on fire guard M4 Power engine compartment ground near front right head light M5 Power engine compartment ground near front left head light M6 Power ground in the cab wall below dashboard MS6...

Page 129: ...INES FOR BODYBUILDERS ELECTRONIC SUB SYSTEMS 5 4 ELECTRICAL SYSTEM 21 Printed 692 68 999 3 Ed Base 08 2020 243714 Figure 15 M1 Power ground in battery compartment 262235 Figure 16 M2 Power ground on l...

Page 130: ...TRONIC SUB SYSTEMS 5 4 ELECTRICAL SYSTEM Printed 692 68 999 3 Ed Base 08 2020 243716 Figure 17 M3 MS3 Signal power ground on fire guard M9 Power ground on fire guard 243717 Figure 18 M4 Power engine c...

Page 131: ...M5 Power engine compartment ground near front left head light M10 Power engine compartment ground near front left head light 243719 Figure 20 M6 Power ground in the cab wall below dashboard MS6 Signa...

Page 132: ...R BODYBUILDERS ELECTRONIC SUB SYSTEMS 5 4 ELECTRICAL SYSTEM Printed 692 68 999 3 Ed Base 08 2020 208945 Figure 21 M8 Power ground in the cab on the side panels 262232 Figure 22 MS8 Signal ground in th...

Page 133: ...ol units must be connected to the system ground when equipped with metal housings the negative cables of the electronic control units are to be connected to a system ground point connected to the nega...

Page 134: ...rial must be 50 V m immunity for devices performing secondary functions not impacting on direct vehicle control for frequencies vary ing from 20 MHz to 2 GHz 100 V m immunity for devices primary secon...

Page 135: ...44 50 radiated Narrow band peak 41 34 34 34 24 30 24 31 37 conduit LISN 50 5 H 0 11 F Broad band almost peak 80 66 52 52 36 36 Not ap plicable dB V conduit Broad band peak 93 79 65 65 49 49 conduit N...

Page 136: ...see Figure 29 in order to avoid interference and malfunctioning create a path the shortest possible which maintains a suitable dis tance min 50 mm from pre existing cabling or from other cables radio...

Page 137: ...ROS value Stationary Wave Ratio must be as close as possible to the unit the recommended value is 1 5 while the maximum acceptable value must never be greater than 2 The AERIAL GAIN values must be as...

Page 138: ...the steering wheel ceiling fixture with microphone USB socket wiring 208938 Figure 30 1 Buttons on the steering wheel 2 USB port For cowl version vehicles the ceiling fixture with microphone is provi...

Page 139: ...2 68 999 3 Ed Base 08 2020 208947 Figure 31 1 Bluetooth microphone 208949 Figure 32 1 Driver s side 2 Passenger side Table 5 9 Pin Description Cable 1 Ground White 2 Signal Vcc Shielded The connector...

Page 140: ...nce the quality and performance of the receiver The following should therefore be guaranteed an absolute minimum angle of vision of the sky of 90 a distance no less than 30 cm from any other antenna a...

Page 141: ...ers additional heaters power take offs air conditioners automatic gearboxes telematics and speed limiters please contact IVECO in order to establish the compatibility checks The use of non approved tr...

Page 142: ...ded in Chapter 5 4 Page 17 Paragraph Precautions for interventions on the system 262157 Figure 34 1 CBA2 2 Cable path between cab and engine compartment see Figure 38 3 Bodybuilders connector inside c...

Page 143: ...oint protected by fuse FG Fuses FF and FG have a flow rate of 30 A each If necessary they can be replaced with ones of a higher capacity respecting the indication of a maximum total current draw sum o...

Page 144: ...upply SCM and bodybuilders 3 500 Starter and Retarder 4 80 Body Computer power supply 5 TGC opt b Fuses on the CBA2 control unit 209812 Figure 37 Table 5 11 List of fuses on CBA2 Location Amperage A D...

Page 145: ...ed protections from shock heat rubbing with other components in particular with the sharp edges of the bodywork secured separately with insulated cable clamps e g nylon and at suitable intervals appro...

Page 146: ...the signal transmission cables e g ABS for which preferential routing has been provided in order to meet electromagnetic requirements EMI It should be noted that when grouping several cables together...

Page 147: ...Pre installation for trailer If the repetition of rear lights is necessary the vehicle must be fitted with the 13 pin trailer socket Do not hook up directly to the vehicle s light cables This results...

Page 148: ...4x4 GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB SYSTEMS 5 8 MISCELLANEOUS Printed 692 68 999 3 Ed Base 08 2020 262155 Figure 41 1 Trailer electronic control unit 2 Support bracket 3 Guard 4 Chassis sid...

Page 149: ...socket 5 Tail lights Note The graphic is for illustration purposes only 209815 Figure 43 1 Connector 86046_1 to connect to connector 1 OUT of trailer control unit 2 Connector to connect to chassis cab...

Page 150: ...t 2 Pin 12 could be absent as it may have been replaced by a switch integrated in the socket in this case it is not necessary to perform any connection on the trailer 13 Ground 0000 The electrical con...

Page 151: ...rrent A Connected to Remarks 1 Ground 0000 2 5 ST43 1 Ground for left and right side clearance lights 2 Vehicle left side clearance lights 3390 1 25 ST43 2 12 V vehicle left side clearance lights on n...

Page 152: ...eversing warning sound which is activated when the vehicle is reversing This safety device may be originally requested as opt 7638 regardless of the type of gearbox used Application is recommended ins...

