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Iveco EUROCARGO, Instructions Manual

The Iveco EUROCARGO Instructions Manual is a comprehensive guide that provides detailed explanations on operating and maintaining this exceptional product. Easily accessible for free download from our website, this manual ensures users have all the necessary information they need for optimal performance of their EUROCARGO vehicle.

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EUROCARGO Euro 6

–

CHASSIS INTERVENTIONS

CHASSIS INTERVENTIONS

Contents

3

–

Printed 603.95.747

–

1st Ed. - Base 12/2013

Contents

2.1

 

GENERAL CHASSIS MODIFICATION

STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preventive measures . . . . . . . . . . . . . . . . . . . . 5
Characteristics of the material used in chassis

modifications . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stresses on the chassis . . . . . . . . . . . . . . . . . . . 7

2.2

 

DRILLS ON THE CHASSIS . . . . . . . . . . . . . . . 7

Hole position and size . . . . . . . . . . . . . . . . . . . 8
Screws and nuts . . . . . . . . . . . . . . . . . . . . . . . 8
Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sealing holes by welding . . . . . . . . . . . . . . . . .

11

2.3

 

RUST AND PAINT PROTECTION . . . . . . . . .

11

Original vehicle parts . . . . . . . . . . . . . . . . . . .

11

Added or modified parts . . . . . . . . . . . . . . . . .

13

Precautions . . . . . . . . . . . . . . . . . . . . . . . . .

14

2.4

 

WHEELBASE MODIFICATION . . . . . . . . . . .

15

General information . . . . . . . . . . . . . . . . . . . .

15

Authorisation . . . . . . . . . . . . . . . . . . . . . . . .

15

Effects on steering . . . . . . . . . . . . . . . . . . . . .

15

Effects on braking . . . . . . . . . . . . . . . . . . . . .

16

Intervention procedure . . . . . . . . . . . . . . . . . .

16

Checking chassis stress . . . . . . . . . . . . . . . . . .

16

Cross members . . . . . . . . . . . . . . . . . . . . . .

17

Gearbox modifications . . . . . . . . . . . . . . . . . .

17

2.5

 

REAR OVERHANG MODIFICATION . . . . . . .

17

General information . . . . . . . . . . . . . . . . . . . .

17

Authorisation . . . . . . . . . . . . . . . . . . . . . . . .

18

Chassis Shortening . . . . . . . . . . . . . . . . . . . .

18

Elongation . . . . . . . . . . . . . . . . . . . . . . . . . .

18

2.6

 

INSTALLING THE TOW HOOK . . . . . . . . . .

20

General information . . . . . . . . . . . . . . . . . . . .

20

Precautions for Installation . . . . . . . . . . . . . . .

20

Towing hooks for conventional trailers . . . . . . . .

22

Drawbar couplings for centre axle trailers . . . . . .

22

Rear crossbar in lowered position . . . . . . . . . . .

28

2.7

 

ASSEMBLING AN ADDITIONAL AXLE . . . . . .

33

General information . . . . . . . . . . . . . . . . . . . .

33

Reinforcements on the chassis . . . . . . . . . . . . .

33

Added axle . . . . . . . . . . . . . . . . . . . . . . . . .

34

Steering axles . . . . . . . . . . . . . . . . . . . . . . . .

35

Suspension . . . . . . . . . . . . . . . . . . . . . . . . .

35

Stabiliser bars . . . . . . . . . . . . . . . . . . . . . . . .

36

Attachments to the chassis . . . . . . . . . . . . . . .

36

Brake system . . . . . . . . . . . . . . . . . . . . . . . .

36

Lifting device . . . . . . . . . . . . . . . . . . . . . . . .

37

2.8

 

GEARBOX MODIFICATION . . . . . . . . . . . .

37

Lengths allowed . . . . . . . . . . . . . . . . . . . . . .

38

Positioning the sections . . . . . . . . . . . . . . . . .

40

2.9

 

MODIFYING THE ENGINE AIR INTAKE AND

EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . .

43

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

Engine exhaust . . . . . . . . . . . . . . . . . . . . . . .

44

2.10

 

MODIFYING THE ENGINE COOLING

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

2.11

 

INSTALLING AN ADDITIONAL HEATING

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

2.12

 

INSTALLING AN AIR CONDITIONING

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

2.13

 

WORK ON THE CAB . . . . . . . . . . . . . . . .

46

General information . . . . . . . . . . . . . . . . . . . .

46

Work on the roof . . . . . . . . . . . . . . . . . . . . .

47

Spoiler or top-sleeper installation . . . . . . . . . . .

47

Realization of sleeper cabs . . . . . . . . . . . . . . . .

47

2.14

 

CHANGING TYRE SIZE . . . . . . . . . . . . . . .

48

2.15

 

WORK ON THE BRAKING SYSTEM . . . . . .

49

General information . . . . . . . . . . . . . . . . . . . .

49

Brake pipes . . . . . . . . . . . . . . . . . . . . . . . . .

49

ABS electronic brake control devices . . . . . . . . .

52

Withdrawing air from the cooling system . . . . . .

