Iveco DAILY M.Y. 2012 Body Builder Instructions Download Page 38

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2-12

CHASSIS MODIFICATIONS

AILY

Base — 02/2012

Printed 603.95.241

Drills on the chassis

2.2.4

Closing holes by welding

When making new holes, and if they are too close to already existing holes (see Figure 2.2), the latter can be closed by welding

them.
To ensure that this operation will be successful:

smooth the external edge of the hole;

apply a strip of copper inside the side member to retain the weld material;

perform the welding on both sides of the side member and remove the residues.

In order to close holes with a diameter greater than 20 mm, rounded washers can also be used, welding on both sides.

Summary of Contents for DAILY M.Y. 2012

Page 1: ...DAILY M Y 2012 BODYBUILDERS INSTRUCTIONS L I G H T R A N G E ISSUE 2012 ...

Page 2: ...IVECO S p A Technical Application Strada delle Cascinette 424 34 10156 Torino TO Italy www iveco com Printed 603 95 241 2nd ed 02 2012 Revi 10 2012 ...

Page 3: ...3 Index Modification to text October 2012 3 3 4 2 Modification to text October 2012 3 3 9 Modification to table 3 11 and text October 2012 3 3 14 3 Modification to text Modification to figure 3 23 October 2012 5 5 4 9 Modification to table 5 19 October 2012 Appendix B Index Modification to text October 2012 Appendix B B 4 1 Modification to text October 2012 Revi 10 2012 ...

Page 4: ...Base 02 2012 Printed 603 95 241 Update data ...

Page 5: ...al protection devices goggles helmet gloves shoes etc as well as tools and equipment lifting and trans port equipment etc are available and in good working order ensure that the vehicle is parked in a safe condition When any work has been completed the conditions of functionality efficiency and safety required by IVECO must be restored Contact the Assistance Network if any adjustments or fine tuni...

Page 6: ...Page header and footer interpretation Vehicle type Section title Section number page number Print number Chapter title Basic edition month year Base 02 2012 Printed 603 95 241 Foreword ...

Page 7: ...DEX OF SECTION Section General specifications 1 Chassis modifications 2 Fitting superstructures 3 Power Take Offs 4 Special instructions for electronic subsystems 5 Appendix A Daily PASSENGER TRANSPORT A Appendix B Daily CNG and CNG with Recovery Mode B ...

Page 8: ...Index of section Base 02 2012 Printed 603 95 241 ...

Page 9: ...ity System management 1 6 1 10 Prevention of accidents 1 7 1 11 Choice of material to use Ecology Recycling 1 7 1 12 Vehicle management c o Bodybuilder 1 8 1 12 1 Acceptance of the chassis 1 8 1 12 2 Maintenance 1 8 1 12 3 Delivery of the vehicle to the final Customer 1 8 1 13 Vehicles identification 1 9 1 14 Trademarks and logos 1 9 1 15 Dimensions and masses 1 10 1 15 1 General specifications 1 ...

Page 10: ...1 2 GENERAL SPECIFICATIONS DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 11: ...al failure to comply with these Requirements shall not be covered by guarantees on the chassis and mechanical assemblies 1 2 Technical documentation available via computer The following technical documents are available on the Internet at www thbiveco com Directives for transformation and equipping of vehicles technical cards chassis cab diagrams chassis diagrams other specifications concerning th...

Page 12: ...rce in the country the vehicle is destined for any effects on the vehicle s operation safety reliability and in general the good performance of the vehicle of the supply of spare parts for a minimum period of 10 years starting with the latest preparation of an order and for all parts and components that are installed 1 6 Legal provisions The Bodybuilder must ensure that the finished product confor...

Page 13: ...ponsibility to make available in agreed form type approval documentation EC ECE type approval and technical information necessary for correct realisation of the outfitting and or conversion of the vehicle manuals drawings specifications b the Bodybuilder has the following responsibilities design and realisation of modifications on the base vehicle received from IVECO re attainment of type approval...

Page 14: ... by IVECO for specific operations have not been used safety requirements are not respected the vehicle is used for any other purpose than that for which it was designed 1 9 Quality System management For some time IVECO has been promoting Quality System development and training for Bodybuilders This is a requirement due not only to regulations on product responsibility but also to ever increasing q...

Page 15: ...e used must be carefully considered in the study and design phase also from an ecological and recycling point of view In this regard the following should be kept in mind the use of materials which are damaging to health or in any case potentially hazardous is forbidden for example those containing asbestos lead halogen additives CFCs cadmium mercury hexavalent chromium etc it is recommended to use...

Page 16: ...rk for the items regarding the work performed obviously the other items in the ODI will remain the responsibility of the Dealer as per guarantee booklet measure the voltage of the batteries using a digital multimeter 2 digit decimal bearing in mind that a the optimum value is 12 5 V b between 12 1 V and 12 49 V the battery must be trickle charged c with values lower than 12 1 V the battery must be...

Page 17: ...c CNG CNG engine 1 14 Trademarks and logos Factory branding marks and names must not be altered or removed from their original positions since the originality of the vehicle s image must be protected Application of branding for the conversion or outfitting must be authorised If present they may not be placed immediately next to IVECO branding IVECO reserves the right to withdraw branding and marki...

Page 18: ...hassis It must be remembered that variations in mass of 5 for 29L 35S 35C models and 3 for 40C to 70C models are possible 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 Body conversions The body building limits for each model are mainly defined by the following weight distribution ...

Page 19: ...nce 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 3 450 mm with 1 GWW 4 200 kg permitted maximum 1 900 kg on the front and 3 100 kg on the rear 2 KERB WEIGHT 1 955 kg 1 340 kg on the front axle 615 kg on the rear The permitted maximum load body payload will be W...

Page 20: ...rding any equipment the actual position of the centre of gravity must be used When creating the superstructure or containers loading and unloading systems for goods must be created which avoid excessive variations on the payload distribution and or excessive loads on the axles with instructions supplied for end users if necessary Uniform load distribution Uneven load distribution Uniform load dist...

Page 21: ...ansverse stability while in motion The following cases may arise a fixed loads b mobile loads c loads that involve high aerodynamic actions a Fixed loads Check when fully laden 166683 Ht Wc Hc Wb Hb Wc Wb Hb Wc Wb Ht Wc Hc Wb Wc Chassis cab vehicle kerb weight Hc Height of centre of gravity of chassis cab vehicle laden condition Wb Body and payload Hb Height of centre of gravity of body and payloa...

Page 22: ... high aerodynamic actions To conversions characterised by large height and surface area e g vehicles with large advertising panels the height of the centre of thrust determined by high winds must be calculated very carefully Even with a low centre of gravity a converted vehicle presenting a high side area may not guarantee sufficient transverse stability and may be exposed to the danger of rolling...

Page 23: ...e for individual vehicles the weight on the front axle must be considered to have a minimum value of 28 of the actual weight of the vehicle whether with uniformly distributed loads or with loads concentrated on the rear overhang or derived from a possible trailer NOTE Variations in the permissible weight Special dispensations for maximum allowable masses may be given for special uses nevertheless ...

Page 24: ... important elements of the added structure cooling grille radiator air passages cooling circuit etc fuel supply position of pump filters tubing diameters etc and engine air intake must not be altered soundproofing panels must not be altered or removed in order not to change the approved noise emission levels Whenever openings are to be made e g for the passage of longitudinal chassis members they ...

Page 25: ...elbase distance between the centre line of the steering axle and that of the rear axle This definition differs from the definition of wheelbase indicated in EC Directives Rear overhang distance between the centre line of the rear axle and the rearmost point of the chassis side members Dimensions A B and t of the chassis section see the figure Figure 1 6 91473 ...

Page 26: ...1 18 GENERAL SPECIFICATIONS DAILY Base 02 2012 Printed 603 95 241 Convention ...

Page 27: ... 2 2 3 Welds 2 10 2 2 4 Closing holes by welding 2 12 2 3 Rust protection and paint 2 13 2 3 1 Original vehicle components 2 13 2 3 2 Added or modified parts 2 16 2 3 3 Precautions 2 17 2 4 Modification of the wheelbase 2 18 2 4 1 General information 2 18 2 4 2 Authorisation 2 18 2 4 3 Influence on steering 2 18 2 4 4 Influence on braking 2 19 2 4 5 Procedure 2 19 2 4 6 Checking chassis stress 2 2...

Page 28: ...ir intake and engine exhaust systems 2 34 2 9 1 Intake 2 34 2 9 2 Engine exhaust 2 34 2 10 Changes to the engine cooling system 2 35 2 11 Operations on the suspensions 2 36 2 12 Changes to the heating cooling system 2 38 2 12 1 Installation of a supplementary heating system 2 38 2 12 2 Installation of an air conditioning system 2 40 2 13 Operations on sheet metal 2 41 2 13 1 General information 2 ...

Page 29: ...current draws 2 64 2 17 Moving components and fastening supplementary units and equipment 2 65 2 18 Road transport of hazardous goods ADR 2 68 2 19 Application of a retarder 2 69 2 20 Changes to the under run protection bar 2 70 2 21 Rear under run protection and wheelhouses 2 70 2 22 Mudflaps 2 71 2 23 Side protections 2 71 2 24 Chocks 2 71 ...

Page 30: ...2 4 CHASSIS MODIFICATIONS DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 31: ...r and nuts with loosening prevention systems Screws larger than M12 must not be used maximum hole diameter 13 mm unless otherwise specified if connections are restored that use screws it is mandatory to check the suitability of the screws before reusing them and to tighten them to a suitable torque If safety components are reassembled it is prohibited to reuse already used screws and it is mandato...

Page 32: ...ctric 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 ...

Page 33: ...50 35C 40C van 3000 short overhang 840 174 X 69 X 3 114 X 69 X 3 3000 long overhang 1240 3300 1460 3950 1825 45C 50C van 3000 short overhang 840 174 X 70 X 4 114 X 70 X 4 3000 long overhang 1240 3300 1460 3950 1825 60C 65C 70C truck 3450 1355 174 X 69 X 5 174 X 69 X 5 3750 1665 4350 1890 4750 2350 van 3950 1825 1 only 35C 40C 2 only 45C 50C 2 1 3 Stress on the chassis In no case it is allowed to e...

Page 34: ...al rib of the side member and shall be accurately burred and bored 2 2 1 Hole positioning and dimensions The new holes shall not be drilled in the areas subjected to greater stress e g spring supports and areas where the side member section changes The diameter of the holes should be suitable for the thickness of the panel and must not exceed 13 mm unless otherwise specified The distance of the ho...

