Iveco daily Use And Maintenance Download Page 61

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Summary of Contents for daily

Page 1: ...DAILY TURBODAILy J Use and maintenance ...

Page 2: ... one of its thousands of spare parts has been integrated into a logic of the whole with the other parts Iveco engineers have determined the technical specifications with the highest degree of accuracy in order to guaran tee maximum safety and reliability Every part in the system must function in the manner according to which it was designed in order that Iveco remains the Iveco which you chose The...

Page 3: ...DAILY TURBODAILY Use and maintenance ...

Page 4: ...NLY parts which can be perfectly integrated in the logic of the whole with which the vehicle was designed and built To ensure that your Daily or Turbodaily is always in perfect working order we recommend the use of programmed maintenance which provides the bestgua rantee for perfect operation and an opti mization of the operating costs as a result of its fixed maintenance periods b ...

Page 5: ...njury or damage to the vehicle occurring It Personal danger To draw attention to the need to take extra care to avoid possible danger to personnel carrying out the relevant instruction Serious vehicle damage risks To draw attention to the need to follow the relevant instructions to avoid possible damage to the vehicle equipment or component Caution The text following this symbol provides additiona...

Page 6: ...tems Maintenance A few practical hints On the spot maintenance Capacities Tool kit Specifications and data Programmed maintenance Overall maintenance scheme Van Combi access Bus access City access Vehicles with electronically controlled automatic clutch ACS Index 3 4 7 9 5 31 43 49 57 71 75 77 85 101 113 119 127 137 145 ...

Page 7: ...t 40 8 Disc rear 35 8 R S 450211 2 5812 Disc front Disc rear 8140 67F PONA 2826 5 35 8 R S OXICAT 450211 1 5811 Disc front Drum rear 35 8 450311 5811 Disc front Drum rear 40 8 35 8 City Version 35 8 Ex Eu 450311 5811 Disc front Drum rear 40 8 Ex Eu Key PC Indirect injection R 5 Single rear wheels Ex Eu Extra Europe NA Naturally aspirated OXICAT Catalitized exhaust where fitted ...

Page 8: ... Drum rear 450311 5811 Disc front Drum rear 450311 2 5812 Disc front Disc rear 450311 I 5812 Disc front Disc rear 450411 1 5812 Disc front Disc rear 450211 2 5812 Disc front 45031 1 1 5812 Disc rear Key ID TC TCA EDC Direct injection Turbocharged engine Turbocharged and aftercooled engine Electronic Diesel Control system EGR Exhaust Gas Recirculation OXICAT Catalitized exhaust where fitted RS Sing...

Page 9: ...um rear City Version IDfTCA 2826 5 OXICAT 35 12 R S 450211 2 58 2 Disc front 35 12 450311 1 5812 Disc rear 49 12 450411 1 5812 Disc front A45 12 Disc rear 59 12 450517 5811 2 Disc front Drum rear Key ID Direct injection TCA Turbocharged and aftercooled engine R 5 Single rear wheels EGR Exhaust Gas Recirculation OXICAT Catalitized exhaust where fitted ...

Page 10: ...berand manufacturer s plate for identifi cation of your vehicle are provided in the loca tions shown Manufacturer s plate see page 8 Data for vehicle identifica tion according to EEC standards inside the engine hood Chassis Punch marked at front end of frame right hand side member 7 ...

Page 11: ...fic type identification i Wheelbase mm I Engine type m Engine power n Number of axles 0 Production plant 0 IVECO SPA 0 Kg Kg 1 Kg 2 Kg 3 Kg 4 Kg Type N of axle s n Wheelbase eo d Engine type IEngine e KW Made in IVECO 0 0 a b c d e f g h i I 0 Unit No Part No Serial No P I C No Admissible smoke value Product identification plate inside the engine hood This plate shows PI c Product Identification C...

Page 12: ...signed to meet the latest ergonomic requirements and to provide you with the maximum degree ofcomfort in a spacious safe and pleasant environment Let s familiarize ourselves with the following areas Facia Warning lamp cluster Main controls Doors Engine hood 9 ...

Page 13: ...p cluster 6 Lamp test button TEST 7 Fuel gauge with reserve warning lamp 8 Water temperature gauge with high temperature warning lamp 9 Instrument light dimmer 10 and 12 models only IO Speedometer vehicles with GVW under 3 St Tachograph vehicles with GVW over 3 St I I Headlamp levelling control where fitted A Left hand drive vehicles B Right hand drive vehicles ...

Page 14: ...rter 10 and 12 models 5 Low engine oil pressure 6 Turn signal lights 7 Rear fog lamp 8 Air suspension where fitted 10 and 12 models 9 Power steering fluid level low 10 Engine coolant level low I 1 ABS system where fitted 12 Brake system malfunction and front brake lining wear items 10 and 12 rear brake linings also 13 Parking brake ON 14 Low battery charge 15 Parking lights 16 High beam lights I7 ...

Page 15: ...drive vehicles I Windscreen washer wiper control lever 2 Turn indicators control lever 3 Horn and headlights control lever 4 Accelerator pedal 5 Brake pedal 6 Clutch pedal 7 Gearshift lever 8 Handbrake lever 9 Bearing plate Desk ...

Page 16: ...ght hand drive vehicles I Windscreen washer wiper control lever 2 Turn indicators control lever 3 Horn and headlights control lever 4 Accelerator pedal 5 Brake pedal 6 Clutch pedal 7 Gearshift lever 8 Handbrake lever 9 Bearing plate Desk ...

Page 17: ...atch button 5 Glove box 6 Loudspeaker recess 7 Air outlet see page 25 Engine hood The engine hood can be opened from inside the vehicle by pulling knob 8 located either to the left ofthe driver left hand drive vehicles or to the right ofthe driver right hand drive vehicles ...

Page 18: ... Tachograph Exterior lighting switch Turn signal lights Headlights and horn Windscreen washer wiper unit Stowage compartment Vehicles equipped with rear air suspension Digital clock Control switches Auxiliary control panel Rearview mirrors Heating and ventilation Air conditioning Headlight levelling control 15 ...

