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Iveco DAILY 4x4 Instructions Manual Download Page 104

2-80

CHASSIS MODIFICATIONS

D

AILY

4x4

Base - May 2007

Print 603.93.761

Electrical System: Modifications and Drawing-Off Power

Electrical System: Modifications and Drawing---Off Power

2.17

Repositioning Parts and Mounting Auxiliary Assemblies and Equipment

Whenever, in the course of modifying the vehicle, it should become necessary to reposition assemblies such as the fuel tank,

batteries or the spare wheel, such relocation is permitted provided that the functioning of these parts is not impaired and provided
that the same type of connections as originally in use are re-employed. Their transversal location on the vehicle’s chassis may not,
when their weight requires it, be changed radically.

Spare wheel carrier

In the case of chassis cabs not equipped with a spare wheel carrier, and vehicles in which the spare wheel carrier must be

relocated, the spare wheel must be set on a support of suitable size that allows the wheel to be readily removed.

To secure the spare wheel to the side of the vehicle with a support attached to the web of the side member, it is advisable to use
a local reinforcing plate on the inside or outside of the side member. The size of this plate must take into account both the weight
of the wheel and the possible presence of other reinforcements on the side member.

In order to limit the torsional stresses on the vehicle chassis, we recommend that the plate be fitted where there is a cross

member, particularly in the case of heavy units.

A similar procedure should be adopted when fitting additional units such as tanks, compressors etc. When positioning them, due
consideration must be given to the distribution of the weights (see point 1.13). Adequate ground clearance must be ensured with
due consideration given to the operation of the vehicle.

Any new holes that are necessary for the relocation must be made in the web of the sidemember in accordance with the

specifications given in point 2.3 taking care to use existing holes as much as possible.

Figure 2.51

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Summary of Contents for DAILY 4x4

Page 1: ...DAILY VEHICLE 4X4 RANGE BODYBUILDER INSTRUCTIONS L I G H T R A N G E ISSUE 2007 ...

Page 2: ...l Application Strada delle Cascinette 424 34 10156 Turin Italy Publication Nr 603 93 761 1st Edition Printed in Italy 05 07 B U TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio 15 19 10156 Turin Italy Produced by ...

Page 3: ...Print 603 93 761 Base May 2007 Update data DAILY 4x4 Bodybuilders instructions Print 603 93 761 1st edition Base May 2007 UPDATE DATA Section Description Page Revision date ...

Page 4: ...Base May 2007 Print 603 93 761 Update data ...

Page 5: ...explanation required to carry out the work and also help you handle the cases not dealt with in this publication After every single intervention the functioning efficiency and safety conditions established by IVECO shall be restored Contact the IVECO service network for vehicle set up if necessary IVECO shall not be responsible for any change modification or fitting concerning the vehicle The data...

Page 6: ...Page header and footer interpretation Vehicle type Section title Section number page number Print number Chapter title Basic edition month year Base May 2007 Print 603 93 761 Foreword ...

Page 7: ...int 603 93 761 Base May 2007 Index of section INDEX OF SECTION Section General specifications 1 Chassis modifications 2 Fitting superstructures 3 Power Take offs 4 Specific information and instructions 5 ...

Page 8: ...Base May 2007 Print 603 93 761 Index of section ...

Page 9: ... Logos 1 5 1 8 Legal Provisions 1 5 1 9 Prevention of accidents 1 6 1 10 Choice of material to use Ecology Recycling 1 6 1 11 Vehicle delivery 1 7 1 12 Vehicles identification 1 8 1 13 Dimensions and masses 1 9 1 13 1 General Specifications 1 9 1 13 2 Determining the Centre of Gravity of the Body and Payload 1 10 1 13 3 Observing the Permitted Weights 1 13 1 14 Instructions for the Correct Functio...

Page 10: ...1 2 GENERAL SPECIFICATIONS DAILY 4X4 Base May 2007 Print 603 93 761 Index ...

Page 11: ...ereby the value of the newly obtained wheelbase does not fall within the minimum and maximum values available within the IVECO range for the same vehicle work carried out on the braking system work carried out on the suspension system steering wheel modifications changes to the stabiliser bars and suspensions changes to the cab cab supports locking and tipping devices changes to the engine intake ...

Page 12: ...uitable frame has been used for the required conversion or application the specifications standards or instructions issued by the Manufacturer for the flawless execution of the operations have not been heeded original spare parts or components which the Manufacturer has made available for specific interventions were not used read and respect the safety standards and symbols applied before any oper...

Page 13: ...CO They must not be applied near to the IVECO tradenames or logos IVECO reserves the right to withdraw the tradenames and logos if the fitting or conversion fails to conform with requirements The bodybuilder accepts all responsibility for the entire vehicle Instruction for added assemblies Where assemblies are added the bodybuilder must provide the necessary service and maintenance instructions wh...