52

2.16

 

ELECTRICAL SYSTEM: CURRENT

INTERVENTIONS AND DRAWS . . . . . . . . . . . . .

53

Summary of Contents for EUROCARGO

Page 1: ...EUROCARGO EURO 6 M E D I U M R A N G E BODYBUILDERS INSTRUCTIONS ISSUE 2013 ...

Page 2: ...IVECO S p A Technical Application Homologation Strada delle Cascinette 424 34 10156 Torino TO Italy www iveco com Printed 603 95 747 1st ed 12 2013 Images and text IVECO S p A 2013 All rights reserved ...

Page 3: ...IDELINES FOR TRANSFORMATION AND GUIDELINES FOR TRANSFORMATION AND VERSIONS UPDATE DATA 5 Printed 603 95 747 1st Ed Base 12 2013 GUIDELINES FOR TRANSFORMATION AND VERSIONS UPDATE DATA Section Description Page Revision date ...

Page 4: ... Printed 603 95 747 Base 12 2013 ...

Page 5: ...y operation it is necessary to verify that you have the manuals for the vehicle model on which you are about to work ensure that all the safety devices goggles helmet gloves shoes etc as well as the equipment used for work lifting and trans port is available and working ensure that the vehicle is placed in safe conditions At the end of the operation the operational efficiency and safety conditions...

Page 6: ... Printed 603 95 747 Base 12 2013 ...

Page 7: ... SECTIONS Printed 603 95 747 Base 12 2013 GENERAL INFORMATION 1 CHASSIS INTERVENTIONS 2 APPLICATIONS OF SUPERSTRUCTURES 3 POWER TAKE OFFS 4 ELECTRONIC SUB SYSTEMS 5 SPECIAL INSTRUCTIONS FOR SCR EXHAUST SYSTEM 6 ...

Page 8: ... Printed 603 95 747 Base 12 2013 ...

Page 9: ... Printed 603 95 747 Base 12 2013 SECTION 1 GENERAL INFORMATION ...

Page 10: ... Printed 603 95 747 Base 12 2013 ...

Page 11: ...MANAGEMENT 8 1 10 ACCIDENT PREVENTION 8 1 11 CHOICE OF MATERIALS TO USE ECOLOGY RECYCLING 8 1 12 VEHICLE MANAGEMENT ON THE PART OF BODYBUILDER 9 Acceptance of chassis 9 Maintenance 9 Delivery of the vehicle to the final customer 9 1 13 VEHICLE NAMES 10 Commercial name 10 1 14 TRADEMARKS AND SYMBOLS 11 1 15 DIMENSIONS AND GROUND 11 General information 11 Determination of the centre of gravity of th...

Page 12: ...4 EUROCARGO Euro 6 GENERAL INFORMATION GENERAL INFORMATION Printed 603 95 747 1st Ed Base 12 2013 ...

Page 13: ...aults or defects caused by total or partial failure to comply with these Guidelines are not covered by the guarantee on the chassis or relative mechanical units 1 2 TECHNICAL DOCUMENTATION AVAILABLE ELECTRONICALLY On the website www ibb iveco com the following technical documentation is available Guidelines for transformation and fitting of vehicles technical specifications truck diagrams tractor ...

Page 14: ... components that are installed 1 6 LEGISLATIVE REQUIREMENTS The Bodybuilder must verify that the final product is compliant without exception to all applicable legal requirements on the muni cipal autonomous national level of each State in which it is registered and or will circulate Highway code Official Regulations etc and on the international level European Union Directives ONU Geneva ECE Regul...

Page 15: ...echnical service for evaluation appropriate documentation of the changes made in order to give objective evidence of compliance to the aforemen tioned provisions of law e g approval documents test reports Before signing the Technical Agreement IVECO reserves the right to visit the Bodybuilder in order to verify qualifications to carry out the fittings and or processing for which the above collabor...

Page 16: ...echnical knowledge must be taken to avoid damage and functional defects Compliance with these requirements must be overseen by the builders of the structures and devices Seats coatings gaskets protective panels etc may pose a fire hazard when exposed to an in tense heat source Remove them before working with welding and with flames 1 11 CHOICE OF MATERIALS TO USE ECOLOGY RECYCLING In the study and...

Page 17: ...le in the IVECO network for the items being worked on obviously the other items of the PDI will be the responsibility of the Dealer such as the guarantee pamphlet measure battery voltage with a digital multimeter 2 digit decimal keeping in mind that 1 optimal value is equal to 12 5 V 2 between 12 1 V and 12 49 V the battery should be put under a slow charge 3 with values less than 12 1 V the batte...

Page 18: ... in t 60 4x2 trucks 65 4x2 trucks 75 4x2 trucks 80 4x2 trucks 90 4x2 trucks 100 4x2 trucks 110 4x2 4x4 trucks 120 4x2 trucks 140 4x2 trucks 150 4x2 4x4 trucks 160 4x2 trucks 180 4x2 trucks 190 4x2 trucks E Range code E Standard frame height EL Optimal chassis height 19 Engine power no x 10 power in HP P Version Rear mechanical suspension P Rear air suspension FP Front and rear pneumatic suspension...