Page 19: ... the seat is then free to move upwards driver offthe seat or down wards driver partially or totally on the seat Release handles to lock the seat in the desired vertical position Use either handle to adjust cushion rake Seat suspension where fitted Before entering the vehicle the driver should preset the seat suspension by turning handw heelS clockwise or anticlockwise until the indicator aligns wi...

Page 20: ...e and it may lock in the following cases sudden braking or acceleration vehicle driving on a slope when cornering Warning The belt should not be twisted but should correctly adhere to the driver s hips but not to his abdomen to prevent him from slipping forward Regularly ensure that bolts securing the anchorage points are fully tightened and that the belt is not cut or frayed In the event of a ser...

Page 21: ...hand 4 Vehicle overspeed warning light 5 Speed pointer 6 Tachograph recorder malfunction indicator 7 Time scale 8 Odometer 9 Time selector Rest and work times Fortachograph operating instructions reference should be made to the tachograph manu facturer s booklet supplied with your vehicle 1 ...

Page 22: ...lights and horn Backward Headlamp flash Upward low beams Downwards high beams Inward horn Exterior lighting switch three positions a Off b Parking and outline marker lights c Parking outline marker high Iow beam lights right turn left turn Up Down ...

Page 23: ...ated in the engine compartment A mixture of water and a detergent antifreeze product such as Arexons DP I should be used as follows Mixing table Outdoor temperature 35 e 2aoe Iaoe aoe summer Arexons DP I parts 1 1 1 Water parts 2 6 10 Stowage compartment A lockable stowage compartment for the storage of documents maps etc is located in the central part ofthe dashboard and is provided with a key No...

Page 24: ...control unit protection Models 45 49 59 Self levelling position 0 It is set in operation as soon as the engine is started if neither position a or position b Chassis lifting lowering positions a or b This operation can only be carried out with the vehicle at a standstill or when it is running at the max speed of IOkm h The warning lamp lights up at slow intermittent intervals every 2 approx during...

Page 25: ...on causing its switching on has been repaired Control switches 8 Rear fog lamp 9 Extemal rearview mirror defrosting where fitted 10 Fog lamps where fitted I I Headlamp washing unit where fitted 12 Seat heating where fitted Digital clock where fitted It is installed together with the speedometer To set the alphanumeric indicator proceed as follows Press button I to select hours Press button 2 to se...

Page 26: ...cting adjustment of either right or left mirror Power window control switch where fitted 3 Left window regulator 4 Right window regulator In the event of a failure in the power window mechanism you can wind the window up or down manually using the following procedure Remove the protection cap and insert the special device provided with the kit into the proper hole see illustration Screw in knob 5 ...

Page 27: ... from the engine cooling circuit round the radiator heater Summer ventilation by air inlet from the outside through the appropriate vents Air inlet can be increased by means of a fan Obviously in this case it will be necessary to shut offthe flow of hot water through the heater Electro ventilation Enabling a remarkable increase of the quantity of air passing through the system thus permitting wind...

Page 28: ... windows 7 Adjustable side vents a opening D or closing wheel b air flow aiming lever 8 Air outlet to floor area 9 Door outlet Its purpose is to facilitate door opening and closing as well as to ensure heater efficiency On the vehicles equipped with air conditioning device see next page close the air outlet so as to improve the capacity of the air conditioning itself 10 Centre outlets They are mai...

Page 29: ...nob I TEMP on max position when running at fast speed turn it counterclockwise by 90 approximately In the event of a prolonged stop under the sun put the air conditioner on maximum position AIR and TEMP and ventilate the cab by opening the windows for a few minutes Ifwater leakages from underthe vehicle are noticed these are due to normal condensate drain caused by the de humidifying effect of the...

Page 30: ...h regard to his own vehicle 27 7 _ 0 f f Model Wheelbase Rear leaf springs Switch position Note vehicles fitted with rearairsuspension are not equipped with headlight beam alignment switch tandard headlamp setting value The label inside the engine hood states the headlanp beam angle with switch in position O See page 54 for setting instructions D1 ...

Page 31: ...ions 35 10 Truck 35 10 Van Wheelbase 2800 3300 3600 3300 2800 3600 2800 3300 3950 Rear leaf S Sr S Sr S Sr S Sr S Sr S Sr S Sr S Sr S Sr springs Switch 3 2 2 3 2 3 2 3 2 2 2 I position Switch positions with fully laden vehicle Model 35 10 Dual purpose 40 10 Truck and Van 45 10 49 10 45 10 49 10 Van Truck Wheelbase 2800 3300 2800 3300 3600 3950 3300 I 3600 3300 I 3950 Rear leaf S Sr S Sr S Sr S Sr ...

Page 32: ...Model 35 12 Truck 35 12 Van 35 12 Dual purpose Wheelbase 2800 3300 3600 2800 3300 3950 2800 3300 3600 Rear leaf S Sr S Sr S Sr S Sr S Sr S Sr S Sr S Sr S Sr springs Switch 3 3 2 2 3 2 2 I 3 2 3 2 2 position Switch positions with fully laden vehicle Model 40 12 Truck 40 12 Van Wheelbase 2800 3300 3600 3300 3950 Rear leaf S Sr S Sr S Sr S Sr S Sr springs Switch 3 2 2 2 I position Legend S Semiellipt...

Page 33: ...180 3300 I 3600 3950 3950 Rear leaf PIS PIS PIS S S springs Switch 3 I 3 2 I 2 3 I 3 4 4 position Legend S Semielliptical Sr Reinforced semielliptical P Parabolic Combi All versions Swtch positions with vehicle in the following conditions o Driver one passenger on the farthest from the driver front seat I Driver one passenger on the farthest front seat all farthest rear seats taken I All seats tak...