Page 35: ...tings are Geomet and galvanisation If the screws are subjected to welding the Geomet coating is not recommended If space permits use screws and nuts with a flanged head Use nuts with loosening prevention systems and remember that the tightening torque must be applied to the nut Table 2 4 Screw resistance classes Resistance class Use Ultimate tensile strength N mm2 Yield strength N mm2 4 8 Non load...

Page 36: ...ons to protect the electric components and electronic control units before disconnecting the power cables ensure there are no active electric users if an electric circuit breaker main switch is present wait for it to complete the cycle disconnect the battery negative pole disconnect the positive battery pole without grounding it and DO NOT short circuit it with the negative pole disconnect the con...

Page 37: ...welding with several passes using carefully dried basic electrodes Avoid current overload the weld must be free from marginal cuts and waste material e Repeat in the other direction and make the weld as specified in point d f Allow the side members to cool slowly and uniformly They must not be cooled using an air jet water or another method g Grind off the excess material h Apply angular steel rei...

Page 38: ...ure 2 2 the latter can be closed by welding them To ensure that this operation will be successful smooth the external edge of the hole apply a strip of copper inside the side member to retain the weld material perform the welding on both sides of the side member and remove the residues In order to close holes with a diameter greater than 20 mm rounded washers can also be used welding on both sides...

Page 39: ...arts in direct contact with atmospheric agents Body Rear view mirrors Windscreen wipers Sun visor metal structure Metal bumper Cab hook up lock Door stop device Body fixing elements screws bolts nuts washers etc B B2 Parts in direct contact with atmospheric agents with mainly structural characteristics in direct view Chassis and relative parts including fastening elements Parts under the grille cl...

Page 40: ...0 8 GEO 321 8 PM GEO 321 8 PML GEO 321 8 PL GEO 500 8 PL GEO 321 5 yes GEO 500 5 GEO 321 5 PM GEO 321 5 PML GEO 321 5 PL yes Class B1 wheel studs GEO 500 5 PL Galvanisation HH FE ZN 12 II 18 1102 yes yes FE ZN 7 IV FE ZN 12 IV yes yes FE ZN 7 IV LUB FE ZN 7 IV S yes yes yes FE ZN 12 IV S Aluminium Anodic oxidation 18 1148 yes yes yes yes Painting See Table III yes Coupling with other metal materia...

Page 41: ... μm yes ENAMEL Single 130 C or bi component 30 40 μm yes yes L yes L yes L Powders 40 110 μm yes Single component at low temperature 30 40 μm yes Operation to be performed if there are shearing burrs oxidation welding scraps laser cut surfaces Two layer body cycle Three layer body cycle As an alternative to single or bi component enamel only for body parts windscreen wipers rear view mirrors etc R...

Page 42: ... providing that the same oxidation and corrosion protection is guaranteed Do not use powder enamels directly after degreasing Parts in light alloy brass and copper are not protected Table 2 8 Added or modified painted parts Cycle phase description Class A B D 1 Mechanical surface cleaning including the removal of burrs oxidation and cleaning cut parts Brushing sanding sandblasting Pretreatment Deg...

Page 43: ... contact areas ensure suitable protection for the brake discs Electronic components and modules must be removed b Engines and their electrical and electronic components Suitable precautions must be taken to protect engine and vehicle wiring including ground contacts sensor actuator side and wiring side connectors sensors actuators on the flywheel on the flywheel rev sensor support bracket the plas...

Page 44: ...ngth If both these conditions do not exist simultaneously with which the diagram of the transformed chassis is identical to the diagram of an original chassis the change must be submitted for approval The workshop that makes the transformation must provide sufficient guarantees from a technological and control point of view qualified personnel suitable operating processes etc The work must be carr...

Page 45: ...hafts the brake system pipes wiring and anything else that could prevent the work from being performed correctly identify the reference points on the chassis e g pilot holes suspension mounts mark the reference points with a light punching line on the upper wings of both side members after checking that the connecting one is perfectly perpendicular to the vehicle s longitudinal axis if moving the ...

Page 46: ... by national regulations are observed The stress may not exceed the stress on the chassis in the original wheelbase in the case of a uniformly distributed load and with the chassis considered as a beam placed in correspondence of the suspension mounts If elongation is done starting from a longer original wheelbase the reinforcements must be provided in function of not only the amount of elongation...

Page 47: ... chassis that are no greater than those on the chassis of the original vehicle in the corresponding sections Figure 2 7 1 Bracket 2 Plate 3 Screws or rivets 102422 To prevent consequences on the resistance of the original sections it is not permitted to apply reinforcement plates directly on the wings of the side members using holes filled with welding Alternatives may be authorised by IVECO only ...

Page 48: ...r each model if implemented according to the instructions provided here do not need to be specifically authorised For vehicles intended for special use where load distribution is predefined and fixed the rear overhang can be lengthened with values greater than 60 of the wheelbase providing that they comply with the conditions set forth in Paragraph 1 15 3 Directive EEC 97 27 and the relative natio...

Page 49: ...8 Figure 2 9 Figure 2 10 102427 If the amount of the elongation is considerable it is necessary to assess on a case by case basis if a supplementary cross member is needed in order to ensure suitable torsional rigidity for the chassis A supplementary cross member with the standard characteristics must be inserted when the distance between the two cross members is greater than 1200 mm ...

Page 50: ...e cross member it is necessary to comply with the requirements of the hook manufacturer as well as the limitations determined by current regulations minimum spaces for the electrical system joint and brake joint maximum distance between the hook pin axle and rear edge of the superstructure etc If the hook attachment flange does not have drill holes suitable for the existing ones on the rear vehicl...

Page 51: ...the following formulas Dc g T S C T S C V a X2 L2 C Dc representative value of the hook class kN It is defined as the theoretical force of reference for the horizontal force between the towing vehicle and the trailer g gravity acceleration 9 81 m s2 T maximum weight t of the towing vehicle T S maximum weight t of the towing vehicle including if necessary the vertical load of the central axle trail...

Page 52: ... 65C 70C 14 Calculation example for the attachment device class for central axle trailers Considering a 65C15 vehicle with a maximum weight of 6250 kg that must tow a central axle trailer weighing 3500 kg with S 250 kg length of the loading surface of 5 m and theoretical drawbar length of 4 m Therefore from the data 1 S 0 25 t 2 C R S 3 5 0 25 3 25 t 3 T S 6 25 0 25 6 5 t 4 X2 l2 25 16 1 5 the fol...

Page 53: ...lemented in the same way and using screws of the same type diameter and resistance class as originally foreseen Loosening prevention systems must be used in the connections Figure 2 12 173258 1 Frame side member 2 Bracket for the lowered cross member For vehicles with a 3000 mm wheel base in order to avoid possible interference with parts of the rear suspensions IVECO provides a different solution...

Page 54: ...ations contain the conditions for towing and if necessary provides information regarding the changes and operations to be implemented on the vehicle reinforcements to the standard cross member see Figure 2 12 or assembly of a reinforced cross member when available or adjustments to the braking system The tow hook must be suitable for the new use and its attachment flange must coincide with that of...

Page 55: ...o properly implement and position the sections The purpose of the information contained in this manual is to ensure proper operation of the transmission limit its noise and avoid the triggering of stress transmitted by the power unit This does not exempt the fitter from his responsibility for the work performed 2 8 1 Permitted lengths a The maximum operating lengths that can be implemented both fo...

Page 56: ...0 13 F1AE3481B A 3600 15 F1AE3481C A 3900 15 F1CE3481J B 3500 17 F1CE3481K B 3500 21 F1CE3481D B 3500 15EEV F1CE34818 C 3500 17EEV F1CE3481C C 3500 14G F1CE0441A B 3500 1 Check the engine code on the engine plate Table 2 15 Gearbox iG 2830 5 0 777 2835 6 0 701 2840 6 6AS400 0 791 2850 6 0 685 Calculation example for the maximum implementable transmission length Considering a 35C13 vehicle with a 2...

Page 57: ...s of the pipe must be agreed upon on a case by case basis depending on the dimensions of the propeller shaft e g dimensions of the universal joint with the authorised workshops of the propeller shaft manufacturers The minimum operating length between flanges must not be less than 600 mm for sliding shafts and 300 mm for intermediate shafts Table 2 16 Implementable transmission characteristics CRIT...

Page 58: ...th the useful stroke select a position with the static position in the central area as much as possible 173260 Figure 2 15 1 Engine clutch gearbox axis 2 Sliding articulated shaft 3 Shaft support 4 Articulated shaft 5 Rear axle casing camber static load 6 Rear axle casing camber max compression 7 Rear axle casing camber unloaded vehicle 8 Articulated shaft sliding and rear axle casing axis must ha...

Page 59: ...by IVECO When shortening the wheelbase the intermediate shafts should be disassembled when the length of the articulated shaft is less than approx 600 mm Figure 2 17 1 Intermediate shaft 2 Support plate 3 Base plate 4 Intermediate shaft support 102426 The considerations made up to this point also apply to vehicles with a separate gearbox Furthermore for these it is usually not possible to shorten ...

Page 60: ...oming deformed The compartment must keep the air passage section effective over the entire path Any openings that have to be made in the van bodies must have a useful area no less than approx twice that of the master section of the pipe upstream of the filter these openings example grid holes must have a minimum dimension to prevent them from being blocked Not permitted changing or replacing the o...

Page 61: ...reseeing suitable bleeding that could make water circulation difficult check the priming of the water pump when the engine starts and that its subsequent operation at idle speed is immediate perform a few accelerations if necessary also with the circuit not pressurised When controlling check that the water pump delivery pressure with the engine at maximum no load speed is no less than 1 bar To che...

Page 62: ...r suspension require the corrector to be adjusted see Chapter 2 15 No changes are permitted to suspensions on vehicles equipped with ESP See Paragraph 2 15 4 Transforming the suspension from mechanical to pneumatic This type of transformation is strongly advised against as it involves components of the suspension and chassis anchoring parts that are essential to the vehicle s active safety Any com...

Page 63: ...may be changed by an Authorised Workshop To avoid changing the vehicle s braking capacity the load on the ground braking pressure ratio indicated on the specific plate on the corrector must be respected under the various load conditions To regulate this ratio proceed as indicated in point 2 15 2 foreseeing a value corresponding to the rigidity characteristics of the new spring for the load to be a...

Page 64: ... done independently of the engine power supply and if the new circuit is perfectly sealed define the path of the pipes and the electrical cables and the positioning of the flexible joints based on the dimensions and the influence of heat on the various chassis components Avoid exposures that could be dangerous and use suitable guards as necessary The entire positioning of the system must provide g...