Page 14: ...ign stage to the choice of materials to be used This is especially the case as regards the aspects connected with ecology and recycling in the light of domestic and international regulations that are constantly being developed in the sector In this connection everyone must be aware of the prohibitions on using harmful or potentially hazardous materials such as ones containingasbestos lead halogen ...

Page 15: ...ith regard to the items affected by the work done provide a guarantee for the modifications made in the event that the connections originally provided with screws have been mounted and restored the same screws shall not be used In such an instance and in the event that nails have been replaced with screws you must check again the closing of the connection after travelling approximately 500 1000 km...

Page 16: ...ommercial designation of IVECO vehicles is not the same as the type approval homologation designation Two types of commercial designation are shown below with the meaning of the codes used GVW tx10 Class Engine rating HP 10 Version Suspension 3 5 S 1 8 W 5 5 S 1 8 W Class Rear wheels GVW t Version S single 3 5 Truck D Crewcab 6 1 Suspension mechanic ...

Page 17: ... our vehicles lights and rear view mirrors are designed for widths of up to 2350 mm Weighing the Chassis As a result of production factors there could be at a 5 variation in the published weights for models 35S and a 3 for models 55S It is therefore advisable to weigh the vehicle in the chassis cab condition before fitting the body and equipment and establish the weight distribution on the axles B...

Page 18: ...e of the centre of gravity from the rear axle centre line mm L Wheelbase mm L1 W1 L W Example of calculation of the load barycentre position Consider a 40C13 vehicle with a wheelbase of 3450 mm with 1 GWW 4200 kg permitted maximum 1900 kg on the front and 3100 kg on the rear 2 KERB WEIGHT 1955 kg 1340 kg on the front axle 615 kg on the rear The permitted maximum load body payload will be W 4200 19...

Page 19: ...quipment the actual position of the centre of gravity must be used When building bodies or containers loading and unloading systems must be devised which preclude excessive variations in the distribution of the load and or excessive loads on the axles Relevant instructions should also be given to the operator Uniform load distribution Uneven load distribution Uniform load distribution Uneven load ...

Page 20: ...ody and payload Hb Height of centre of gravity of body and payload in relation to ground Wt Vehicle weight when fully loaded Ht Height of centre of gravity of vehicle with full load To check the vehicle with its body but no payload use the above formula but for Ws use only the vehicle unladen weight The position for Hv will depend on the load and deflection of the suspension The height of the cent...

Page 21: ...liary components and superstructures A 4 variation on the rated load 50 of load on the axle is permissible for each wheel for example permissible load on axle 3000 kg 1440 to 1560 kg allowed for each wheel side in compliance with load allowed by tyres without affecting braking properties and vehicle driving stability Apart from different specifications for specific vehicles the following may be ta...

Page 22: ... must be possible without necessitating the removal of major components of the added structure The cooling system radiator cowling radiator air passages cooling circuit etc fuel supply pump position filters pipe diameter etc and the engine air intake must not be altered The anti noise panels must not be altered or moved in order to prevent changes in the approved noise levels of the vehicle Should...

Page 23: ...sential for bodybuilders to be equipped with an organization where the following are defined and available Organization charts for functions and responsibilities Quality system Quality goals Technical design documentation Process and control phases with relevant resources Product improvement plan obtained also with corrective actions After sales service Staff training Manufacturer liability docume...

Page 24: ...ine of the first steering axle and the centreline of the first rear axle driven or non driven This definition differs from the definition of wheelbase in the CE Directives The rear overhang is taken as the distance between centreline of the last axle and the rear end of the chassis runner For dimensions A B and t of the frame and counterframe section please refer to the figure below Figure 1 5 120...

Page 25: ...cs of the material to be used when modifying the chassis 2 13 2 3 3 Stresses on the chassis 2 14 2 3 4 Welding the Chassis 2 15 2 3 5 Closing of existing holes 2 16 2 4 Modifying the Wheelbase 2 17 2 4 1 General Specifications 2 17 2 4 2 Authorisation 2 17 2 4 3 Consequences for steering 2 17 2 4 4 Effect on Braking 2 17 2 5 Modifying the Rear Overhang 2 18 2 5 1 Authorisation 2 18 2 6 Installing ...

Page 26: ...eral Specifications 2 34 2 13 2 Roof Panel Modifications 2 35 2 13 3 Occupant protection 2 37 2 14 Changing the Size of the Tyres 2 38 2 15 Modifications to the Braking System 2 39 2 15 1 General remarks 2 39 2 15 2 Brake pipes 2 39 2 15 3 Fitting pipes on the vehicle 2 40 2 15 4 Instructions for adjusting the braking load proportioning valve 2 43 2 16 Electrical System Modifications and Drawing O...

Page 27: ...DAILY 4x4 Print 603 93 761 Base May 2007 Index Page 2 18 Retarder Installation 2 82 2 19 Modifications to the Rear Underrun 2 82 2 20 Rear mudguards and wheel boxes 2 83 2 21 Mudflaps 2 83 2 22 Side Guards 2 83 2 23 Chocks 2 85 ...