Page 34: ...aximum power during the first 1500 km of operation This chapter provides information on how to carry out the following operations Iveco Engine Immobiliser System Engine starting Engine stopping Engine starting in cold weather Fuel filter heater Self diagnosis system Use of the transmission Rear brake self adjustment Differential locking Power take off Fuel economy and long life ...

Page 35: ...nit in it s memory Important The Master Key should be removed from the vehicle at the earliest opportu nity and stored in a safe secure location Should the red Master Key be lost it will be necessary for you to buy a new Master Key and Immobiliser System Control Unit which are supplied as an electronically matched set Under no circumstances should the Master Key be left in the unattended vehicle T...

Page 36: ...ey code are erased from the memory This is a security measure to ensure that any lost stolen or misplaced keys are unable to start the engine It is forthis reason that when additional keys are issued the codes ofall keys need to be re stored in the memory ofthe Control Unit Ignition Switch Positions O Key insert remove engine stopping steering lock on Iveco Engine Immobiliser System on I Engine pr...

Page 37: ...start the engine refer to an Authorised Dealer Important Ifthe led 3 illuminates either briefly or permanently while driving or once the engine has started it does not necessarly indicate a malfunction in the Immobiliser System but can so metimes indicate a condition that the system interprets as an attempt to interfere with the device or that the vehicle battery charge is low To test the system i...

Page 38: ...lowed a puffofblack smoke will be emitted on starting the vehicle Ifstarting does not occur immediately do not operate the starter motor for longerthan 30 seconds After starting the engine proceed slowly and keep engine at an average speed until normal operating temperature is reached By this method it is possible to obtain Optimum oil flow throughout the lubrication circuit Exhaust gases within t...

Page 39: ...o safeguard your natural environment and the engine of your vehicle take immediate action if you notice that the exhaust is excessively smokey In the first instance the fuel filter cartridges should be replaced Should inspection adjustment of the fuel injection system be necessary it should only be carried out by a skilled Technician For maximum benefit use only original Iveco cartridges Any opera...

Page 40: ...e engine coolant temperature is in below 2 e the glow plugs will operate and the warning light illuminate for approximately 35 to 40 seconds After this time the warning light will flash flash for 6 to 10 seconds While the warning light is flashing start the engine without depressing the accelerator pedal by turning the key to position 2 AW During starter motor engagement the warning light will rem...

Page 41: ...ed from electrical circuit failures short cir cuits etc and operates automatically when the ignition key is turned to position I MAR A malfunction ofthe cold start system is indicated by slow or fast flashing ofthe warning light 2 In cases of malfunction refer to an Authorised Dealer Note The warning lamp does not light up in the foilowing cases I Mistaken polarity 2 Electromagnetic disturbances 3...

Page 42: ...her the front or rear brake circuit your vehicle can be safely broughtto a halt although with increased stopping distances due to the continued operation ofthe remaining brake circuit Rear brake auto adjustment vehicles with rear brake drum only The above models are fitted with rear drum brakes which incorporate an automatic adjust ment facility to compensate for brake wear The auto adjustment fac...

Page 43: ...r take off device generally occurs during this stage The transmission should therefore be started as slowly and gradually as possible Led 3 illuminates to indicate that engagement has occurred Now rev up the engine to the speed required for a satisfactory performance of the system Engine rpm can be increased from the ground through the hand accelerator control located on the driver s seat left han...

Page 44: ...educed wear of major components yet obtaining maximum performance in keeping within the limits imposed by currently effective regulations To this end you should consider the following suggestions I Reduce engine speed rates The best performance consumption ratio is obtained by keeping engine r p m within the green area approximately corresponding to maximum torque rate A 12 fuel saving is thus obt...

Page 45: ...42 ...

Page 46: ... These simple checks and inspections will ensure that yourvehicle is maintained in first class working order Warning If exhaust is excessively smokey refer to an Authorised Dealer to have the injectors checked and if necessary calibrated If tappets are noisy refer to an Authorised Dealer to have the valve clearances checked and if necessary adjusted ...

Page 47: ...urney 1 Engine oil level 5 2 Engine coolant level 4 3 Brake fluid level 2 4 Windscreen washer fluid level 8 5 Air filter warning lamp l Weekly 6 Power steering fluid level where fitted 7 Fuel filter S Jack 6 3 9 Tyres 7 ...

Page 48: ...Driver check items 45 Before each journey Pull knob I to unlock engine hood from insi de the vehicle Release hook 2 and lift the hood Insert rod 3 in its seat Carry out inspections described on page 46 ...

Page 49: ...dealer Check the level of windscreen wiper fluid Use a mixture of water and Arexons DP I additive see page 20 for topping up Also check that pipes are not c1ogg ed use a needle to clean the nozzles if necessary 4 5 Visually check the efficiency of air filter restriction signalling system Also check Condition of battery terminal connection cables Efficiency of service and parking brakes Efficiency ...

Page 50: ...of power steering reservoir and check that the oil level reaches the upper reference mark on dipstick With engine stopped wheels in straight ahead position the oil level must exceed the upper reference on dipstick by I or 7 7 2 cm remove cap 2 to top up if necessary 7 Aspirated engine A Through perspex check for possible accumulation of water in fuel filter If so drain it through tap 2 Supercharge...

Page 51: ... pressure is too high tyres tend to wear on the central part ofthe tread Should abnormal wear of tread be noticed either on the inside or on the outside ofthe tread have wheel toe in checked Never exceed max permitted load on each axle however this should not affect the weight ofthe fully laden vehicle Also check Efficiency ofthe exhaust system Check the oil level in oil bath air filter where fitt...

Page 52: ...ic maintenance work yourself Used Engine Oils Warning Prolonged and repeated contact may cause serious skin disorders including dermatitis and cancer Avoid excessive contact wash thoroughly after contact Keep out of reach of children PROTECT THE ENVIRONMENT It is illegal to pollute drains water courses or soil Use authorised waste disposal facilities including civic amenity sites and garages provi...