Page 65: ...diagram of a supplementary heating system with an additional heater Figure 2 18 159346 1 Main heater 2 Optional supplementary heater 3 Solenoid valve 4 Additional heater responsibility of the fitter A Open solenoid valve 3 B Closed solenoid valve 3 Engine coolant Diesel oil NOTE Heaters 2 and 4 may also be used individually ...

Page 66: ...aintenance When delivering the vehicle the fitter must provide the necessary instructions for servicing and maintenance Furthermore in function of the type of system a system positioned inside the cab the position of the condenser must not have a negative impact on the original engine cooling characteristics of the vehicle reduction of the exposed area of the radiator engine the positioning of the...

Page 67: ...functionality Controls and devices power take off engagement control external operating cylinder control etc may be installed in the cab under the following conditions the positioning is rational precise and accessible for the driver the safety control and signalling devices foreseen by national regulations have been adopted Make sure that the pipes and cables are correctly positioned also in func...

Page 68: ...ent Upon request versions created by IVECO based on its own designs and checks are available If installing kits of another origin comply with the specific indications provided by the manufacturer If foreseen by national standards these installations must be checked by the responsible approval bodies Operations on the roof panel and the rear wall of the cab If it is necessary to remove the rear wal...

Page 69: ...Printed 603 95 241 Base 02 2012 Operations on sheet metal Figure 2 19 1 Roof panel 2 Cutting limit area 3 Side headlining 4 Door compartment ring 5 Rear internal cross member 6 Rear wall 7 Rear door compartment trim 8 Side trim 173262 ...

Page 70: ...ements are provided for all wheel bases in order not to change the vehicle s stability in curves the load must not exceed a total value of 150 kg the permitted weight on each fastening element must not exceed 25 kg Figure 2 20 140847 Table 2 18 Dimensions in mm 1 2 3 4 5 6 Van wheel base 3000 low roof short protrusion 1760 754 932 1548 1548 1548 Van wheel base 3000 low roof long protrusion 1760 95...

Page 71: ...ucent roof 500360077 1 Cross member 500360079 2 Support 500360089 2 Figure 2 21 102772 cutting area 25 mm cut the roof panel approx 25 mm from the original connection area with the body see Figure 2 21 weld the four structural elements mentioned above cross members and supports to the body using the 25 mm tab that was left when cutting carefully place the translucent roof on the structural element...

Page 72: ...b Installation of a hatch A hatch may be installed on the roof panel providing that the operation does not involve the hoops and that the seal and resistance of the modified part is guaranteed Figure 2 22 shows an installation example Figure 2 22 102773 cutting area sealant anchoring section ...

Page 73: ...ing the height of the roof panel is a very complicated and onerous operation therefore this operation must be limited to the medium and high roof versions that have the same structure as the roof panel Figure 2 23 shows the cross section of two versions where it is possible to see that the roof panel is a unified structure To permit the correct connection with the original roof panel the fitter mu...

Page 74: ...Remove the pillar in the window area providing suitable reinforcement to the base node Figure 2 24 102434 inner support structure gasket gasket inner support structure gluing with semi structural material gluing with semi structural material cutting area inner support structure e Internal shelves Internal shelves must be created so that they are sufficiently rigid and are self supporting The lower...

Page 75: ...st gas the possible lowering of the rear wheel arch must account for the jolting of the suspension as well as the simultaneous presence of snow chains For this purpose Figure 2 25 shows the possible cases and the resulting maximum lowering values that are possible Figure 2 25 173263 A Windowed van Vendor 3 5 t P 3000 3300 B Minibus Vendor Windowed van 4 2 4 5 5 t C Van 6 5 7 t 1 Standard van versi...

Page 76: ...tions on sheet metal If working on the bodywork of vehicles equipped with a front suspension with a torsion bar it is necessary to guarantee accessibility to the position adjustment system NOTE Figure 2 26 112216 Area free of obstructions for accessing the regulation unit ...

Page 77: ... To help preserve the integrity and rigidity of the cab it is recommended to maintain the rear structure as intact as possible The cut may be made laterally without damaging the door compartment ring The fitter must implement the necessary connections to the weight bearing structure composed of longitudinal sections and pillars and connect the new floor to them furthermore inspection panels must b...

Page 78: ...ng on the dashboard changes to the steering column replacement or installation of seats with an H point different than the original one In the case of a passenger side airbag comply with the regulations for the installation and use of child seats NOTE The supplementary circuits must be separate from the main vehicle circuit and protected with a suitable fuse Safety belt anchoring Operations carrie...

Page 79: ...y with appropriate and type approved types see Chapter 2 20 requires verification of compliance of the transversal limit contour with the regulations Prescriptions Replacing the tyres with others with a different external diameter may have an impact on vehicle performance e g speed max negotiable gradient driving force braking capacity etc therefore the body computer speedometer tachograph and spe...

Page 80: ...ding to IVECO std 17 4000 CONNECTING ELEMENTS Thread TIGHTENING N Name CLASS Torque Nm CHARACTERISTICS S Min Max 1 Front and rear wheel fastening 29L 35S M14 stud II 144 176 S 2 Front and rear wheel fastening 35C 50C M18x1 5 nut II 290 350 S 3 Front and rear wheel fastening 60C 65C 70C M18x1 5 nut II 290 350 S Characteristic S safety tightness see IVECO std 19 0405 If using brackets for fastening ...

Page 81: ... the involved brake piping must be replaced with new piping implemented in a single piece if this is not possible it is necessary to use the same type of unions that were originally used When making the replacements respect the minimum internal dimensions of the existing pipes The specifications and material of the new pipes must correspond with those of the originally used pipes The assembly must...

Page 82: ...f specific flexible pipes is necessary The operations must include materials and dimensions Standards DIN 73378 and 74324 Maximum operating pressure 11 bar curvature radiuses min 6 ext referred to the centre line of the pipe Preparation and assembly Cut the pipe at a right angle maximum error 15 using a specific tool in order to prevent imperfections that compromise the seal In an indelible manner...

Page 83: ...he pipe into the union for the section of length L that was previously marked using a force between 30 and 120 N based on pipe dimensions The components can be replaced valves etc as the coupling and the union permit internal rotation during unscrewing and screwing operations New unions must be used when replacing a pipe A union may not be reused after it has been opened Pipe installation The new ...

Page 84: ...e traditional manual bleeding operation may not be sufficient It is necessary to carry out the operation controlled by the program included in MODUS or in E A SY This program makes it possible to perform a complete bleeding operation primary circuit and secondary circuit of the modulator under System filling emptying Follow the instructions that appear on the video being careful not to exceed the ...

Page 85: ...ectly settle the rear suspension before carrying out the adjustment For this purpose it is recommended to partially load the vehicle approx 2 3 of the permitted maximum drive on an uneven road and then perform a series of braking operations in forward and reverse gears NOTE Connect pressure gauges 1 and 2 to the pressure test points upstream and downstream of the corrector using the test unions 3 ...

Page 86: ...em Figure 2 29 102436 Single circuit corrector for model 35C 1 Pressure gauge upstream of the corrector 2 Pressure gauge downstream of the corrector 3 Test unions 4 Breaking corrector 5 Rod 6 Main lever 7 Adjustment lever 8 Coupling screw 9 Hole for the application of the calibration load ...

Page 87: ... time Figure 2 30 156930 1 Electro hydraulic modulator 2 Braking system control unit 3 Yaw and acceleration sensor 4 Steering angle sensor The following parameters are relevant for the correct programming of the ESP control unit vehicle configuration van truck camper wheelbase G V W type of suspensions type of gearbox wheel circumference possible presence of a retarder Each change to one or more o...

Page 88: ...m is installed Therefore if authorisation is granted the downgrading of this system is mandatory Transformation from van to truck The transformation from van to truck must be authorised by IVECO and is not compatible if an ESP system is installed Therefore if authorisation is granted the downgrading of this system is mandatory Variation of the G V W The variation of the G V W must be authorised by...

Page 89: ... with the vehicle via the CAN network and therefore cannot be managed b the retrofitting of an electronically operated electro magnet retarder is compatible but requires IVECO authorisation also due to the resulting changes to the mechanical components see Chapter 2 19 In the case of a favourable result the authorisation is released and instructions are provided for connection to the CAN network b...

Page 90: ...d 603 95 241 Electrical system work and current draws Electrical system work and current draws 2 16 Electrical system work and current draws For information regarding work on the electrical system refer to what is described in section 5 Chapter 5 4 NOTE ...

Page 91: ...r For cabs not supplied with a spare wheel holder or if it is necessary to move the location of the spare wheel a suitable support must be implemented that permits quick removal and that respects a minimum entry angle of 7 Two possible solutions are shown in figures 2 31 and 2 32 For the fastening of the spare wheel on the side of the vehicle with a support placed on the rib of the side member it ...

Page 92: ...ew positions must be made on the rib of the side member according to the requirements specified in Chapter 2 2 and being careful to use already existing holes as much as possible Figure 2 32 102451 Clutch control tank This is located in the front part of the chassis the tank cover must not be removed and the unit does not require maintenance Figure 2 33 126198 ...

Page 93: ...configuration Figure 2 34 specifies the types of IVECO tanks available as an alternative to the original one Figure 2 34 173267 Shaped 100 l Shaped 70 l Rectangular 70 l Rectangular 90 l Rectangular 120 l Please note that if the tank is replaced with a different type the body computer must be updated In fact the body computer processes the signals of the level indicator associating them with the e...

Page 94: ...uipment is different based on the said categories IVECO does not provide ADR versions although the vehicles are already compliant on the level of some electrical parts mechanical components and materials inside the cab The fitter who makes a request is issued a declaration containing the detail of the paragraphs of the ECE document with which the vehicle is already compliant Anything that is missi...

Page 95: ... of the maximum braking torque Considering a 50C15V P vehicle with axle ratio of 3 15 and 195 75R16 tyres From the data 1 iP 3 15 2 R 0 317 m 3 PTT 5200 kg the following is obtained Cf 5200 0 317 3 15 520 Nm A retarder brake with a maximum braking torque of 500 Nm may be applied The application must be taken care of directly by the supplier in strict compliance with Chapters 2 2 2 8 and 5 4 of the...

Page 96: ...he required characteristics If another under run protection device must be fit compliance with current regulations must be checked The inspection certificates or documentation must be presented if requested to the competent Authorities Rear under run protection and wheelhouses 2 21 Rear under run protection and wheelhouses In cab vehicles supplied without mudflaps these can be positioned by implem...