Page 28: ...2 4 CHASSIS MODIFICATIONS DAILY 4x4 Base May 2007 Print 603 93 761 Index ...

Page 29: ...nged head screws and nuts of min class 8 8 or by hex screws of the next greater diameter and self locking nuts Screws greater than M12 must not be used max diameter of hole 13 mm unless otherwise specified In cases where the original joints were detached and rejoined with bolts it is forbidden to reuse the same bolts In this event and when rivets are replaced with bolts the bolt torque must be che...

Page 30: ...eneral rule the original earth connections of the vehicle must not be changed If it is necessary to move these connec tions or to implement further earth points use the existing holes on the chassis as far as possible and Remove mechanically and or with an appropriate chemical product the paint on the chassis side and on the terminal side creating a resting plane free from indentations or ridges A...

Page 31: ...ntact with atmospheric agents Body Door mirrors Windscreen wipers Aerodynamic kit metal structure sun blind metal structure Metal bumpers Cab attachment lock Door stopdevice Body fasteners screws bolts nuts washers etc B B2 Parts in direct contact with atmospheric agents with mainly structural characteristicsin direct view Frame and parts includingfasteners Parts beneath grille category B Exterior...

Page 32: ...ry B1 wheel studs GEO 321 8 PM yes GEO 321 5 Geomet HHH GEO 321 5 PM 18 1101 yes GEO 321 5 PL yes Category B1 wheel studs Fe Zn 12 III yellow yes yes Fe Zn 12 V olive green Zinc coating H Fe Zn 25 V olive green 18 1102 yes Fe Zn 12 III S yellow 18 1102 yes Fe Zn 12 V S olive green Zinc coating Fe Zn 12 II yes yes Zinc coating HH Fe Zn 12 IV S yes Aluminium Anodic oxidation 18 1148 yes yes yes yes ...

Page 33: ...TANT PRIMER Mono 130 C or bicomponent 30 40 µm yes Mono 130 C or bicomponent 30 40 µm yes yes L L ENAMEL Powders 40 110 µm yes yes L yes L yes L Single component lowtemperature 30 40 µm yes Carry out operation in presence of shearing burrs oxidation welding swarf laser cut surfaces Two coat body cycle Three coat body cycle As an alternative to single or dual component enamel only for body parts wi...

Page 34: ...wder enamels directly after degreasing Parts in light alloy brass and copper must not be protected Table 2 4 Added or modified painted parts Description of the cycle phase Class Description of the cycle phase A B D 1 Mechanical surface cleaning including the removal of burrs rust Mechanical surface cleaning including the removal of burrs rust and cleaning of modified parts Brushing sanding sand bl...

Page 35: ...ncluding earth contacts on all connectors on sensor actuator side and wiring side on all sensors actuators on flywheel on flywheel rev sensor bracket on the whole diesel fuel system pipes plastic and metallic on complete diesel fuel filter base on control unit and control unit base on the whole soundproofing cover inner side injectors rail pipes on common rail pump including regulator on vehicle e...

Page 36: ...body versions advertising vehicles etc from a technical point the values shown in the table may be exceeded provided the vehicle is driven carefully e g low speed gradual running direction changes etc Table 2 6 Maximum heights in relation to the centre of gravity of the payload and cornering stability Models Max height approx of centre of gravity of payload include body and equipment in relation t...

Page 37: ... screws and nuts with flanged heads Use self locking nuts Nuts must be tightened using a torque wrench set to the correct torque setting for the fixing Table 2 7 Classes of resistance for screws Class of resistance Usage Tensile strength N mm2 Yield point N mm2 4 Non load bearing screws 400 320 5 8 Low resistance screws 500 400 8 8 Medium resistance screws cross members cleat plates brackets 800 6...

Page 38: ... 55S18W truck 3400 962 134 x 60 x 5 134 x 60 x 5 2 3 3 Stresses on the chassis Do not exceed the following stress values under static conditions Table 2 10 Range Permitted static stress on the chassis N mm2 σ amm Off road use Daily 4x4 100 When prescribed by national regulations the bodybuilder must check that the stress limits are not exceeded Welding activity will cause a deterioration in the ch...

Page 39: ...it it with negative pole disconnect ECUs connectors operate carefully and do not touch ECU connector pins In case of welding next ECU disconnect it from vehicle connect welding machine ground directly on part to be welded protect plastic material pipes against heat sources and disassemble if required in case of welding near leaf springs or air springs against welding spatters carefully protect sur...

Page 40: ...to 1 2 mm Recommended welding rod DIN 8559 SG3 M2 5243 gas DIN 32526 M21 or DIN EN 439 If FeE490 is used at very low temperatures we recommend PrEN 440 G7 AWS A 5 28 ER 80S Ni 1 gas DIN EN439 M21 Avoid current overloading Welding must be free from marginal cuts and waste material d Repeat the operation on the reverse side by welding as detailed in point c e Allow the side members to cool slowly an...