Page 153: ...Computer and a peripheral system This system consists of a key with remote control buttons for distance locking unlocking actuators for closing the cab doors and sliding side doors in the case of a va...

Page 154: ...BODYBUILDERS ELECTRONIC SUB SYSTEMS 5 8 MISCELLANEOUS Printed 692 68 999 3 Ed Base 08 2020 271321 Figure 47 1 Bonnet open sensor 2 Engine bonnet socket 3 Alarm siren For the operation mode refer to th...

Page 155: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 6 ADBLUE AND SCRT SYSTEM...

Page 156: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 157: ...ted 692 68 999 3 Ed Base 08 2020 Contents 6 1 GENERAL INFORMATION 5 6 2 THE NITROGEN OXIDE CATALYTIC REDUCTION PRINCIPLE 5 6 2 1 Main components of the SCRT system 5 6 3 INSTRUCTIONS 6 6 3 1 AdBlue ta...

Page 158: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS ADBLUE AND SCRT SYSTEM Printed 692 68 999 3 Ed Base 08 2020...

Page 159: ...a dedicated tank by means of a SM Supply Module pumping module to a DM Dosing Module which injects AdBlue into the exhaust pipe The mixture of exhaust gas and additive is then fed into the catalytic...

Page 160: ...DM and the AdBlue pipe bundle may only be removed just before assembly the SM and DM fittings must be handled with care to ensure they are not broken during the operations the screws securing the DM...

Page 161: ...AdBlue corresponding to the maximum reading of the level sensor with re spect to the tank total volume so as to guarantee enough room for AdBlue to expand during freezing at temperatures below 11 C 6...

Page 162: ...CRT SYSTEM 6 4 MOVING ADBLUE SYSTEM COMPONENTS Printed 692 68 999 3 Ed Base 08 2020 208932 Figure 3 1 SCR catalytic converter 2 Pumping module SM 3 AdBlue tank 4 AdBlue refuelling inlet 5 AdBlue deliv...

Page 163: ...Printed 692 68 999 3 Ed Base 08 2020 SECTION 7 EXPANSION MODULE...

Page 164: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 165: ...Contents 3 Printed 692 68 999 3 Ed Base 08 2020 Contents 7 1 GENERAL INFORMATION 5 7 2 WIRING DIAGRAM 5 7 2 1 20 way EM connector black 61071B 6 7 2 2 12 way EM connector black 72075B 8 7 2 3 9 way E...

Page 166: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS EXPANSION MODULE Printed 692 68 999 3 Ed Base 08 2020...

Page 167: ...under the dashboard on the passenger side 261815 Figure 1 7 2 WIRING DIAGRAM To ensure the functional integrity of the electrical system IVECO has pre installed specific connection points to be used...

Page 168: ...n indicator not activated 3 Left stop light 9132 Output 1 5 A EM X1 4 1 12 V stop light activated No signal stop light not activated 4 Left turn indicator light 6986 Output 1 5 A EM X1 8 1 12 V turn i...

Page 169: ...no action 19 Spare 5983 EM X4 29 20 Run Lock relay 6987 Output 1 A EM X4 1 Possible reconfiguration via Customer Service CS 12 V RunLock activated No signal RunLock not activated 1 Activation require...

Page 170: ...ce If enabled the PTO ISC stored speed is not available 12 V low beams activated No signal low beams not activated 2 Left low beam light relay 6989 Output 1 A EM X4 3 To be enabled via TeleService If...

Page 171: ...or yellow 72071 197421 Figure 4 Existing part on vehicle male Counterpart to be coupled female This connector is only present in the case of EM installation with CAN open opt 75979 Table 7 9 Code Desc...

Page 172: ...NAL FUNCTIONS The Expansion Module can make additional functions available 1 Run Lock ignition key removal with the vehicle stationary without the engine being stopped or electrical power supplies bei...

Page 173: ...Printed 692 68 999 3 Ed Base 08 2020 APPENDIX C Hi MATIC AUTOMATIC GEARBOX...

Page 174: ...Printed 692 68 999 3 Ed Base 08 2020...

Page 175: ...999 3 Ed Base 08 2020 Contents C 1 GENERAL INFORMATION 5 C 2 LAYOUT 5 C 3 REQUIREMENTS 6 C 3 1 Gearbox release lever 6 C 3 2 Bowden cable 6 C 3 3 Propeller shaft 7 C 3 4 Rear cross member 7 C 3 5 Coo...

Page 176: ...4 DAILY 4x4 GUIDELINES FOR BODYBUILDERS Hi MATIC AUTOMATIC GEARBOX Printed 692 68 999 3 Ed Base 08 2020...

Page 177: ...he indications that must be followed before outfitting commences See the Bodybuilders Manual on vehicles equipped with mechanical gearbox for other information C 2 LAYOUT 261977 Figure 1 Some essentia...

Page 178: ...ompulsorily remains inside the cab is accessible from the drivers seat does not entail great variation of the connected Bowden cable route C 3 2 Bowden cable 210250 Figure 3 In order to maintain effic...

Page 179: ...volve changes in one or more of these characteristics e g wheelbase modification are the full respons ibility of the person who makes these modifications C 3 4 Rear cross member A specific crossbar is...

Page 180: ...IVECO Engineering for approval which will provide correct instructions for the new layout b Fan The fan intake air flow must not be altered or decreased in comparison to the original situation For the...

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Iveco DAILY 4x4 2020, Body Builder Instructions

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