Page 97: ...ble the existing holes in the vertical rib of the side member in accordance with Chapter 2 2 When implementing the external protection according to what is specified by the regulations e g EC Directive it is permitted to use a single section on an extended surface in a vertical direction or multiple longitudinal sections with predefined dimensions and distances from each other The side protection ...

Page 98: ...2 72 CHASSIS MODIFICATIONS DAILY Base 02 2012 Printed 603 95 241 Chocks ...

Page 99: ...ng characteristics 3 10 3 3 3 Connection with brackets flexible joint 3 11 3 3 4 Elastic connections 3 12 3 3 5 Connection with U bolts clamps 3 13 3 3 6 Connection with plates for longitudinal and transverse fixing rigid joint 3 14 3 3 7 Mixed connections 3 15 3 4 Fitting box bodies 3 16 3 4 1 Fixed boxes 3 16 3 4 2 Tipper boxes 3 19 3 5 Tractor for half trailers 3 21 3 6 Transport of indivisible...

Page 100: ...34 3 11 Municipal fire fighting and special services 3 35 3 12 Installation of front snowploughs 3 36 3 13 Winch installation 3 37 3 14 Special body conversions 3 38 3 14 1 Chassis cowls 3 38 3 14 2 Motor homes 3 38 3 14 3 Installation of overhead platformsInstalling an aerial platform 3 39 Revi 10 2012 ...

Page 101: ...ds to be easily weldable and that it must not have values lower than those 1 shown in Table 3 1 Materials with better mechanical characteristics may be used when stress limits require them e g in cranes or if excessive section heights are to be avoided However take into account that reducing the inertial moment of the reinforcing profile causes greater flexion and stress on the main chassis The fo...

Page 102: ...cm3 Recommended C section profile mm 16 W 19 80 X 50 X 4 80 X 60 X 4 80 X 50 X 5 20 W 23 80 X 60 X 5 24 W 26 80 X 60 X 6 27 W 30 80 X 60 X 7 100 X 50 X 5 31 W 33 80 X 60 X 8 100 X 60 X 5 34 W 36 100 X 60 X 6 37 W 41 100 X 60 X 7 42 W 45 80 X 80 X 8 100 X 60 X 8 46 W 52 120 X 60 X 6 120 X 60 X 7 53 W 58 120 X 60 X 8 59 W 65 140 X 60 X 7 120 X 70 X 7 66 W 72 140 X 60 X 8 120 X 80 X 8 73 W 79 160 X 6...

Page 103: ...ports Cases when excessive stress on the chassis requires relatively big sizes of steel reinforcing profiles or shear resistant connections are exceptions b When the sub frame must also provide support in resistance and rigidity for example structures with high concentrated loads tilting bodies cranes central axle trailers etc using aluminium is not recommended and it must be authorized from time ...

Page 104: ...tion the front ends of the profile must be tapered in height to an angle no greater than 30º or with another tapering having an equivalent function see Figure 3 1 the front end in contact with the chassis must be coupled appropriately with a min radius of 5 mm 91136 Figure 3 1 When the components of the cab rear suspension e g with deep cabs do not allow the profile to pass through in its entire s...

Page 105: ...uously leaning on the profiles of the chassis if it is not so continuity can be re established by means of sheet metal or light alloy straps If a rubber antiskid element is positioned here we recommend specifications and thickness identical to those used for normal production hardness 80 Shore max thickness 3 mm The application of antifriction material may prevent abrasive actions which can cause ...

Page 106: ...desired construction can be performed as per Figure 3 5 Figure 3 4 Figure 3 5 Stiffening the subframe The sub frame must be made more rigid in the rear part for some structures e g tilting bodies cement mixers cranes on the rear overhang structures with high centre of gravity This can be performed with a greater amount of rigidity to achieve joining the rear section of the longitudinal member by a...

Page 107: ...subframe Figure 3 7 166685 Self supporting bodies as subframes When installing self supporting structures e g vans tanks or when the basic structure of the equipment to be installed is already shaped as a sub frame the use of a sub frame longitudinal profiles and cross members can be avoided ...

Page 108: ...to be installed e g a tilting body on a chassis approved for a fixed tray suitable connections must be prepared e g shelves must be replaced with shear resistant plates in the rear area of the chassis When anchoring the structure to the chassis no weldings must be performed on the vehicle chassis and its wings must not be pierced In order to improve the longitudinal or transverse securing of the c...

Page 109: ...ber only by means of bolts or rivets In order to better sustain transversal loads usually the shelves are applied so that they protrude slightly in the vertical direction with respect to the upper edge of the chassis If the shelves must be exactly flush the side guide of the structure must be anchored in other ways e g using guide plates connecting only to the sub frame or to the vehicle chassis s...

Page 110: ...tioned near the rear suspension Therefore the first fastening behind the cab must always be performed with one of the solutions shown in Figure 3 9 and this solution must be repeated also for the following fastening changing only its rigidity especially when the vehicle has a long wheelbase For example when using brackets with silentblocks elements having the same hardness sh 83 must be used and a...

Page 111: ...tructure added to the chassis in the transversal direction this type of fastening can be completed by adding plates welded to the sub frame as shown in Figure 3 10 The characteristics of this connection are not suitable for a general integral use on the vehicle in any case the fastening must be accompanied by longitudinal and transversal plates toward the rear part in order to provide the structur...

Page 112: ...sis and the capacity of the chassis to resist shearing must be improved or when the height of the sub frame needs to be limited as much as possible e g towing central axle trailers crane on the rear overhang tail lifts etc If this occurs the indications of the following table must be observed Table 3 3 Chassis subframe section height ratio Max distance between the centre line of the shear resistan...

Page 113: ... rigid longitudinal and transversal plates connections rationally As a general rule elastic connections are preferable in the front part of the sub frame one or two for each side while plate connections are recommendable for the rear part of the vehicle when the additional structure needs to contribute to a greater overall rigidity e g tilting bodies cranes on the overhang etc To this purpose the ...

Page 114: ...base should be made so that it can make an adequate torsion contribution to the chassis frame of the vehicle Fastening must be performed by means of suitable shelves fitted to the vertical rib of the side members if these fastenings are not already fitted by IVECO they must be created following the indications in point 3 3 3 In order to perform an adequate longitudinal containment when connecting ...

Page 115: ... can be created to connect to the vehicle chassis For longitudinal profiles see Table 3 4 Figure 3 14 shows an example where the longitudinal profiles are completed by cross members and shelves for the entire length in order to limit the height of the structure In this case the rear wheel arches can be inserted into the base of the structure Figure 3 14 102465 ...

Page 116: ...high torsion rigidity requires elastic connections toward the front of the structure in order to avoid excessive reduction in deformability of the main chassis Front bulk head It must be resistant and robust enough to sustain the forces generated by the transported load in the event of sudden high deceleration Bodies integrated with the cab In these cases the connection must be performed so as to ...

Page 117: ...r excessive strain If this is not possible use sub frame profiles of greater size compared to usual and strengthen the rear part further In particular cases when long trays are required for greater volumes we recommend using longer wheelbases rather that creating long overhangs d Particular care must be taken in positioning the lifting device both with regards to the necessary strength of the supp...

Page 118: ...tting box bodies Figure 3 16 166687 1 Subframe 2 Body mounting brackets 3 Shear resistant plates 4 Hinge constraint Table 3 5 Models Minimum reinforcing longitudinal Modulus of resistance Wx cm3 Dimensions mm 35C 40C 19 80x50x5 45C 50C 60C 65C 70C 36 100x60x6 Revi 10 2012 ...

Page 119: ...sections Furthermore take the following into consideration for its construction the structure must be sized appropriately for vertical and horizontal loads transmitted by the fifth wheel the characteristics of the structure material must refer to point 3 1 the upper and lower surfaces of the structure must be flat to ensure good support on the chassis the components of the structures when constitu...

Page 120: ...e quantity of screws the size and position of the longitudinal and transversal stoppers Since it is an important element for vehicle safety the fifth wheel must not be modified Braking system The Bodybuilder must provide a specific braking system for the semitrailer The braking system must be extremely well designed and constructed due to its great significance for the active safety of the vehicle...

Page 121: ... the tractor with the semi trailer Semitrailers must not have construction characteristics e g excessive chassis flexibility insufficient braking capacity etc such as to cause negative effects on the driving behaviour of the semitrailer When coupling the tractor and semitrailer all relative movements must be checked under the various use conditions of course the required safety tolerances must be ...

Page 122: ...ensions exceed normal ones is regulated in various countries by special legislation For transport systems where particular force configurations arise following concentrated vertical loads and dynamic thrust during braking a preventive check on the vehicle s suitability must be carried out directly with IVECO The structure to support the load on the tractor must be of the sub frame type while other...

Page 123: ...hrough which the forces are discharged is similar here The rigid mounts go in a position corresponding to the rear suspension supports and the flexible mounts as near as possible to the rear support of the front suspension When this is not the case reinforcement longitudinal profiles may be required having a greater size compared to that shown in Table 3 7 Table 3 7 Installing a tank Models Wheelb...

Page 124: ...ons must be authorized by IVECO Self standing tanks can be placed directly on the vehicle chassis if suitable supports are used located immediately behind the cab and in the rear axle area Quantity and distribution of the supports depend on the wheelbase and at least two for each side must be fitted e g for short wheelbase vehicles To ensure that the max allowed limits for the axles are respected ...

Page 125: ... below in Figure 3 19 If the vehicle version e g tilting body requires a profile with greater resistance modulus than that required for the crane that profile can be considered valid for the crane as well Particular cases when the values of the MG moment correspond to value E in Table 3 8 or greater values must be checked from time to time and must be expressly authorized by IVECO Figure 3 19 MG k...

Page 126: ...icles used almost exclusively on the road where the sub frame profile height must be decreased the sub frame can be fastened with shear resistant connections The minimum size of the reinforcing profile for these applications are shown in Table 3 9 We recommend using profiles with a constant section along the entire length of the vehicle the profile section can decrease gradually in the areas where...

Page 127: ...e of tilting equipment take particular care in placing the supports of the device and the rear tilting hinges which must be moved back as little as possible Table 3 8 Cranes fitted behind the driver s cab Subframe fixed by means of brackets Crane capacity MG max kNm Models Chassis section at the centre line mm 0 20 20 30 30 40 40 50 50 60 60 70 70 80 Min value of subframe section modulus Wx cm3 1 ...