Page 53: ... dipstick 3 Refill with new oil through filler 4 see table on page 72 2 Fuel filter replacement Replace filter I and air bleed the system if necessary Proceed as follows Loosen screw 2 Work on lev 3 of feed pump Retighten screw 2 Continue to work on lever 3 until the feed pump starts idling Warning In case of engine stop owing to lack offuel and air inlet into the pipes slac ken the pipe sockets o...

Page 54: ...ndo scews I and remove the guard Release hooks 2 and spring hook 3 and remove the cover Clean the cartridge housing and replace the pressure fitted cartridge Use an originallveco cartridge Position the cover as shown between reference marks and the filter body Refit the guard Bath air cleaner oil change where fitted Maintenance a few practical hints 3 3 51 ...

Page 55: ... a densimeter through filler I to check the percentage of PARAFLU I I in the engine coolant It should be at least 40 this value should be kept constant all the year round Top up if necessary with water and 50 PARAFLU I I to ensure good protection from corrosion Fuel feed system During the cold season it is advisable to use the appropriate fuels produced by oil companies ...

Page 56: ...th rear axle warm remove plug I and drain the oil in a suitable container Mod 59 12 Position either ofthe two screws 3 to the bottom Screws can be easily found as they are placed between two relieves 4 on hub periphery Take off lower screw 3 and drain oil Tighten screw back Take off upper screw 3 and fill with 0 2 I new oil Tighten screw back Carry out same operation on opposite wheel Refill with ...

Page 57: ...icle 10 metres from the wall and switch on the low dipped beams The distance between the crosses and points P corresponding to the head light beam angle should be 10 cm I as specified on label I Light beam horizontal aiming screw Note For the sake of safety have headlight aiming checked by an authorised dealer with the suitable equipment Greasing Lubricate using the relevant pump the hinges of the...

Page 58: ...r Cleaning of plastic components External plastic components should be cleaned using the same procedure as for washing the vehicle Should tracs of dirt persist it is recommended to make use ofspecific products and follow instructions provided by the manufacturer Such products should also be used to clean the cab internal plastic components dashboard doors etc Do not use products containing aromati...

Page 59: ...utting tools thus causing permanent damage to the vehicle body Warning Before carrying out any servicing operation on the vehicle disconnect the battery s negative terminal Stickers Dew strips Do not remove or apply decorative strips using cutting tools blades knifes etc as this might cause deep scoring in the paint layer and result in premature corrosion Doors Regularly check efficiency of door c...

Page 60: ...On the spot maintenance 57 ...

Page 61: ...he side member To pull it off it is necessary to unscrew the two nuts fixing the spare wheel to the wheel carrier On van and combi versions the spare wheel is mounted inside the vehicle To remove it iundo the central wing nut Vehicle towing and emergency starting If the vehicle has to be towed over long distances the propeller shaft must be Cl disconnected at axle end flange I A Ifthe vehicle fail...

Page 62: ...s Note Follow this procedure to make it easier when screwing out the nuts Tighten wheel nuts in the sequence shown in the diagram following the steps described below using the specially provided tools Slightly tighten the nuts so that the wheel is properly positioned on the hub flange Tighten the nuts according to the sequence shown Lower the wheel to the ground and tighten the nuts by loading the...

Page 63: ...ng the door 60 Warning Always disconnect battery cables before proceeding with any servicing operation on the electrical system Do not dismantle electrical system of vehicles equipped with EDC electronic diesel control if maintenance is required refer to an Authorised Dealer C I c EIS ...

Page 64: ...asher pump 21 ISA Electric heater Electromagnetic fan 22 7 SA Push switch lighti g flashing light 23 2SA Power window Electromagnetic fan 24 lOA Emergency control pushbutton Bus On the spot maintenance Fuses 25 20A Air conditioning 26 20A Air conditioning 27 2SA Air conditioning 28 2SA Electric heater 29 40A Thermostarter control unit Relays EI Low beam lights switch contacts E2 High beam lights N...

Page 65: ...e that on reconnection terminals are well secured on terminals Do not disconnect the battery with the engine running Do not use a battery charger to start the engine Disconnect the battery from on board mains when charging it Remove the Electronic Control Units if special operations require temperature higher than 80 C Precautions to be strictly observed Before carrying out any servicing operation...

Page 66: ...ready in operation will stop spontaneously As a temporary measure before having the device replaced by an Authorised Dealer dismantle the unit using spanner I on issue and take out magnetic core 4 and its spring 3 Then reassemble the unit The engine can then be normally started and can be stopped by braking the vehicle with a gear engaged ...

Page 67: ...Lamp holder with double filament removable halogen bulb 4 Tubular removable bulb parking lights Reassemble the two lamp holder 2 fastening clips Install cover I Front indicator bulbs Proceed as follows to replace the front indicator bulb Loosen diffuser fixing screws I Remove the diffuser The bulb to be replaced can be removed through its bayonet eoupling system Refit the diffuser Retighten the di...

Page 68: ...place the bulbs of the rear tail unit Loosen the diffuser fixing screws I Remove the diffuser The bulbs are arranged as follows 2 Spherical bulb indicator lights 3 Spherical bulb stop lights 4 Spherical bulbs parking lights 5 Spherical bulb reversing and rear fog lights 6 Spherical bulb number plate lights All bulbs can be removed through their bayonet coupling system Refit the diffuser Retighten ...

Page 69: ...n Refit the lamp holder retaining springs Screw in the four screws to reassemble the cover 2 Tighten screws I to reassemble the foglight Rotate screw 5 to aim the light beam Interior lights Proceed as follows to replace the bulbs Carefully prise the ceiling light unit from its mounting Bulbs are arranged as follows I Two cylindrical bulbs 2 Tubular bulb adjustable light beam Carefully replace ligh...

Page 70: ...On the spot maintenance 67 Electromagnetic fan Control ofthe fan is of the electromagnetic type and it is operated by the engine working temperature ...

Page 71: ...id level low Remedy Drain the water as described on page 47 If lamp stays on replace filter Renew air filter element With engine cold check oil level and top up if necessary Should the problem persist refer to an Autho rised Dealer Check fluid level and top up if ne cessary Should the problem persist refer to an Authorised Dealer ...