Page 41: ...nce with these instructions by making the necessary changes and adjustments and taking the appropriate precautions e g determining whether ECU parameters need updating rearranging the exhaust pipes ensuring compliance with specific load limits on the rear axle etc by taking into due account the requirements specified for the original wheelbase lengths 2 4 3 Consequences for steering In general cha...

Page 42: ...ecially intended cross members In trailers with one or more axles close together centre axle trailers considering the stress resulting in particular from the vertical dynamic load to which the rear cross member is subjected the instructions given in point 2 6 2 must be taken into account The tow hook must be appropriate for the permitted loads and of the type approved by national laws Since tow ho...

Page 43: ...ed without obtaining prior approval only on crossmembers provided for this purpose and to vehicles on which IVECO provides for a towing hook to be installed The installation of a towing hook on vehicles which IVECO does not provide a towing hook installation then authorisation from IVECO must be obtained before any installation is carried out The towing hook must be chosen on the basis of the foll...

Page 44: ...etween the towing vehicle and the trailer g acceleration due to gravity m s2 T maximum weight in tonnes of the towing vehicle T S maximum weight in tonnes of the towing vehicle the vertical load of a trailer with a centre axle R maximum weight in tonnes of the trailer S value of the static vertical load in tonnes which in static conditions is transmitted to the point of attachment S must be 0 1 R ...

Page 45: ...se in bending stress on the rear chassis overhang as well as an increased torsional stress of the rear towing cross member resulting from the vertical static and dynamic loads which the tow bar exerts on the hook for example when braking or on bumpy roads On vehicles for which towing of a trailer is permitted and in accordance with values laid down by IVECO for each model towable weights with mid ...

Page 46: ... to using a suitable cross member Unless supplied directly by IVECO they will both need to have type approval in compliance with current standards They must be installed according to the instructions provided by the respective manufacturers 13 Pole connector If not already fitted by IVECO it can be retro fitted following the instructions given in point 2 16 7 2 6 4 Lowered Rear Cross Member If the...

Page 47: ...ed Such authorisation will include the conditions that must be complied with and where necessary specifications concerning modifica tions and work to be carried out on the vehicle These include possible reinforcements to the standard cross member see Figure 2 7 the instructions for installing a reinforced cross member when available and those on the brake system to be made The tow hook must be sui...

Page 48: ...e the proper functioning of the transmission to limit its noise and to avoid the build up of stress transmitted from the engine assembly In no way does this diminish the responsibility of the bodybuilder for the work he has completed 2 8 1 Permitted lengths The maximum operating lengths obtainable for both the intermediate shaft sections and the sliding shafts LG or LZ see Figure 2 8 can be determ...

Page 49: ...o in the fastest gear refer to Table 2 13 Table 2 12 Maximum number of engine revs Engine Engine code 1 nmax 18 F1CE0481H C 3500 1 Check the engine code on the engine rating plate Table 2 13 Gearbox ratio with the fastest gear Gearbox iG 6S400 2840 6 0 8 Example of calculation of the maximum obtainable transmission length Let us consider a 35C13 equipped with a ZF S5 200 gearbox Let us assume you ...

Page 50: ... tubes available Therefore the thickness of the tube should be agreed upon as each occasion arises with the workshops authorised by the manufacturers of the transmission shaft depending on its dimensions i e size of the universal joint The minimum operating length from flange to flange must not fall below 600 mm for the sliding sections and 300 mm for the intermediate sections Table 2 14 Obtainabl...

Page 51: ...d length Complying with the useful travel position the static arrangement in an area as central as possible 120362 Figure 2 9 X 10 If the wheelbase is lengthened considerably it may be necessary to apply an extra propeller shaft between the reduction unit transfer box and rear axle In this case the angle between the various propeller shafts must be constant and contained within the maximum limit e...

Page 52: ...42 kg mm2 may be used Modifications to the universal joints are not permitted Whenever the transmission or part thereof is modified each modified section must be subjected to careful dynamic balancing Since transmission is important to vehicle driving safety it should be borne in mind that any modification to it must bear maximum operational guarantees Only very specialised and transmission manufa...

Page 53: ...ing surface of not less than two and a half times that of the master hose located upstream of the filter These apertures e g openings in the grill must be of such a dimension that they do not become obstructed It is prohibited to alter the air filer or replace the original filter with a lower air capacity unit Modifications to the equipment fuel injection pump regulator injectors etc are not permi...

Page 54: ...ets or back flow of air The performance of the fan must not be altered if it is necessary to re position the hoses this must be done without affecting the complete filling of the system which must occur at a continuous flow without forming blockages at the mouth or the normal flow of water The maximum stabilising temperature of the water must not be altered even under the most severe operating con...