Page 128: ...e weight on the front and rear axles respects the limit defined for each vehicle see point 1 15 Since the rigidity required by the sub frame depends on various factors e g crane capacity sizing of the support base tare of the vehicle overhang of the chassis we cannot provide instructions for all situations therefore the Bodybuilder must operate if necessary also by means of behaviour tests on the ...

Page 129: ...ble cranes on the rear overhang can be performed according to the previous paragraph provided that the type of fastening used between the crane and the sub frame does not generate additional stress on the vehicle chassis Taking into account the possibility of using the vehicle with or without crane when allowed we recommend marking the position of the payload for both cases on the structure When t...

Page 130: ...dance to the capacity of the tail lifts have already determined average values in the second case these moments must be calculated each time Table 3 11 Installation of tail lifts Tail lift capacity kN kg Models Overhang mm 3 300 5 500 7 5 750 10 1000 12 5 1250 15 1500 Minimum value of the resistance modulus of the sub frame section Wx cm3 29L 35S E E E 35C 40C 45C 50C 1240 1355 16 21 26 S 31 S E 3...

Page 131: ... Therefore always assess if it is necessary to use stabilizers even when it would not be required taking into account only the stress generated on the chassis Stabilizers must be fixed to the support structure of the tail lift and must be preferably hydraulically operated Stabilizers must be operated under all loading conditions of the tail lift When installing electro hydraulic tail lifts check t...

Page 132: ...ds and correct fastening of components and assemblies used to move the rescued vehicle This equipment must comply with towing weights vertical loads on the hook and the minimum ratio between front and rear axle weights as defined in the specific authorizations issued by IVECO The Bodybuilder must also provide plates labels indicating the specific conditions under which transport isauthorized towin...

Page 133: ...rhang When very short overhangs are required the chassis may be shortened immediately behind the rear spring hanger or after the anti roll bar connection in the case of pneumatic suspension keeping the cross member connection to the chassis intact vertical positioning of the exhaust behind the cab use of more rigid rear suspensions or suspensions with asymmetrical springs new position of rear ligh...

Page 134: ... all national norms and regulations governing the application of this equipment must be respected as well as maintaining the function and possibility of using original elements placed in the front of the vehicle e g towing hook Otherwise the Bodybuilder must install equivalent systems complying with safety norms and regulations Due to the limited maximum speed for most IVECO vehicles used as snow ...

Page 135: ...ly locally see point 2 17 according to the pull of the winch rope and in particular of its transversal component when traction is on a diagonal Installation of a winch in the area behind the cab requires an additionalsub frame with size andstructure crossand diagonalmembers for rigidity suitable to the winch capacity In the event of winches with hydraulic drive hydraulic pumps already installed fo...

Page 136: ...efully observed 3 14 2 Motor homes The limits to weights for single axles and overall weight must be strictly complied with taking into account the number of people on the vehicle and a sufficient margin to load the following uggage curtains sports equipment water tank toilets gas bottles etc Ensure that the load to be transported is placed in specific compartments allowing for suitable safety mar...

Page 137: ...instructions see Chapter 3 3 and Table 3 2 and Table 3 3 the Fitter must also assess the maximum static momentum and the envisaged position for the superstructure avoid sudden section changes realize a fastening solution as shown in Figure 3 2 on page 3 6 or in the event of extreme mechanical stress as shown in Figure 3 23 Figure 3 23 INITIAL FASTENING OF THE COUNTERFRAME 173275 The Fitter must ca...

Page 138: ...spare parts no 504267869 Figure 3 24 LOWER SIDE VIEW CAB SILENTBLOCK FIRST SUB FRAME FASTENING DETAIL OF SECTION OF CHASSIS STRAP 1050 145179 The straps must have a minimum thickness of 4 mm and a length sufficient to cover the side member of the chassis in front of the cab silentblock areas and behind the first sub frame fastening see Figure 3 24 the total length must not be less than 1050 mm The...

Page 139: ...earbox 4 5 4 3 Power Take Off from transfer box 4 8 4 4 Power Take Off from drive line 4 8 4 5 Power Take Off from engine 4 9 4 6 PTO management 4 10 4 6 1 General specifications 4 10 4 6 2 PTO mode 4 13 4 6 2 1 Mechanical gearbox 4 13 4 6 2 2 Automatic transmission 4 14 4 6 2 3 Engine speed control for Power Take Off 4 15 4 6 2 4 Multiple State Switch 4 16 ...

Page 140: ...4 2 POWER TAKE OFFS DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 141: ... that power uptake occurs within the flexible engine operating range avoid low speeds lower than 1000 rpm to rule out unevenness and jerkiness in vehicle operation The power taken in relation to the number of revolutions of the Power Take Off at the required torque P PS M n i 7023 P kW M n i 9550 P Useable power M Torque permitted for the Power Take Off Nm n Power Take Off rpm i Transmission ratio...

Page 142: ...es must be realised for good homokinetics see Figure 4 1 these must be no more than 7 solution Z is preferable to W as the loads on the bearings of the PTO and the driven equipment are lower In particular when it is necessary to realise a transmission line with shafts inclined in the space according to an angle ϕ as illustrated in Figure 4 2 it must be remembered that the overall homokinetics can ...

Page 143: ...normally be used with the vehicle parked and must be engaged and disengaged with the clutch disengaged to avoid excessive stress on the synchronisers When under exceptional circumstances it is used with the vehicle in movement no gear changes must be performed The same PTOs for manual gearboxes can be used with gearboxes fitted with torque converters It must however be remembered that for engine r...

Page 144: ...le 4 1 Gearbox Position 1 Output 1 Direction of rotation 2 Max torque Cmax Nm 2 PTO ratio 2830 5 2835 6 Left hand side Rear Clockwise 120 1 00 2840 6 2850 6 6AS400 Left hand side Rear Clockwise 180 1 04 1 With respect to forward direction of travel 2 When viewing the PTO output from the front 3 The maximum torque that can be taken refers to an engine speed of 1 500 r p m output from the PTO For hi...

Page 145: ...ertial effects of any added masses must be verified so as not to induce resonance conditions in the power unit inside the operational range of engine speeds For torque drawing keep values defined in Table 4 1 Transmission oil temperature must not exceed 110 C during prolonged use Coolant temperature must not exceed 100 C Not all types of Power Take Off available on the market are suitable for cont...

Page 146: ...r more shaft sections the PTO may also be installed in correspondence with the oscillating mount between the first and second section follow indications in point 2 9 2 the original transmission angles in the horizontal and vertical planes must be maintained as closely as possible anything added to the transmission must not cause abnormal vibrations or instability or otherwise damaging effects on t...

Page 147: ...de 1 nmax rpm 2 Max take off values Max no load speed r p m Max torque that can be taken Nm Max inertia moment kgm2 Max bending moment Nm 3 F1A Euro 5 Series 11 F1AE3481A A 3900 4600 35 0 005 42 13 F1AE3481B A 3600 4600 35 0 005 42 15 F1AE3481C A 3600 4600 35 0 005 42 F1C Euro 5 Series 15 F1CE3481J B 3500 4200 35 0 005 42 17 F1CE3481K B 3500 4200 35 0 005 42 21 F1CE3481D B 3500 4200 35 0 005 42 F1...

Page 148: ...where only the PTO is present a control panel is installed on the instrument cluster Figure 4 6 page 4 11 which consists of PTO section which provides management of the engagement and disengagement of the Power Take Off using a pushbutton 1 with a warning light 2 signalling the situation in progress VALVE section for managing the operation of a dump body if present and interaction with the hydraul...

Page 149: ... additional functions and safety features in the manufacturer s handbooks After market PTO installation After market installation of the PTO is possible on vehicles with or without Expansion Modules Installation of the PTO is possible only where this is provided for on the vehicle c For vehicles without an Expansion Module it is necessary to order the components for installation of the PTO the cab...

Page 150: ...Module relay T61 30 87 for PTO X 15 A0 X X X F80 30 Expansion Module relay T62 30 87 for PTO X 15 A0 X X X F86 AVAILABLE A0 F88 AVAILABLE A0 F89 AVAILABLE A0 F90 AVAILABLE A0 SCM1 C Power Protection Presence Capacity Type EURO5 4x2 EUROV 4x2 BIFUEL S OPT T61 Expansion Module X 20 X X X T62 Expansion Module X 20 X X X With the PTO installed the Engine Control Unit can be configured by IVECO service...

Page 151: ... that works also when the vehicle is running non stationary PTO the same procedure basically applies except for the need to engage the right gear for the work first reverse or possibly neutral before slowly releasing the clutch pedal To adjust the engine speed see paragraph 4 6 2 3 PTO disengagement Irrespective of the type of PTO installed stop the equipment press the clutch pedal press the pushb...

Page 152: ...hicle is running non stationary PTO it will moreover be necessary to engage the right gear for the work first reverse or possibly neutral In both situations with the gearbox in neutral and PTO correctly engaged the ECU closes the clutch when 1100 rpm is reached Also pickup is possible in first or reverse gear in this case the gearbox control unit is arranged for closing the clutch at approx 900 rp...

Page 153: ...km h After setting the selector in Figure 4 9 to ON it is possible to adjust the Cruise Control lever in or direction in order to increase or decrease the rpm in two ways a in steps of 50 rpm if the lever is operated for between 0 5 and 2 seconds b with a ramp of 400 rpm for each second of continuous lever operation over 2 seconds It is possible to store with PTO activated a new rpm setting by hol...

Page 154: ...ual operation press RESume button on the Cruise Control to bring the engine speed to the programmed rpm Assisted operation supplying a positive signal to pin 15 of the 20 way Bodybuilder connector the engine speed will increase to the programmed rpm value 2 Vehicle stationary with switch in 0 position without pressing the RESume button the engine speed will remain at idle Upon changing the positio...

Page 155: ...o be taken with the installed electronic control units 5 17 5 3 2 Disconnecting ECUs 5 19 5 3 3 Repositioning ECUs 5 19 5 4 Electrical system modifications and drawing off power 5 20 5 4 1 Earth points 5 23 5 4 2 Electromagnetic compatibility 5 28 5 4 3 Two way radio systems 5 29 5 4 4 Additional equipment 5 36 5 4 5 Current drawing 5 39 5 4 6 Additional circuits 5 49 5 4 7 Harness modifications d...

Page 156: ...5 2 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 157: ...ust not be connected directly to the control units described below It is only possible to use the connectors listed in the following paragraphs Figure 5 1 A Instrument panel B Trailer control unit C Steering column switch unit and ignition switch D CPL Connection control unit Body Computer E Oil control unit F Engine control unit G Positive 30 distribution CBA control unit and CFO H ABS ESP contro...