Page 72: ...checked and or brake pads renewed The ABS system warning lamp should be on in the following conditions When the key is inserted in the starting switch When the vehicle speed is less than 5 to 10 km h Low battery charge Engine coolant level low Refer to an Authorised Dealer Check fluid level and top up if ne cessary Should the problem persist refer to an Authorised Dealer Note In case of temporary ...

Page 73: ...ce Refer to an Authorised Dealer power reduced to about 40 HP Fuel system malfunction Refer to an Authorised Dealer Warning water in fuel filter may damage the EDC system Therefore stop the engine and drain the water as soon as the warning lamp Water in fuel filter Drain the water as described on page 47 If lamp stays ol replace filter ...

Page 74: ...Capacities 71 ...

Page 75: ...k Cooling system Protective antifreezer 50 concentration Freezing point 40 C Tutela ZC 90 Tutela W 140 M DA Tutela W 140 M DA Tutela GI A Tutela DOT SPECIAL DOH Arexons DPI Paraflu 11 It Kg 5 9 5 3 7 6 3 1 5 1 35 1 9 1 7 3 2 7 1 4 1 3 I ll 1 0 2 6 70 13 6 5 In any case the engine oil must be changed once a year even ifthe specified mileage interval is not reached within this period ...

Page 76: ...A Temperate warm climates 73 SAE 80W 90 oil not EP for mechanical transmission Containing anti wear additives MIL L 2105 oppure API GL3 Hydrostatic transmission oil A TF DEXRON 11 0 Lithium based grease consistency N L G I n 2 Lithium based grease consistency N L G I n 3 Hydraulic brake and clutch control fluid Conforming with specifications F MVS s n I 16 ISO 4925 SAE JI703 CUNA NC 956 0 I Iveco ...

Page 77: ...74 ...

Page 78: ...Tool kit 75 ...

Page 79: ...r the passenger s seat I Chocks 2 Jack 3 Tool bag containing Cutting pliers Screwdriver for standard and cross head screws Special spanner for dismantling electrical stop device Double ended spanner 10 x I I mm Double ended spanner 13 x 17 mm Double ended spanner 19 x 22 mm Box spanner 14 mm Emergency handle for electric window regulator where fitted Bus kit 4 First aid box where fitted ...

Page 80: ...Specifications and data 77 ...

Page 81: ... stroke Indirect injection Direct injection Performance Max power rating kW HP 60 82 81 109 Rated power speed r p m 4200 3800 Max torque rating Nm kgm 155 16 250 25 5 Rated torque speed r p m 2400 1700 Fuel injection system Injection pressure bar 120 8 240 8 Injection order 1 3 4 2 1 3 4 2 Adjustment cold engine Valve clearance intake mm 0 50 0 05 0 50 0 05 Valve clearance exhaust mm 0 50 0 05 050...

Page 82: ...2800 2800 Type Diesel four stroke Direct injection Performance Max power rating kW HP 76 103 90 122 90 122 Rated power speed r p m 3600 3600 3600 Max torque rating Nm kgm 250 25 5 285 29 235 24 Rated torque speed r p m 1900 1900 1600 Fuel injection system Injection pressure bar 230 8 230 8 230 8 Injection order 1 3 4 2 1 3 4 2 1 3 4 2 Adjustment cold engine Valve clearance intake mm 0 50 0 05 0 50...

Page 83: ... 35 8 CV 35 10 CV 35 12 CV 35 12 RG A40 1 D A40 12 A45 12 35 10 RS 49 10 A45 1 D A49 1 0 30 8 35 8 CV 35 1 0 RG 35 12 RG 35 12 RS 49 10 49 12 59 12 59 12 35 8 RG 35 10 RS A40 ID A45 1 D A45 12 35 8 RS 59 12 35 8 RG 35 8 RS 35 8 RG Iveco 2826 5 6 19 3 89 2 26 1 42 1 00 5 69 Ratios 3 357 3 909 3 615 3 917 4 182 4 300 4 556 4 444 4 889 5 125 5 222 5 857 Legend CV City Version RG Twin rear wheels R s ...

Page 84: ...ear suspension Leaf springs with spring bushing parabolic on van and combi Multiple leaf spring type on trucks van dual purpose chassis cowl vehicles and bus Telescopic shock absorbers Stabilizer bar Optional rear air suspension on 10 and 12 Brakes Front disc type Rear disc or drum according to model Vacuum brake indipendent circuit hydraulic system Wheels Disc type Front wheel geometry 30 Toe in ...

Page 85: ... 4 5 1550 3 75 35 8 40 8 35 10 185 75 R 16 3 5 1650 4 0 1550 3 5 195 75 R 16 3 25 1650 3 75 2600 175 75 R 16 1650 4 5 3 75 1650 4 0 185 75 R 16 3 5 35 12 1800 4 25 1650 3 75 195 75 R 16 3 25 1800 4 25 35 8 RS 35 10 RS 1550 3 0 215 75 R 16 4 5 RS Single rear wheels 1650 3 25 2300 35 12 RS 1650 3 25 215 75 R 16 4 5 RS Single rear wheels 1800 3 5 ...

Page 86: ...R 16 4 0 40 12 A40 12 1800 4 5 1650 3 75 195 75 R 16 3 75 1800 4 25 45 10 185 75 R 16 4 5 3400 4 5 A45 10 A45 12 195 75 R 16 1800 4 25 4 25 49 10 49 12 195 75 R 16 4 25 3700 4 5 A45 10 A45 12 A49 10 59 12 205 75 R 16 4 5 5 25 Reinforced 2000 4650 59 12 225 75 R 16 3 75 4 5 35 8 35 10 35 12 165 55 R 14 2600 5 75 City Version on rear axle 2600 3 0 1550 3 5 3100 3 75 Extra Europe model 6 50 R 16 1650...