Page 55: ...g e g no of leaves spring rate etc requires adjusting the brake load apportioning valve so as not to alter the vehicle s braking performance When work on the suspensions follows rather large changes in the permitted loads on the axle s or the total weight of the vehicle it may be necessary to adapt the braking forces to permit compliance with the requirements for the brake regulations in force The...

Page 56: ...oir connected to the engine fuel return line Direct feed from the vehicle fuel tank is permitted only if this is independent from the engine fuel system and the new circuit is perfectly leakproof trace pipe and cable paths the location of brackets and hoses bearing in mind that the overall dimensions and heat affect the various units on the chassis Avoid runs and arrangements that could lead to ha...

Page 57: ...s that could lead to hazards when the vehicle is running Use shields or armouring if necessary the complete installation should be designed to ensure good accessibility for quick and easy servicing At vehicle delivery the bodybuilder will supply all service and maintenance instructions which are deemed necessary Furthermore according to the system operations Equipment installed inside the cab The ...

Page 58: ...aking care to restore the protective elements to their original condition ensuring the previous operating capability Controls and equipment power take off engagement control external operating cylinder control etc may be fitted in the cab pro vided that They are positioned properly and are easily accessible to the driver Safety control and warning devices are fitted which meet the requirements of ...

Page 59: ... is recommended that these versions are used as they are specifically checked If fitting a spoiler other than the one designed by IVECO follow the manufacturer s instructions for its installation Whenever national regulations require it these installations must be inspected by the agencies responsible Modifications to the roof panel and the cab rear wall In the event that the rear wall has to be f...

Page 60: ...ay 2007 Print 603 93 761 Cab Modifications Figure 2 11 Section B B Section A A Section C C 1 Roof panel 2 Limit cutting area 3 Roof panel side covering 4 Doorway ring 5 Internal rear crosspiece 6 Rear wall 7 Doorway rear covering 8 Side covering ...

Page 61: ...s outlined below are an integral part of the overall safety of the occupants Any modification to these components may jeopardize the safety of the passengers and compliance with legal requirements Anchoring safety belts Any work carried out in the areas of the seat belt fixing points may affect their compliance with EC certification The company carrying out the work must verify compliance with all...

Page 62: ...pension components and the length of wheel studs etc Where there is local national legislation specifying overall widths e c Jersey etc these must be complied with The use of tyres with a different outside diameter affects the performance of the vehicle in terms of speed maximum gradability pulling force braking power etc The tachograph must be recalibrated by an authorised workshop The load capac...

Page 63: ...event that the vehicle wheelbase is modified the brake pipes affected by the change must be replaced by new one piece pipes If this is not possible fittings of the same type as the ones originally used on the vehicle must be used When replacing pipes the minimum internal dimensions of the new pipes must not be less than that of the existing pipes The new pipes must have the same characteristics an...

Page 64: ...sis frame sidemember or cross members appropriate precautions must be taken to avoid damage Observe adequate distances between the various fixing elements As a rule the maximum distance of 500 mm should be considered For plastic pipes in order to prevent distortion and tension on the connectors when fitting them take the necessary precautions when arranging the pipe runs and fitting the fixing bra...

Page 65: ...rake area surrounding the bleed screw remove the rubber cap protecting the bleed screw using a transparent flexible tube fix one end over the bleed screw and immerse the other end in a container part filled with brake fluid loosen the bleed screw by one turn and press the brake pedal down to the floor with the pedal held down on the floor tighten the bleed screw and then release the pedal screw th...

Page 66: ... time on the screen taking care not to exceed the solenoid valve and pump operating time so as to avoid component overheating If this occurs the system will be deactivated and you will have to wait for the established time in order to let the system cool down before the operation can be started again In the event that the modulator is replaced the modulator is supplied by the Spare Parts Departmen...

Page 67: ...ol data are given on the appropriate rating plate whose location on the vehicle is given in the specific literature Should it become necessary to adjust the braking load proportioning valve this can be done following the instructions given below Table 2 16 Vehicle Load proportioning valve Leaf spring Load on rear axle for adjustment Weigh for adjustment Clearance between bar and load proportioning...

Page 68: ...t not be less than the minimum value indicated by the manufacturer Figure 2 16 Disconnect the control link 1 from the rear axle and raise through its travel Ensure that the load proportioning valve pushrod slides properly in its seat and reconnect the link Start the engine Fully depress the brake pedal and use a feeler gauge to check that the adjustment clearance 0 1 mm between the load propor tio...

Page 69: ...he brake pedal to obtain a pressure of 100 bars on the pressure gauge 3 Figure 2 15 fitted upstream of the load proportioning valve This pressure must be constant whether the vehicle is laden or unladen Check that the pressure reading on the pressure gauge 2 Figure 2 15 fitted downstream of the load proportioning valve corre sponds to the values on the plate Figure 2 16 For example with a load of ...