Page 158: ...uarantee its functional integrity and therefore the validity of the guarantee Two connectors 61071 and 72068 are provided inside the cab A special kit consisting of connectors and cable terminals must be ordered as a spare part in order to use these connectors Any interfacing between the body and the vehicle shall be made by means of diodes and relays clean contact unless otherwise specified in th...

Page 159: ...der connectors 5 2 1 20 pin connector 61071 20 way connector Figure 5 3 101564 Existing parts on the vehicle Counterpart to be connected Table 5 1 Code number Description 500314817 20 way male holder joint 500314820 Male contact for 0 3 to 0 5 mm2 cable 500314821 Male contact for 1 to 1 5 mm2 cable ...

Page 160: ...tive 4 Vehicle stationary Output max 500 mA When the vehicle is stationary a ground is obtained Earth vehicle parked Open circuit vehicle in motion 5 Parking brake Output max 500 mA interface with uncoupling diode When the handbrake is operated an earth signal is generated Earth brake engaged Open circuit brake released 6 Battery positive Output max 20 A Positive protected by a fuse present on the...

Page 161: ...ition live positive protected by a fuse present on the Body Computer F49 12 Cruise Control Command Input max 10 mA Cruise Control negative analogue signal in parallel controlled from the steering column switch unit See specification 3 13 Cruise Control command splitter reference ground Input max 10 mA See specification 3 14 Not connected 15 Not connected 16 Not connected 17 Earth Output max 15 A 1...

Page 162: ...der connectors 5 2 2 12 pin connector 72068 12 way connector Figure 5 4 101554 Existing parts on the vehicle Counterpart to be connected Table 5 3 Code number Description 500314814 12 way male holder joint 500314820 Male contact for 0 3 to 0 5 mm2 cable 500314821 Male contact for 1 to 1 5 mm2 cable ...

Page 163: ... Power Take Offs 4 Speed signal B7 See Specification 1 5 Key ON repeat Input max 500 mA Positive signal supplied to simulate initial key rotation key ON position Only the main loads are powered the vehicle cannot be started from outside because key recognition absent 12 V key active Open circuit Key inactive 6 Power Take Off activation Output max 500 mA When the Power Take Off is engaged an earth ...

Page 164: ...iable duty cycle due to the vehicle s tachometric constant Figure 5 5 114186 VEHICLE SPEED SIGNAL Input signal on the pulse transmitter Output signal from the pulse transmitter B7 signal from the tachograph Below are the electric features of the signal Minimum voltage level 1 5 V Maximum voltage level 5 5 V Max frequency 1 5 kHz Pulse duration TH 0 67 6 7 ms Pulse duration tolerance 1 Load impedan...

Page 165: ... equal to that shown with a max Vdc of 5 volt and pull up pull down in order not to lower the VON voltage and increase the response time set by the vehicle interface Speed calculation following signal B7 reading involves controlling both the frequency and the duty cycle of the signal itself since the frequency is a function of the vehicle whereas the duty cycle is a function of the tachometric con...

Page 166: ...2 65 kΩ I Out 50 mA t Rise Signal output time from 10 to 90 10 5 μs R ON Output current 0 05 A 33 8 Ω V I 5 4 13 5 15 7 V Pulses per rev 4 Figure 5 7 Bodybuilders connector Interface for processor designer Processor signal COMPULSORY separation diode 143780 The Bodybuilder must fit a separation diode so that the VON voltage is not lowered The signal processing designer must ensure an input interfa...

Page 167: ...0 Pin 11 20 way Bodybuilder connector 15 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS 5 13 DAILY Printed 603 95 241 Base 02 2012 Bodybuilder connectors Specification 3 Cruise Control via Bodybuilder socket The Bodybuilder must fit the splitter outlined below by connecting it to the 20 way Bodybuilder connector by referring to the pins shown R1 2490Ω 1 R2 649Ω 1 R3 261Ω 1 R4 133Ω 1 ...

Page 168: ...ook Provision for rear door These options offer a key with a 3 button remote control one button is dedicated to the rear door to control the additional rear door as well as a button locks unlocks all the doors on the dashboard The connector is located beneath the plastic pillar trim behind the passenger seat see Figure 5 9 Figure 5 9 139393 The Diagram below shows the connection between to rear do...

Page 169: ...s plug Driver door and passenger door connecting diagram 1 Open circuit when door is closed Closed circuit when door is opened Bodybuilder s Switch Button Bodybuilder s Actuator Figure 5 11 Pinl Driver Passenger Door actuator Pin3 Driver Passenger Door actuator Pin2 Closed door Signal Pin4 Closed door Signal 1 Only for Stripped Camper Cowl Chassis cowl and Stripped Chassis Cowl version Driver Door...

Page 170: ... and bonnet open sensor Figure 5 12 alarm siren 12 V Figure 5 13 Current absorption of the antitheft device is 30 40 mA The Bodybuilder must provide a door closed signal so that the anti theft system can also monitor any break in attempt on the bonnet Engine bonnet button connecting diagram 2 2 Only for Stripped Camper Chassis cowl and Stripped Chassis Cowl version with opt 5865 Pin1 Closed door S...

Page 171: ...ponents interlocked with electronic modules with the vehicle s nominal voltage via movable cables connect ECUs supplied with a metal casing to the system ground using a screw or bolt unless otherwise specified In case of actions to the taken on the chassis which require electric arc welding the following shall be done disconnect the CBA from the positive battery terminal and do not connect it to t...

Page 172: ...ical system e g removal of cables addition of circuits replacement of equipment or fuses etc carried out in a manner not compliant with IVECO s instructions or carried out by unqualified staff may cause serious damage to the on board systems affecting safety and reliability Operations carried out on the electrical system in a non compliant manner may cause significant damage e g short circuits wit...

Page 173: ... down cycle the warning light in the button will go out turn on the map reading lights located in the middle of the header rail isolate the battery by disconnecting the power cables first the negative pole then the positive the spots mentioned above are out disconnect the ECU 5 3 3 Repositioning ECUs IVECO recommends to avoid modifications which entails moving ECUs Follow the instructions below if...

Page 174: ...Y 2012 This manual is available at the Service network and can be requested from the relevant Departments of the IVECO Sales Organisation NOTE Precautions for operations on the system Work on the system e g removing wiring harness making additional circuits replacing equipment changing fuses etc that is not done in conformity with IVECO instructions or is carried out by unskilled personnel can sev...

Page 175: ...capacity Change them only after eliminating the problem with keys and ancilliaries disconnected Restore the original conditions of the wiring routing guards and binding preventing the cable at all costs from coming into contact with metal surfaces of the structure that may impair its integrity Precautions for operations on the frame During work on the chassis frame to safeguard the electrical syst...

Page 176: ...le with a flat battery when starting the engine on vehicles with a manual gearbox turn the key ON and wait for all the engine warning lights on the instrument panel to go off Start the vehicle engine The starter motor must not be used for longer than 10 seconds Do not depress the accelerator pedal during start up when starting the engine on vehicles with an automatic gearbox turn the key ON and pr...

Page 177: ...surface without notches or steps apply a suitable paint with high electric conductivity properties between the cable terminal and the metal surface connect the earth within 5 minutes of applying the paint As regards the signal related ground connections e g sensors or low absorption devices do not use the standardized points for engine ground connection and chassis ground connection Additional sig...

Page 178: ...e compartment ground left chassis side member m3 ms3 Engine compartment ground under the servo brake m4 Engine compartment ground near right front light m5 Engine compartment ground near left front light m6 ms6 Ground inside cab central zone m7 Ground inside cab central zone 173253 m power grounds ms signal grounds Figure 5 16 m2 Left frame rail engine compartment earth 128823 BATTERY EARTH FRAME ...

Page 179: ...STEMS 5 25 DAILY Printed 603 95 241 Base 02 2012 Electrical system modifications and drawing off power Figure 5 17 m3 ms3 Engine compartment earth beneath brake servo 128824 Figure 5 18 128825 m4 Engine compartment earth near right front light ...

Page 180: ...S DAILY Base 02 2012 Printed 603 95 241 Electrical system modifications and drawing off power Figure 5 19 m5 Engine compartment earth near left front light 128826 Figure 5 20 162250 m6 ms6 m7 Grounds inside cab on the central body under the tachograph ...

Page 181: ...ground point connected 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 sheath shall come into electric contact only at...

Page 182: ... must be immune to negative interference such as 300 V spikes 100 V positive spikes bursts of 150 V They must operate correctly during the phase when voltage drops to 5 V for 40 ms and 0 V for 2 ms Moreover they must resist the load dump phenomena up to 40 V NOTE The maximum radiated emission levels measured at the bench and levels of conducted emissions generated by devices and also by 12 V power...

Page 183: ...regulations 5 4 3 Two way radio systems The most frequent applications include amateur receiver transmitter units for CB City Band and 2 m bands receiver transmitter units for cellular telephones GPS receiver and satellite navigation units General instructionss a The equipment must be approved according to the law and be of fixed type not portable The use of non approved transmitters or supplement...

Page 184: ...mitter equipment must be positioned as shown in Diagram 5 25 e The quality of the antenna the mounting position and a perfect connection to the vehicle structure ground are factors of fundamental importance to guarantee the best performance of the transmitter equipment Some specific instructions are given below for each type of equipment Amateur equipment for CB 27 MHz and 2m band 144 MHz The tran...

Page 185: ... Antenna 6 Roof 7 Antenna extension lead 98915 Figure 5 24 1 Antenna connector 2 Ground wire 3 Insulator 4 Signal wire 5 Capacitor 100 pF 6 Cable RG 58 characteristic impedance 50 Ω 7 Clamp 8 Protective cap 9 Connector N C SO 239 transceiver side 10 Test executed sticker 11 The 100 pF capacitor must be soldered on the lower pin and crimped to the ground braid 12 The lower pin must be soldered to t...

Page 186: ...GAIN values must be as high as possible and guarantee a sufficient level of spatial uniformity characterised by deviations in relation to the average value of the order of 1 5 dB in the 870 960 MHz band and 2 dB in the 1710 2000 MHz band The value of the RADIATED FIELD in the cab must be as low as possible and therefore 1 V m The limits imposed by the current European Directive must not be exceede...

Page 187: ...components In the case of shielded vehicles the ceiling fitting with microphone is supplied in the equipment kit case If required by the installation in the cab the microphone can be removed and replaced It must however be positioned at a point distant from possible noise sources and according to the reception area described in the following picture 166093 Figure 5 27 166095 REAR cable side FRONT ...