Page 87: ...ts Rear indicators Rear stop lights Number plate lights Reversing lights Rear fog lights tnternallights Marker lights 88Ah 90Ah II0Ah only Bus 2 2 I0N 55 A 85 A Type Double filament halogen halogen tubular spherical spherical spherical spherical spherical spherical spherical tubular cylindrical spherical front Wattage 60 55 55 4 2 5 21 21 5 21 21 4 10 10 rear body only cylindrical 5 ...

Page 88: ...aintenance operations must be carried out by an Authorised Dealer at the speci fied mileage intervals Such operations are to be considered as mandatory during the warranty period failure to comply will invalidate the warranty Maintenance operations must be performed exclusively by an Authorised Dealer who will affix the date stamp and signature in the specially provided spaces ofthe Overall Mainte...

Page 89: ...e The Programmed Maintenance Plan covers the following types of vehicle use R On road operation H Heavy duty operation The following specifications should be adhered to regarding the driving performance Models Type of use Km intervals Hours intervals EO MI M2 EO MI M2 Indirect R 10 000 km 20 000 km 60 000 km 200 400 1200 injection 8 H 10 000 km 20 000 km 60 000 km 200 400 1200 R 20 000 km 60 000 k...

Page 90: ... C Vl J l t J tJ tJ c H Heavy duty 10 c l c 5 5 Vl c iij J C 0 l l c 0 J Qj l l J 0 J 0 L 0 0 0 w w U U Cl l CJ co L L l L co l L Civil protection H Municipal works H R Light off road duty H R H H I 0 a H Heavy off road duty c l l I Long distance duty R R R R R R R R R R R R R R 0 250 km Cll a Medium distance duty R R R R R R R R R R R R R R R R R 200 km Suburban distribution R R R R R R H R R R R...

Page 91: ...0 370 490 610 EO 20 140 260 380 500 620 MI 30 150 270 390 510 630 EO 40 160 280 400 520 640 MI 50 170 290 410 530 650 EO 60 180 300 420 540 660 M2 70 190 310 430 550 670 EO 80 200 320 440 560 680 MI 90 210 330 450 570 690 EO 100 220 340 460 580 700 MI 110 230 350 470 590 710 EO 120 240 360 480 600 720 M2 ...

Page 92: ......

Page 93: ... of Ownership Check M 12 This will enable him to check your vehicle and make any necessary adjustments in order to assure you of continued trouble free operation The Quality of Ownership Check M 12 is free with the exception of mate rials used eg oils fluids etc We would like to remind you that the Authorised Dealer places the skill of its Technical and Sales personnel at the Customer s disposal f...

Page 94: ...condition of pneum suspension rubber bellows Check of power steering hydraulic stop device Visual check of state of wear of tyres Check condition of sleeves boots gearbox clutch steering Programmed maintenance Brakes Check operation of service brakes Check operation of emergency and parking brakes Check brake discs pads shoes for wear Cab and electrical components Visual check of vehicle ext scrat...

Page 95: ...Including engine oil change only R Every 10 000 Km I Every 200 hours models 8 only H Every I 0 000 Km I Every 200 hours 1 The engine oil must be changed at least once ayear even it the annual mileage is less than that specified ...

Page 96: ...EO service I Change engine oil Programmed maintenance 93 ...

Page 97: ...M I R Every 20 000 Km I Every 400 hours H Every I 0 000 Km I Every 400 hours 3 1 7 5 L 4 L 2 6 11 f5 L 10 The engine oil must be changed at least once a year even it the annual mileage is less than that specified ...

Page 98: ...ages steering knuckles and steering column a Check wheel nuts tightening torque follow specifications provided on page 59 9 Check adjustment of brake and clutch pedals 10 Check adjustment of hand brake lever 11 Grease propeller shafts and the hinges ofthe rear door ofthe van With mileage peryear equal to or below 20 000 km propellershafts should be greased at least once a year Also Security and co...

Page 99: ...lus those described on the opposite page REvery 60 000 Km I Every I 200 hours H Every 60 000 Km I Every I 200 hours 5 1 6 2 I 7 3 The oil in mechanical components must be changed at least once a year even if the annual mileage is less than that specified ...

Page 100: ...ck headlamp alignment 6 Carry out a functional test of preheating plugs 8 model 7 Replace additional fuel filter 8 model Also Functional test of E G R system Dismantle and wash all oil bath air cleaner components Chang the oil where fitted Check leaf spring fastening Check engine suspension fastening Check universal joints and flange security Check security of air suspension bellow mountings where...

Page 101: ...98 Non standard maintenance 9 6 I 2 5 L 8 34 ...

Page 102: ...000 km Every 2000 hours 3 Replace alternator and water pump drive belts 4 Replace timing drive belt Every 120 000 km Every 2400 hours 5 Check injector settings 6 Change cooling fluid before the cold season 7 Replace air suspension drier filter where fitted Mod 45 49 59 Every year 8 Change brake fluid Every two years 9 Replace dry air filter cartridge regardless condition Programmed maintenance 99 ...

Page 103: ...100 ...

Page 104: ...Programmed maintenance Overall maintenance and lubrication plan Model Registration Surname First name Address City Chassis Registration date Telephone 101 ...

Page 105: ...ed Maintenance summary schemes provided on the following pages include the necessary spaces for affixing dealer stamps confirming that the service has been carried out as required at the specified mileage intervals The service operations involved are described on the pages detailed below EO 92 MI 94 M2 96 ...

Page 106: ...cation plan Programmed maintenance 103 Km Date H R Affix x Actual mileage at which stamp 1000 service was performed day month year here Tick off selected plan 10 EO EO 20 MI MI 30 EO EO 40 MI MI 50 EO EO 60 M2 M2 70 EO EO 80 MI MI ...

Page 107: ...nce and lubrication plan Km Date H R Affix x Actual mileage at which stamp 1000 service was performed day month year here Tickoff elected plan 90 EO EO lOO MI MI 110 EO EO 120 M2 M2 130 EO EO 140 MI MI ISO EO EO 160 MI MI ...