Page 70: ... surface braking a number of times while travelling forwards and while reversing Connect the pressure gauges 1 and 2 to the pressure test points 3 upstream and downstream of the braking load proportioning valve Loosen the clamping screw 8 of the proportioning valve adjustment lever 7 Apply adjustment load specific to each model to hole 9 after loading the engine axle to the specified reference val...

Page 71: ...CHASSIS MODIFICATIONS 2 47 DAILY 4x4 Print 603 93 761 Base May 2007 Changing the Size of the Tyres Figure 2 18 119383 An example of a load apportioning plate for a 55S18W vehicle ...

Page 72: ...onformity with IVECO instructions or is carried out by unskilled personnel can severely damage the systems control units wiring sensors etc jeopardizing safety and operation of the vehicle besides causing significant damage e g short circuiting with the risk of fire and destruction of the vehicle that is not covered by warranty It is absolutely prohibited to make any changes or connections to the ...

Page 73: ...icle it is important to ensure the tanks contain sufficient fuel during start up Attempting to start the engine with insufficient fuel could cause serious damage to the injection system Observe all current accident prevention precautions including the use of gloves Use a battery trolley with specifications similar to those of the vehicle battery Use an appropriate cable to connect the battery trol...

Page 74: ... taking care to remove by mechanical means i e by using a file and or a suitable chemical the paint both on the chassis side and on the terminal until the anaphoretic paint is fully taken off the chassis thus obtaining a base surface free from nicks and steps apply a suitable paint with high electric conductivity properties between the cable terminal and the metal surface connect the ground not la...

Page 75: ...und under the power brake m4 engine compartment ground next to the front right headlamp m5 engine compartment ground next to the left right headlamp m6 ms6 right side cab interior on the dashboard carrier m7 ms7 left side cab interior on dashboard carrier m8 Earth on frame behind cab m9 Earth on left rear crossmember 120364 m power grounds ms signal grounds m4 m6 ms6 m3 ms3 m2 m5 m7 ms7 m9 m8 Figu...

Page 76: ...LY 4x4 Base May 2007 Print 603 93 761 Electrical System Modifications and Drawing Off Power Figure 2 22 m3 ms3 Engine compartment earth beneath brake servo 119372 Figure 2 23 119373 m4 Engine compartment earth near right front light ...

Page 77: ...System Modifications and Drawing Off Power Figure 2 24 11 m5 Engine compartment earth near left front light 119374 Figure 2 25 114177 m7 ms7 Left side cab interior earth on dashboard carrier m6 ms6 Right side cab interior earth on dashboard carrier m7 ms7 114176 m6 ms6 Figure 2 26 ...

Page 78: ...IS MODIFICATIONS DAILY 4x4 Base May 2007 Print 603 93 761 Electrical System Modifications and Drawing Off Power Figure 2 27 m8 Earth on frame behind cab 120382 Figure 2 28 m9 Earth on left rear crossmember 120383 ...

Page 79: ...round point and to the negative terminal of the battery The analog grounds sensor shall feature very good conductivity though they are not connected to the system ground negative terminal of the battery As a result the greatest care shall be taken with the cable terminal stray resistance oxidation seaming defects etc The screened circuit metal braid shall come into electric contact only at the end...

Page 80: ...supplied devices must be free from immune from negative noises such as 300V spikes posi tive 100V spikes 150V burst They must operate correctly during voltage lowering phases to 5V for 40mS and to 0V for 2mS Moreover they must resist the load dump phenomena up to 40V NOTE Max levels measured on bench for radiated and driven emissions generated by 12V devices are shown in table below Table 2 17 Fre...

Page 81: ...ed in of remarkable importance to ensure max performance to receiver and transmitter equipment It shall be of very good quality and installed with utmost care even the mount position is of essential importance as it determines the aerial efficiency therefore its transmission range Therefore the SWR Stationary Wave Ratio gain and generated electromagnetic field characteristics must be ensured withi...

Page 82: ...wing guidelines to ensure that the radio cable aerial is working effectively and assess whether the aerial is adjusted 1 If the SWR is higher on low channels than high channels extend the aerial 2 If the SWR is higher on high channels than low channels shorten the aerial After adjusting the aerial it is advisable to re check the SWR on all channels The best position to install the aerial is the ce...

Page 83: ...the gear lever area or in the header rail above the driver see Figure 2 33 Figure 2 31 1 Antenna support 2 Gasket P N for spares 244614 3 Fixed joint cover P N for spares 217522 4 Fixing screw M6x8 5 torque to 2 Nm 5 Antenna spare P N for complete rod 675120 6 Roof 7 Antenna extension lead 98915 Figure 2 32 1 Antenna connector 2 Ground wire 3 Insulator 4 Signal wire 5 Capacitor 100pF 6 Cable RG 58...