Page 188: ...bility possible of the sky In fact as the signals received from the satellite are at very low power around 136dBm almost any obstacle can influence 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 horizontal position that is never underneath any metal ...

Page 189: ...e speed integration with Convergence V2 system integration with the Blue Me system recognition antitheft system with Body Computer Car radios of other types do not allow access to the previous functions The pins available for the installation are listed in fig 5 29 Figure 5 29 128829 Box pin Description A 1 CAN B CAN H A 2 NC A 3 CAN A CAN L A 4 Permanent 12V KL 30 A 5 Automatic Antenna A 6 NC A 7...

Page 190: ...s 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 vehicle system is designed to supply the power necessary for the equipment sup...

Page 191: ... 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 elect...

Page 192: ...tted The additional alternators must be the type with rectifiers with Zener diodes to avoid damage to the electric electronic equipment due to accidental removal of the batteries Each alternator must also have a no battery charging warning light or led The auxiliary alternator shall feature the same characteristics as the standard one and the cables shall be properly dimensioned If it is necessary...

Page 193: ...s connector cab interior Figure 5 32 Drawing current from CBA on battery The battery is fitted with a control unit to deliver the positive and protect the services CBA Figure 5 33 143781 Table 5 8 Ref Function Fuse rating A Cable section mm2 1 30 positive from F75 for starter motor alternator and retarder if present 500 50 or 35 2 30 positive from F70 for SCM BUS BAR 150 35 3 30 positive from F73 ...

Page 194: ...r position insert the terminals into the studs and secure them using the special nuts M5 flanged nut self locking etc tightened to torque 4 6 Nm then fix the CFO control unit optional fuse control unit to the CBA control unit as in Figure 5 34 fitting the hole of the strip on the stud bolt of the battery terminal no 6 incorporated in the CBA of Figure 5 33 and tightening the special nut to the req...

Page 195: ...is absolutely prohibited to take current from points that are not shown Figure 5 35 162238 1 Lever for fast disconnection of battery negative terminal from the electrical system 2 3 Only current take off points To secure the additional terminal on the free pin M6 of the negative battery terminal 3 tighten the nut with a tightening torque of 5 5 Nm It is absolutely forbidden to draw power from unau...

Page 196: ...F34 30 fitter socket X 20 A0 X X X F36 30 T20 relay for MODUS car radio tachograph convergence siren parking sensor X 15 A0 X X X F37 15 instrument panel stop lights trailer socket X 7 5 A0 X X X F38 30 central locking X 20 A0 X X X F42 15 ABS9 or ESP9 X 5 A0 X X X F43 30 T23a relay 86 87 for windscreen washer and T23b relay 86 87 X 20 A0 X X X F47 30 T25a relay 86 87 and T25b 86 87 for driver s s...

Page 197: ...ight X X X X T12b 30 right foglight X X X X T23a 30 windscreen washer X X X X T25a driver s side electric window UP X X X X T25b driver s side electric window DOWN X X X X T26a passenger side electric window UP X X X X T26b passenger side electric window DOWN X X X X T37a rear doors central closing X X X X T37b central closing common X X X X T37c side doors central closing X X X X T37d rear door c...

Page 198: ... 44 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS DAILY Base 02 2012 Printed 603 95 241 Electrical system modifications and drawing off power Fuse box and relay in engine compartment Figure 5 37 162236 ...

Page 199: ...ssion MAIN RELAY T9 86 X 10 A0 X X X F15 30 T2 relay 30 87 for BOSCH cooling pump X 10 A0 X X F16 15 A cigarette lighter from T7 X 15 A0 X X X F17 EDC F1C secondary loads from MAIN RELAY X 10 A0 X X Smart Drive Unit CNG 15 X F18 30 rear differential lock X 30 A0 X X X F19 30 T6 relay 30 87 for horn X 7 5 A0 X X X F20 30 13 pin socket X 10 A0 X X X F21 30 T14 relay 30 for cylinder solenoid valves C...

Page 200: ...19 windscreen wiper speed activation X 10 20 X X X T20 diagnostics with MODUS X 20 X X X T30 cab heating fans X 50 X X X T31 fuel filter heater and sediment filter X 30 X X X SCM1 A fuse and relay list Table 5 14 SCM1 A Power Protection Presence Capacity Type EURO5 4x2 EUROV 4x2 BIFUEL S OPT F60 30 supplementary climate control X 30 A0 X X X F61 30 T51 relay 30 87 for air conditioner compressor X ...

Page 201: ... X F67 AVAILABLE A0 F68 AVAILABLE A0 F69 30 optional 4448 for bus X 5 A0 X X F77 AVAILABLE A0 F78 AVAILABLE A0 SCM1 B Power Protection Presence Capacity Type EURO5 4x2 EUROV 4x2 BIFUEL S OPT T53 unit heater X 20 X X X T54 headlight washers X 20 X X X T55 Power Take Off X 10 20 X X X T56 stop lights with TELMA retarder activated X 10 20 X X X SCM2 relay list Table 5 16 SCM2 Power Protection Presenc...

Page 202: ...ab 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 Figure 5 38 119355 Any damage caused by failure to comply with procedure is not covered by the warranty ...

Page 203: ... water dust or fumes Establish suitable distance between electrical wiring harnesses and other components as follows 10 mm from static components 50 mm from moving components minimum distance 20 mm 150 mm from components that generate heat e g engine exhaust Wherever possible it is good practice to follow a different cable route for signal cables interfering at high absorbed intensity e g electric...

Page 204: ...s with refrigeration chambers provide for periodic battery charging to maintain efficiency 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 vehicle shall be used Whenever various applications or modifications should require assemblies various components etc to be moved this is permissible on the co...

Page 205: ... 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 conn...

Page 206: ...ons and drawing off power Figure 5 42 1 To be connected to the chassis cable 2 13 pin socket for trailer 166056 For more details on connections and assembling ask IVECO for the wiring diagrams Any damage to the lighting system caused by the failure to comply with the above procedure shall not be covered by the warranty ...

Page 207: ...es only NOTE Description of 13 pin interface Table 5 18 13 pole connector pin Cable no Description Remarks 1 1120 Rear left turn indicator 1 bulbs 21 W 12 V 2 2283 Right rear direction indicator bulb 2 bulbs 21 W 12 V 3 0000 Ground 4 1125 Rear right turn indicator 1 bulb 21 W 12 V 5 3335 Front left and rear right parking light Left number plate light Left clearance light 3 bulbs 5 W 12 V 6 1175 Br...

Page 208: ... equipped with specific terminals to make the electric connection required to power the side marker lights The external Bodybuilders 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 illus...

Page 209: ...nectors are in any case available In the event that the side dimmers need be installed the vehicle shall be delivered to an IVECO service centre in order to have the body computer enabled Side marker lights are compulsory for vehicles of total length greater than 6 m 5 4 10 Operation of emergency control on dashboard option The dashboard central emergency control is used in hazardous situations Fi...

Page 210: ...connector Indicator RED disconnector open CLEAR off disconnector closed Disconnector 120375 Circuit breaker reset button and relative indicator on battery control unit CBA To restore the vehicle to its original conditions press the central emergency control again open the bonnet and press the yellow button on the CBA to reset to the disconnector turn the key to STOP re start the vehicle ...

Page 211: ... and drawing off power External hazard control In some cases activation of the direction indicators is required according to the functioning of the version This functionality can be managed by supplying an unstable negative signal via a button to pin AD09 of connector D see fig 5 47 on the Body Computer Figure 5 47 162241 ...

Page 212: ...5 58 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS DAILY Base 02 2012 Printed 603 95 241 Electrical system modifications and drawing off power ...

Page 213: ... concerning the fire proofing materials A 6 A 3 5 Seat supporting structures and their fixing A 6 A 3 6 Rear baggage compartment A 9 A 3 7 Side access door A 9 A 3 8 Inserted structures and handrail fixing A 9 A 3 9 Fixing the disabled persons ramp and lift to assemble the wheelchair area A 9 A 4 Noise emissions and thermal insulation A 10 A 4 1 External noise A 10 A 4 2 Internal noise A 10 A 4 3 ...

Page 214: ...A 2 APPENDIX A DAILY PASSENGER TRANSPORT DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 215: ...es or side members NOTE The chassis must only be secured to the transporter by fastening the axles only and the weight must only be supported by the wheels A 1 3 Delivery The chassis is subjected to detailed quality checks prior to delivery At the time of delivery the Bodybuilder must perform an inspection to check for missing materials or faults that may have occurred during transportation IVECO ...

Page 216: ... the weights of the models 40C 50C and 65C have a tolerance of 3 Therefore prior to fitting it is good practice to verify the vehicle weight cab van or chassis and its distribution over the axles A 2 General rules for fixing the bodywork to the chassis Particular attention should be paid to the joints between chassis components and the sides of the bodywork since these joints must guarantee perfec...

Page 217: ...artial or fully tinted glass may also be fitted Driver s seat if different from the one provided The height angle and longitudinal distance of the steering wheel must be adjustable and each of these adjustments must be independent The seat must offer sufficient support and be covered with breathable material Driver station ergonomics In the case where the instrument unit supplied with the vehicle ...

Page 218: ...s of primary importance for safety adopting IVECO original solutions immediately ensures relevant regulations are complied with Other solutions on the other hand shall remain the full responsibility of the Bodybuilder including the execution of destructive testing NOTE On standard production vehicles the framework is made from zinc plated sheet thickness 2 mm and with transversal plates thickness ...

Page 219: ...APPENDIX A DAILY PASSENGER TRANSPORT A 7 DAILY Printed 603 95 241 Base 02 2012 Building the bodywork Figure A 2 Diagram for installing fixed seat see drawing 504208108 173265 ...

Page 220: ...A 8 APPENDIX A DAILY PASSENGER TRANSPORT DAILY Base 02 2012 Printed 603 95 241 Building the bodywork Figure A 3 Diagram for installing seats on guides see drawing 504208109 173266 Guide fixing section ...

Page 221: ...eps Figure A 4 162233 A 3 8 Inserted structures and handrail fixing The handrails must be installed in such a way as not to entail risks of injury for passengers their surface must be in a contrasting colour with a non slip finish Construction and application on the vehicle must respect European Directive 2001 85 EC or ECE107 The zones where the handrails are anchored to the original vehicle struc...

Page 222: ...dB A with regard to the exhaust silencer A 4 2 Internal noise Measurements must be performed in compliance with the provisions set out in ISO 5128 and at constant speed a 60 80 and 100 km h in the second last gear b 80 and 100 km h in top gear whether with manual or automatic transmission With regard to the position of the noise meter it is essential to distinguish between rear area centre of seco...