Page 108: ...rication plan Km Programmed maintenance Date 105 x 1000 Tick off I cted plan 170 H EO R EO Actual mileage at which service was performed day month year Affix stamp here 180 f 12 l M2 EO MI 210 220 230 240 EO MI EO M2 EO MI EO M2 ...

Page 109: ... and lubrication plan Km Date H R Affix x Actual mileage at which stamp 000 service was performed day month year here Tick off I_selected plan _ 250 EO EO 260 MI MI 270 EO EO 280 MI MI 290 EO EO 300 M2 M2 310 EO EO 320 MI MI ...

Page 110: ...ion plan Programmed maintenance 107 Km Date H R Affix x Actual mileage at which stamp 1000 service was performed day month year here Tickoff selected plan 330 EO EO 340 MI MI 350 EO EO 360 M2 M2 370 EO EO 380 MI MI 390 EO EO 400 MI MI ...

Page 111: ... and lubrication plan Km Date H R Affix x Actual mileage at which stamp 1000 service was performed day month year here 1 Tickoff selected plan 1 410 EO EO 420 M2 M2 430 EO EO 440 MI MI 450 EO EO 460 MI MI 470 EO EO 480 M2 M2 ...

Page 112: ...n plan Programmed maintenance 109 Km Date H R Affix x Actual mileage at which stamp 1000 service was performed day month year here 1 Tick off I selected plan 490 EO EO 500 MI MI 510 EO EO 520 MI MI 530 EO EO 540 M2 M2 550 EO EO 560 MI MI ...

Page 113: ... and lubrication plan Km Date x H R Actual mileage at Affix 1000 which service was per stamp formed day month year here 1 Tick off selected plan 570 EO EO 580 MI MI 590 EO EO 600 M2 M2 610 EO EO 620 MI MI 630 EO EO 640 MI MI ...

Page 114: ...n plan Programmed maintenance III Km Date x H R Actual mileage at Affix 1000 which service was per stamp formed day month year here Tick off selected plan_ 650 EO EO 660 M2 M2 670 EO EO 680 MI MI 690 EO EO 700 MI MI 710 EO EO 720 M2 M2 ...

Page 115: ...112 ...

Page 116: ...Vans Combi Van Access from outside Combi Access from outside Side door Twin rear loading door Interior lighting III ...

Page 117: ...114 Van Access from outside I Driver s door 2 Fuel filler 3 Rear loading doors 4 Side sliding door 5 Passenger s door 6 Engine hood ...

Page 118: ...Vans Combi 115 Combi Access from outside I Driver s door 2 Fuel filler 3 Rear loading doors 4 Side sliding door 5 Passenger s door 6 Engine hood ...

Page 119: ...tside The handle is provided with a key lock for locking from outside To open pull the handle and push the door to the left Opening from inside Pull lever I to open the door Press lever 2 to lock the door Door closing Press lever 3 and push the door to the right until it closes ...

Page 120: ... provided with a key lock for locking from outside Pull the handle to open the door Vans Combi 117 Opening from inside Proceed as follows Lift lever 2 to unlock the door Use lever I to open one ofthe two doors Turn handle 3 outwards to open the other door ...

Page 121: ...h them on press on one ofthe two points indicated by the arrows Lights located above the twing rear loading door are switched on when doors are opened or pressed on either side Trailer hook where fitted For trailers having inertial braking I Spheric trailer hook 2 7 pin 12 V for lighting system ...

Page 122: ...Bus Access from outside Interior lighting Emergency control pushbutton Driver s control panel Electromagnetic retarder Swing door 119 ...

Page 123: ...120 1 Access from outside I Engine hood 2 Driver s door 3 Fuel filler 4 Luggage compartment ...

Page 124: ...sisting of I Two IOW removable white bulbs 2 One SW removable blue bulb Courtesy and driver s lights 3 One IOW removable bulb Push fit diffuser Bus 121 ID 11 Control switches I Heater 2 Aspirator 3 White aisle lights 4 Blue aisle lights ...

Page 125: ...s control panel I TELMA retarder control 2 Emergency control pushbutton 3 TELMA retarder warning lamp 4 Swing door controls School Bus version 5 Main relay control switch 6 Horn switch 7 Hazard lights warning lamp ...

Page 126: ... the following functions Hazard lights connection warning lamp 2 Engine stop Main current relay disconnection 123 Note To reset the relay contact press switch 3 4 Horn switch A 45 regular service bus Battery switch It is fitted inside the engine hood The electric system is switched offby operating the battery S Witch ...

Page 127: ...hed off I Minimum 2 Medium 3 Maximum Switching on is indicated by the warning lamp Warning After retarder has been in use for long time it is recommended that you do not switch offthe ignition immediately to permit cooling ofthe electric brakes When vehicle is at a standsill switch off Telma by moving lever to 0 position ...

Page 128: ...t device is switched on where fitted r 125 Controls for School Bus version The system is provided with a control panel with two luminous pushbuttons Red button 5 it lights up when the door opens and remains lit until it is open Green button 6 it only lights up when the door is perfectly closed Fuse holder 7 with IsA strip fuse protects the whole system Safety device The swing door is equipped with...

Page 129: ...ually To reset after using the emergency handle proceed as follows Press the black lever 10 beside the gearmotor Turn the door control support shaft thus making the gearmotor gear mesh easier Reset lever 8 to its normal position External emergency device It consists of an handle fitted outside the vehicle for the manual opening of the swing door in case of an emergency It is connected to the antit...

Page 130: ...Daily City 35 8 TurboDaily City 35 10 35 12 Special versions for door to door delivery 127 ...

Page 131: ...128 Access from outside I Swing door 2 Engine hood 3 Driver s door 4 Fuel filler 5 Twin rear doors ...

Page 132: ...Daily City TurboDaily City 129 Access from the swing door I Access door steps 2 Gangway for easier transport of goods Rear access 3 Loading platform 4 Rear spare wheel 5 Front spare wheel ...