Page 84: ...1 5 while the maximum acceptable value must not in any case be greater than 2 The AERIAL GAIN values must be as high as possible and ensure sufficient spatial uniformity normally with deviations from the average value in the order of 1 5dB in the 870 960 MHz band and 2 dB in the 1710 1880MHz band The RADIATED CAB FIELD value must be as low as possible We suggest 1 V m as a quality target In any ca...

Page 85: ... range 1575 42 1 023 MHz The AERIAL GAIN values must be as high as possible and ensure sufficient spatial uniformity normally with deviations from the average value in the order of 1 5dB in the 1575 42 1 023 MHz band The GPS antenna must be installed in a position ensuring maximum visibility of the sky The minimum angle of visibility must be 90 Sky visibility must not be obscured by objects or met...

Page 86: ... CD player Radio with CD MP3 player The IVECO radio is built into the system on the CAN network and allows Message repetition to comfort control panel Volume adjustment according to vehicle speed Integration with Convergence V2 system Recognition antitheft system with body computer If the original radio is not present an aftermarket radio may be fitted 119375 Radio connector Aerial connector 11937...

Page 87: ...ry amplifiers may seriously affect correct operation of the electric electronic units fitted to the vehicle with adverse effects on the vehicle and or driver safety Any damage to the system caused by the use of receiving transmitting units not approved or the addition of auxiliary amplifiers shall not be covered by the warranty The vehicles system is designed to provide the necessary power to all ...

Page 88: ...terior shall be provided In the event that type B batteries are installed the batteries shall be equipped with a cover with a system for blowing the gas off to the outside fitted with tube for conveying the acid spray to the outside a flame anti return system by means of a porous pellet flame arrester Moreover gas escape shall take place far from points liable to spark ignition as well as mechanic...

Page 89: ...a heavy duty alternator is used or an auxiliary alternator is fitted The auxiliary alternator shall be of the type equipped with Zener diode rectifiers to avoid possible damage to the installed electric electronic pieces of equipment owing to accidental battery disconnection Moreover every single alternator shall feature a warning light or LED signalling failed battery recharge The auxiliary alter...

Page 90: ...ll be installed in accordance with the instructions given in paragraph 2 16 5 114081 1 Body builders node for power take off engine compartment on battery 2 Passage of wires between cab engine compartment 3 Body builders connector cab interior Figure 2 36 CBA voltage supply on battery Figure 2 37 107635 Ref Function Fuse range Sect 1 Positive 30 for alternator motor 500 50 2 Positive for engine op...

Page 91: ...tallation precautions 1 Do not lose any parts when overturning the component 2 Fuses must not be removed from their position during installation 3 Fit terminals on the studs and secure with nuts M5 flanged nut self locking nut etc Tighten the nuts to torque 4 min 6 max Nm 4 Then secure the CFO Centralina Fusibile Opzionale optional fuse unit to the CBA control unit taking care to fit the hole in t...

Page 92: ...C 3 A F 32 Not used 15 A F 33 Air heater cigar lighter 15 A F 34 Current draw 20 A F 35 STANLEY solenoid 10 A F 36 Central locking 20 A F 37 Switch for brake lights and miscellaneous loads under 15 5 A F 38 BC ceiling light internal relay power supply 10 A F 39 Car radio tachograph 15 A F 40 Not used 10 A F 41 Not used 10 A F 42 Reversing light switch 5 A F 43 Windscreen wiper 20 A F 44 Spare F 45...

Page 93: ...0 A F 6 Fan electromagnetic coupling Baruffaldi 20 A F 7 Side lights 20 A F 8 Heater or air conditioner fans 30 A F 9 Windscreen washer 20 A F 10 Warning horn 7 5 A F 11 EDC 16 secondary loads 10 A F 14 Right high beam headlight 7 5 A F 15 Left high beam headlight 7 5 A F 16 EDC 16 T02 T14 auxiliary heater 5 A F 17 EDC 16 primary loads 15 A F 18 Not used 10 A F 19 Fan electromagnetic coupling Baru...

Page 94: ... 20 A T06 Fan electromagnetic coupling power supply Baruffaldi 20 A T07 Side lights 50 A T08 Heater or air conditioner fans 20 A T09 EDC 16 main relay 30 A T10 Fuel pump 20 A T14 Left and right fog lights 20 A T17 Windscreen washer 20 A T19 Fuel filter heater 20 A T20 MODUS or E A SY diagnosis 20 A Table 2 22 Not incl in control unit Utilization Rated output T25 Windscreen wiper switch on switch o...

Page 95: ...ary lights 20 A T16 12 Working lights 10 A T15 3 Free T22 4 Air conditioning compressor actuation 20 A T18 6 Baruffali cut out 20 A T24 7 Power takeoff actuation enable 20 A T23 9 Air conditioning compressor 20 A T21 10 Compressor ON signal fro EDC 16 20 A Table 2 24 Not incl in control unit Drawing ref Utilization Rated output F 55 2 Rotary lights 10 A F 25 5 Trailer connector 10 A F 28 8 APU pow...

