Iveco DAILY M.Y. 2012, Body Builder Instructions

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2-6
CHASSIS MODIFICATIONS D
AILY
Base — 02/2012 Printed 603.95.241
General standards regarding changes to the chassis
Precautions for the alternator and the electric/electronic components
In order to prevent damage to the rectifier with diodes, the batteries must never be disconnected (and the disconnecting switch
must not be opened) while the engine is running.
If the vehicle must be started by means of towing (which is strongly advised against), make sure that the battery is charged and
connected in order to provide the ECU engine control unit with the minimum operating voltage.
If the battery must be charged, it must be disconnected from the vehicle circuit. If the engine must be started using external charging
devices, do not use the ”start” function (if the equipment has this function) in order to prevent peaks of current that could damage
the electric and electronic components.
The start-up must only be carried out using an external battery carriage, being careful to respect the polarity.
Ground connections
In general, the vehicle’s original ground connections must not be changed. If it is necessary to move these connections or create
additional ground points, use the holes already existing in the chassis if possible, being careful to:
- remove mechanically, through filing and/or with a suitable chemical product, the paint from both the chassis and terminal sides,
creating a contact surface that is smooth and even;
- apply suitable paint with high electric conductivity between the terminal and the metal surface (e.g. zinc based paint Part number
IVECO 459622 from the company PPG);
- connect the ground within 5 minutes of applying the paint.
For signal level ground connections (e.g.: low absorption sensors or devices), do not use the standardised IVECO points ”m1” (on
the engine block, near the starter motor) or ”m2” and make the ground connections of the signal cables on points separate from
the power cables and cables used as radiofrequency shields.
For electronic equipment, avoid making ground connections between devices in a linked manner, foreseeing individually wired
ground connections, optimising the length (prefer a shorter path).
Braking and electrical system
For more information about the braking and electrical systems, see chapters 2.15 and 5.4.
2.1.2 Characteristics of the material to be used when modifying the chassis
When making changes to the vehicle chassis (all models and all wheelbases) and when applying reinforcements directly on the
side members, the material to be used must comply with what was used originally for the chassis with regard to quality (Table 2.1)
and thickness (Table 2.2).
If it is not possible to find material that has the indicated thickness, material may be used with the next highest standard thickness.
Table 2.1 - Material to be used when making changes to the Standard IVECO chassis 15-2110 and 15-2812
Steel name
Ultimate tensile
strength
(N/mm
2
)
Yield strength
(N/mm
2
)
Elongation
(%)
IVECO FEE420
530 420 23
Europe S420MC
Germany S420MC
UK S420MC
N.B. For 70C vehicles only, the material must be FEE490 with:
- Ultimate tensile strength 610 N/mm
2
- Yield strength 490 N/mm
2
- Elongation 19%