Page 223: ...or example by means of a layer of insulating felt covered with a sheet of aluminium capable of withstanding a constant temperature of 250ºC and with maximum coefficient of thermal conductivity of 0 1 W mK In any case the minimum distance between a critical point and the insulation must be no less than 80 mm When the available space is limited especially to protect the polyamide piping and the elec...

Page 224: ...y hot enough then it is necessary to install a pre heater capable of providing at least 25000 kCal h The pre heater becomes compulsory when the vehicle operates routinely at temperatures below 0ºC Having defined the insulation for the engine it is necessary to measure its efficacy by testing the capacity of the cooling system and the capacity of the heating system After the tests it may be necessa...

Page 225: ...supply 30 from F75 for starter motor and TELMA 50 or 35 500 2 power supply 30 from F70 for SCM BUS 35 150 3 power supply 30 from F73 for pre heating glow plugs 10 60 4 power supply 30 from F72 for braking node 4 40 5 power supply 30 from F71 for Body Computer 16 80 6 power supply 30 from F64 in SCM A for IBS sensor for Stop Start 4 1 Starter motor and Telma power supply 2 SCM power supply 3 Pre he...

Page 226: ... reset to the disconnector Turn the key to STOP re start the vehicle Bodybuilder connectors A 6 Bodybuilder connectors For information regarding the 20 PIN connector 61071 please refer to Section 5 NOTE 12 PIN connector 72068 for People Carrier Figure A 6 Counterpart to be connected Existing parts on the vehicle 101554 Table A 3 Code number Description 500314814 12 way male holder joint 500314820 ...

Page 227: ...door is open Ground door closed Open circuit door open 4 Speed signal B7 See specification 1 Section 5 5 Door status Output max 500 mA With central locking an led indicates door status 12 V doors closed Open circuit doors open 6 Not connected 7 Supplementary acoustic signal control Output max 10 mA Additional horns interfaced by relay or duplicate of horn control Ground horn ON Open circuit horn O...

Page 228: ...nd absence of excessive force on the pedal gradual clutch operation gradual steering without resistance or jolts maintaining the direction of the vehicle without continuous corrections With regard to system function it should be verified that no fault message appears on the instrument panel and no danger or warning signal remains lit which should not be present the electric retarder has a short re...

Page 229: ...B 3 2 Repainting of outfitted frames B 5 B 3 3 Tightening torques B 6 B 3 4 Parts list B 7 B 3 5 Emptying the gas system B 10 B 3 6 VBE solenoid valve replacement B 15 B 3 7 Repair interventions on fittings and pipes B 17 B 4 Cylinders B 18 B 4 1 Periodic overhauling B 19 B 4 2 Cylinder replacement B 20 B 5 Fuses and relays B 21 B 5 1 Fuse box and CNG relay under dashboard B 21 B 6 Bodybuilder con...

Page 230: ...B 2 APPENDIX B DAILY CNG AND CNG WITH RECOVERY MODE DAILY Base 02 2012 Printed 603 95 241 Index ...

Page 231: ...recovery mode a small petrol tank is also present that is activated automatically to enable the vehicle to cover short distances if the gas runs out The greater technical complexity must therefore be taken into consideration by the Bodybuilder during the design of the conversion and above all during its implementation The highly flammable properties of compressed gas mean that authorisation cannot...

Page 232: ...PLOSION so it is important to not only follow all the rules set out by the law and competent authorities to but also observe the following safety rules Close the shut off taps on the gas cylinders the refuelling pump and the refuelling station tank Switch off the main switch of the electric system of the building or refuelling area Block access to the hazardous area and have unauthorized people mo...

Page 233: ...st not be removed until immediately prior to positioning Observe the direction of installation for all electrical connections All threaded connections must be tightened to the specified torque see point B 3 3 Fuel system components cannot be serviced and must be replaced if they are not efficient Washers tapered washers self locking nuts and seals deform to improve tightening and they are also of ...

Page 234: ...3 3 7 Stainless steel stiff pipe connection M12x1 to VBE solenoid valve side opposite check valve 24 26 2 4 2 6 Stainless steel stiff pipe connection M12x1 to VBE solenoid valves 24 26 2 4 2 6 Blank plug M12x1 on solenoid valve 33 37 3 3 3 7 Fittings M14x1 5 connecting pipe to T fittings and cross fittings Figures B 4 B 5 B 6 74 82 7 4 8 2 Fittings M 14x1 5 fastening cross fitting to chassis 67 70...

Page 235: ...elical structure internal diameter of 6 5 mm protected by a AISI 304 stainless steel braid in turn coated when a shrink wrap sheath and AISI 303 stainless steel fittings Refuelling high pressure gas lines Figure B 2 1 Manufacturing date 117680 The gas hose connecting the VBE refuelling solenoid valve of the first cylinder is of the type It is made of ISO 84342 stainless steel diameter 6 4x11 8 mm ...

Page 236: ...tructions refer to point B 3 7 Figure B 18 For safety reasons both during bodybuilding and servicing IT IS FORBIDDEN to use gas pipes as brackets for other pipes In specific cases where space is restricted it is acceptable to fasten only electrical cables to the gas pipes by means of PVC collars provided that the pipes only serve as a guide and do not act as a support During maintenance operations...

Page 237: ...2 2012 Operations on the system Figure B 4 ADJUSTABLE T FITTING 117682 Front tipped AISI 3 16 TJ stainless steel Figure B 5 INTERMEDIATE T FITTING 117683 AISI 316 TJ stainless steel front tipped fitting Figure B 6 STAIGHT FITTING 117714 AISI 316 TJ stainless steel front tipped fitting ...

Page 238: ...n some cases Decide which procedure is required on a case by case basis according to the severity and type of intervention to be performed If in doubt choose the safest solution complete emptying If the engine conditions so allow e g no leakages it is advisable to use up all the gas by running the engine Running the engine with system pressure under 20 bar does not ensure the correct fuel metering...

Page 239: ...s 4 on all cylinders 3 are closed cock 5 on position C Disconnect gas delivery pipe 2 from pressure reducing valve 1 by slowly undoing it and paying attention to the effects caused by the gas pressure in the pipes Connect a rubber pipe methane compatible with the gas deliver pipe 2 to dispose of the gas the free end of the tube must be at least 5 metres away from sparks During this operation the c...

Page 240: ... 9 117661 With a screwdriver 1 stop rotation of the threaded pin 4 and use tool 2 to remove the nut 3 fastening the coil 5 Remove the coil 5 from the sleeve 6 Figure B 10 117662 Remove the washer 4 A small amount of high pressure gas will remain in the valve To prevent damage to the operator it is advisable to decrease the pressure by slowly unscrewing ring nut 2 from the coil sleeve 1 With no res...

Page 241: ...s Replace them if needed during assembly Fasten the empty coil holder sleeve with its o ring and fasten the ring nut at a torque of 28 Nm Repeat the operations on all the VBE valves of the cylinders Emptying Open the manual valves half way 5 Figure B 7 This operation ensures that pressurised gas enters the pipes for this reason exercise maximum care After emptying operations check that the engine ...

Page 242: ...nsert the piston 5 in the shutter 4 and lock it with the pin 3 Insert the spring 2 and push well into the specific seat in the piston 5 Fit the resulting assembly into coil sleeve 1 with the tapered part of plunger 4 turned toward the outside of the coil carrier sleeve Check the presence and conditions of the o ring on the sleeve 1 Figure B 13 87392 Fasten the coil holder sleeve ring nut and tight...

Page 243: ... Connect the electrical connection to the coil 4 Repeat the previous operations on all VBE valves of the cylinders B 3 6 VBE solenoid valve replacement Removal VBE solenoids may be removed as a result of a fault or during periodic overhaul of the cylinders Because removed solenoids cannot be reused they must always be replaced whatever the reason for their removal It is advisable to scrap them imm...

Page 244: ...autions the VBE valve protective caps must not be removed to avoid damage to the valve during assembly The use of percussion pneu matic screw runners or of any other tool which could deform the valve body and compromise functionality must be avoided if the cylinder is off vehicle secure the cylinder preferably in vertical position with the collar facing upwards fasten the threading of the valve se...

Page 245: ... it is to be connected to prevent pretensioning Pre tighten the fitting nuts by and then tighten to the specified torque For EMER fittings follow the procedure described in the relevant chapter Apply the fastening brackets checking that the tube is not subjected to excessive tension Restore system operation by carrying out a hydraulic seal test following the procedure described in the warnings at ...

Page 246: ...t the release of gas into the outside environment when the valve is extracted after the refuelling operation A faulty flow valve or solenoid valve may lead to incorrect indications regarding the cylinder contents Refer to the solenoid valve inspection and replacement procedures in the corresponding paragraph B 3 6 NOTE Important information concerning the cylinders is punched into their upper surf...

Page 247: ...date is located on the cylinders and in the documentation which accompanies the vehicle NOTE Any cylinders subjected to impact during collision of the vehicle must be inspected by a body authorised by the Manufacturer unless otherwise indicated by the appropriate Authority Such cylinders may only be reintroduced into service if they have not been damaged in any way otherwise they must be returned ...

Page 248: ...s 3 from the solenoid valve 2 Support the cylinder 6 with an appropriate support 9 Remove the screws 7 turn the brackets 8 and remove the cylinder 6 from the chassis Disconnect the VBE valves 2 from the cylinder 6 as described in the corresponding chapter Refitting Reverse the removal sequence to refit and observe the following precautions Position the cylinders in the basket directing the VBE val...

Page 249: ...X B DAILY CNG AND CNG WITH RECOVERY MODE B 21 DAILY Printed 603 95 241 Base 02 2012 Fuses and relays Fuses and relays B 5 Fuses and relays B 5 1 Fuse box and CNG relay under dashboard See specific section 5 4 ...

Page 250: ...LY CNG AND CNG WITH RECOVERY MODE DAILY Base 02 2012 Printed 603 95 241 Bodybuilder connectors Bodybuilder connectors B 6 Bodybuilder connectors For information on Bodybuilders connectors see Section 5 Paragraph 5 2 NOTE ...

Page 251: ...Take Off Power Take Off B 7 Power Take Off The PTO engagement and disengagement procedures are analogous to those described in Section 4 for diesel engine vehicles except for the need during engagement to run the engine at 1200 rpm prior to pressing the button in Figure 4 6 on the PTO control panel ...

Page 252: ...B 24 APPENDIX B DAILY CNG AND CNG WITH RECOVERY MODE DAILY Base 02 2012 Printed 603 95 241 Power Take Off ...

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