Page 96: ...he connectors are located behind the passenger side compartment in an easily accessible area Passing cables from inside the cab to outside Electric cables may be passed from outside the cab to the engine compartment through five 10 mm diameter holes stamped in the bulkhead coupling near the brake servo Seal the cable routing point to prevent fumes passing from the engine compartment to the cabin F...

Page 97: ...e engines of which are frequently started in the presence of current drawing and short engine rotation time e g vehicles equipped with refrigerating bodies the battery shall be recharged at regular intervals in order to ensure efficiency of the same The connections with plugs and terminals shall be of the protected weather proof type Components of the same type as the one originally fitted to the ...

Page 98: ...rbed intensity e g electric motors solenoid valves and signals that are susceptible to low absorbed intensities such as sensors maintaining in any event a position as close as possible to the metal structure of the vehicle in both cases Plug and terminal connections must be protected resistant to weathering and executed using components of the same type as those utilised originally on the vehicle ...

Page 99: ...d to connect directly to the original equipment tail light lights Connection to the original vehicle tail lights could cause current overloads that will be indicated by the on board computer as operating faults If it is necessary to make changes to the system other than those described in this manual e g inclusion of LED lights the operation must be carried out in conjunction with Iveco a Trailer ...

Page 100: ...s cable 3 Yellow taping connect to the cab bonnet cable 4 Connect to the chassis cable found on the vehicle 5 Connect to the chassis ground 114197 Figure 2 48 1 To be connected to the chassis cable from where the reversing gear sensor connection had come off 2 To be connected to the reversing gear sensor 3 Connect to the chassis ground 4 To be connected to the control unit connector 5 Cable to be ...

Page 101: ...n of 13 pin interface Table 2 26 13 pole connector pin Cable no Description Remarks 1 1120 Rear left indicator bulb 1 bulb 21 W 12 V 2 2283 Rear fog light power supply 2 bulbs 21 W 12 V 3 0000 Ground 4 1125 Rear right indicator bulb 1 bulb 21 W 12 V 5 3335 Front left rear right sidelights left licence plate light left clearance light 1 bulb 5 W 12 V 6 1175 Brake light power supply 2 bulbs 21 W 12 ...

Page 102: ...with specific terminals to make the electric connection required to power the side marker lights The external body builders shall take care to make the connections and install the lights on the respective added structures boxes vans etc To ensure the electrical properties of the female connector contacts remain unchanged over time leave the cap provided by IVECO in place Below is an illustration o...

Page 103: ... rubber piece 3 Cap 1 Connector pin out Table 2 28 Pin Cable code Function Cable section mm2 Max current A 1 0000 Ground 1 10 2 3390 Vehicle right side marker lights 1 10 3 3390 Vehicle left side marker lights 1 10 As regards the vehicles on which the side dimmers are not compulsorily required the respective connectors are in any case available In the event that the side dimmers need be installed ...

Page 104: ...ize that allows the wheel to be readily removed To secure the spare wheel to the side of the vehicle with a support attached to the web of the side member it is advisable to use a local reinforcing plate on the inside or outside of the side member The size of this plate must take into account both the weight of the wheel and the possible presence of other reinforcements on the side member In order...

Page 105: ...365 The use of fuel tanks other than the original tanks will lead to incorrect readings for fuel reserve fuel consumption range etc on the control panel The new electrical systems architecture will process the fuel gauge level signals by associating the emptying concept as for the fuel tank original fitted Fuel tanks are subjected to homologation ...

Page 106: ...itioned in compliance with current regulations keeping the same connection with the chassis as the original vehicle When modifying the vehicles or installing special equipment e g tail lifts it may be necessary to modify the structure of the underrun bar Such modifications must not change the original resistance and stiffness specifications so as to comply with local government regulations if any ...

Page 107: ...O The maximum width of the vehicle over the tyres must comply with the legal limits The supporting structure should be sufficiently strong enough avoiding any sudden variation in section The connection can be made to the vertical web of the vehicle s side members or to the longitudinal sections of the subframe In the first case the connection must be made solely with screws or directly under the s...

Page 108: ...embers vertical web in compliance with point 2 3 In accordance with EC regulations the external protection element can consist of either a single runner whose surface extends in the vertical direction or of several longitudinal sections with preset sizes and distances between them The side guards must be connected to its own supporting structures in order to allow quick removal or tilting should m...

Page 109: ...se are fitted directly at the factory Should this not be the case or if it is necessary to change their original position the Bodybuilder must work out a new arrangement in compliance with local regulations The new position must ensure reliability and safety as well as easy access for operation by the user ...

Page 110: ...2 86 CHASSIS MODIFICATIONS DAILY 4x4 Base May 2007 Print 603 93 761 Chocks ...

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