Page 133: ...130 1 2 3 4 5 Driver s control panel I orn I TELMA retarder control where fitted 2 Swing door controls 3 TELMA retarder warning lamp where fitted 4 Available for switches 5 Available for warning lamp ...

Page 134: ...lights up only when the door is perfectly closed Yellow led 3 it lights up only when the emergency handle 5 page 132 is pulled Orange led it lights up only when the antitheft device is switched on where fitted Safety device The swing door is equipped with an automatic device which stops the door in the closing stage when an obstacle ora person is in the way itwill also automatically reopen thus av...

Page 135: ...e door compar tment In case of emergency proceed as follows Pull the above handle downwards thus releasing the driving shaft and the door from the gearmotor Open the door manually To reset after using the emergency handle proceed as follows Press the black lever 6 beside the gearmotor Turn the door control support shaft thus making the gearmotor gear mesh easier Reset lever 5 to its normal positio...

Page 136: ...s equipped with a remote control locking device for door opening and closing As soon as he leaves the vehicle with the goods the driver can lockthe doors with the remote control swing door rear door and driver s door After the delivery he can through the remote control open only the swing door the other doors remaining locked 2 Sensor for infrared remote control ...

Page 137: ...e remote control a Press and hold the programming push button 5 led 4 lights up and remains litto indicate ready to receive code b Keeping the push button 5 pressed operate the push button I ofthe transmitter The extinction of led 4 on the receiver means that code has been received c Release push button 5 At this point led 4 flashes for about 15 sec Led flashing means that the code has been memori...

Page 138: ...programming transmitter loss It is possible to programme a new code without having a transmitterwhose code has already been memorized in the receiver for example in case oftransmitter loss In this case it is necessary to have the metal plate 3 supplied along with the original transmitter that has lost On this metal plate are stamped four numbers representing the code to input following these instr...

Page 139: ...136 Passenger s seat where fitted This seat can be completely tilted forward pressing lever I so as to make the transport of goods easier ...

Page 140: ...Vehicles with electronically controlled automatic clutch ACS 137 ...

Page 141: ...with the amount of throttle applied When the vehicle is running the gear shift is performed simply by operating the gear lever Description Warning strategy see pages 139 and 140 An audible warning buzzer is used to convey the following information associated with the drivers behaviour Clutch overheating caused by irregular use ofthe vehicle Driven plate overspeed possibly caused by down shifting i...

Page 142: ...t 2 Minimum tow start speed has been achieved 3 After 6 sec rolling in opposed gear Pulsing Buzzer Min 2 S I Reverse gear selected I Reverse gear selected 400 mS on 2 Bonnet open whist in gear and engine 400 mS off running 3 Drivers door open whilst in gear and engine running 4 Clutch overheating 5 Wrong take up gear selected 6 Engine started whilst in gear ...

Page 143: ...procedure to check clear faults Switch off engine for at least 10 seconds Key MAR if warning has cleared then proceed as normal Recommend vehicle is serviced as soon as possible If warning will not clear then the vehicle can be driven by following procedure Key STOP Remove ACS fuse 2 page 142 or connector the clutch will remain engage and warning light will be on It is now possible to start the ve...

Page 144: ... gear engagement will result in a clutch driven plate overspeed situation especially during a downshift an audible warning is given to the driver Warning Ifa gear cannot be selected while stationary in neutral especially reverse depress the accelerator pedal for a short time in neutral to rev the engine and then re attempt gear selection when engine speed has returned to idle It is strongly recomm...

Page 145: ...inuous lamp and buzzer indicates aserious system fault and that the driver should stop as soon as possible Key off and restart after approximately 10 seconds may be attempted Ifthe fault is still present engine start may be inhibited Under these conditions restarting is only possible by removing supply fuse 2 of the ECU under which circumstance the warning lamp I remains on First select a gear app...

Page 146: ...everse gear Warning The system doesn t work if the V Battery 8Volt ACS power pack reservoir With the vehicle on level ground check the fluid level every month in the reservoir I key on but don t start the engine when the pump has finished running The fluid level should be above the mark on the reservoir I If not consult dealer for investigation into causes of loss Top up if necessary with Tutela D...

Page 147: ...144 ...

Page 148: ...Index Index 145 ...

Page 149: ...ter 46 51 Air suspension 21 55 Daily Turbodaily City Driver s control panel 130 Daily Turbodaily City Passenger s seat 136 Auxiliary control panel 22 Daily Turbodaily City Rear access 129 B Daily Turbodaily City Remote control 134 Daily Turbodaily City Swing door 131 Bath air cleaner oil 51 De Activating the Iveco Engine Immobiliser System 34 Belts 52 Differential locking 40 Bodywork maintenance 5...

Page 150: ...86 G Maintenance a few practical hints 49 Master key 32 Greasing 54 Model coverage 4 Guide to the selection of the maintenance plan 87 N H Non standard maintenance 98 Headlight aiming 27 54 0 Headlights 64 Heated fuel filter 37 On the spot maintenance 57 Heating and ventilation 24 Overall maintenance and lubrication plan 101 Horn 19 I P Power steering 47 Interior lights 66 Power take off 40 Intern...

Page 151: ... 118 Self liagnosis system 38 Vehicle identification data 7 Service EO 92 Vehicle interior 9 Service interval plan 88 89 Vehicle towing 58 Service M I 94 W Service M2 96 Spare wheel 58 Warning lamp cluster 1I Specifications and data 77 Warning lamp guide 68 69 70 Starting and driving 31 Wheel changing 59 Stowage compartment 20 Windscreen washer reservoir 20 46 T Windscreen washer wiper unit 20 Tac...

Page 152: ...ct to con stant development as a result certain part of this publication might not be up to date Publication edited by IVECOS pA Tea BU Customer Service Lungo Stura Lazio 49 10156 Torino TO Italy Pnnted 603 90 071 lllth Ed 01 98 I rei L L Publication produced by SATIZ S pA EDITORIA TECNICA Pubblicazioni Tecniche do Iveco Lungo Stura Lazio 49 10156 Tonno ...

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