Page 19: ...on the official IVECO website Defects refer to vehicles in their standard versions the use of special equip ment may lead to changes on the masses and their distribution on the axles Weighing of the chassis It should be noted that variations are possible on the masses of the order of 5 For this reason before carrying out the fitting it is a good idea to determine the mass of the vehicle cab and it...

Page 20: ...shown on the chassis and weight allocation diagram 196789 Figure 2 Example to determine the placement of the centre of gravity of the payload plus superstructure Vehicle with 2 axles vehicles with 3 axles having equal loads on two rear axles W Payload plus superstructure W1 Measurement of payload on front axle W2 Measurement of payload on rear axle or tandem L1 Distance of centre of gravity from t...

Page 21: ...n distribution of load Uneven distribution of load 196791 Figure 4 Even distribution of load Uneven distribution of load attention to loads on axles and minimum ratio Height of centre of gravity For the cab version and no load vehicle the value of the height of the centre of gravity is shown on the specific technical docu mentation for each model cab version diagram For the vehicle complete with s...

Page 22: ...ppropriate for the load and between the no load cab version trim and the full load trim 2 Mobile loads In the versions where the load can be moved laterally while cornering e g suspended loads liquid transport animal transport etc high lateral dynamic forces may be generated which may jeopardise the stability of the vehicle With reference to the indications of the regulation ECE 111 special attent...

Page 23: ...r superstructures with high ri gidity e g vans Exceeding the limits In the case of special transport with a high centre of gravity height e g transport of machinery indivisible loads etc from a tech nical standpoint it is possible to exceed the values shown in the table provided that the driving is adjusted appropriately e g re duced speed gradual variations of the trajectory of travel etc Respect...

Page 24: ...terventions on some parts such as suspension and brakes and may require a new calibration for the braking correction operation in these cases the necessary indications may be provided 1 16 INSTRUCTIONS FOR PROPER FUNCTIONING OF THE VEHICLE PARTS AND ACCESS IBILITY In carrying out the transformations and applying any type of equipment there should be no alteration to what enables the proper functio...

Page 25: ...er A Right hand side view B Left hand side view the possibility of disassembly of the various units must be maintained for any support interventions e g in figure 1 6 ref B is shown the case of the DPF silencer assembly with the minimum necessary dimension to allow the use of tools in the fitting that provides the tipping of the lateral tails consider the size of the most protruding parts of the v...

Page 26: ...ump posi tioning filters pipe diameter etc and engine air intake the soundproofing panels must not be altered or moved so as not to affect the approved sound emission limits If any open ings need to be made e g for the passage of pipes or added sections they must be thoroughly closed using fireproof and soundproofing materials equivalent to the original materials used adequate ventilation must be ...

Page 27: ...herefore when pipes must be inevitably installed near the engine exhaust system catalytic converter or turbocharger suitable insulating shields or protective plates must be provided 1 18 CONVENTIONS 91473 Figure 8 In these Guidelines the following conventions are adopted Wheelbase distance between the centre lines of the first steering axle and the first rear axle engine or not Rear overhang dista...

Page 28: ...20 EUROCARGO Euro 6 GENERAL INFORMATION GENERAL INFORMATION Printed 603 95 747 1st Ed Base 12 2013 ...

Page 29: ... Printed 603 95 747 Base 12 2013 SECTION 2 CHASSIS INTERVENTIONS ...

Page 30: ... Printed 603 95 747 Base 12 2013 ...

Page 31: ...0 Precautions for Installation 20 Towing hooks for conventional trailers 22 Drawbar couplings for centre axle trailers 22 Rear crossbar in lowered position 28 2 7 ASSEMBLING AN ADDITIONAL AXLE 33 General information 33 Reinforcements on the chassis 33 Added axle 34 Steering axles 35 Suspension 35 Stabiliser bars 36 Attachments to the chassis 36 Brake system 36 Lifting device 37 2 8 GEARBOX MODIFIC...

Page 32: ...RELOCATION AND ANCHORAGE OF ADDITIONAL UNITS AND EQUIPMENT 53 2 18 TRANSPORT OF HAZARDOUS MATERIALS ADR 55 2 19 INSTALLING A RETARDER 57 2 20 REAR UNDER RUN PROTECTION RUP 58 2 21 REAR MUD GUARDS AND WHEEL ARCHES 58 2 22 RAIN FLAP 59 2 23 SIDE PROTECTIONS 59 2 24 FRONT UNDER RUN PROTECTION FUP 61 2 25 REAR VIEW MIRRORS 61 ...

Page 33: ... diameter and nuts fitted with an anti unscrewing system Screws larger than M14 may not be used maximum hole diameter of 15 mm unless otherwise specified for cases where unions that require screws are restored the suitability of these screws must be checked before being re used and they must be tightened to the appropriate torque As regards remounting safety components it is prohibited to re use t...

Page 34: ...etal surface with a high conductivity paint e g zinc coating Part Number IVECO 459622 from PPG connect to earth within 5 minutes after application of the paint For ground connections at the signal level e g sensors or devices with low absorption absolutely never use standardised IVECO M1 points ground connection of the batteries M2 or M8 grounding the starter motor depending on the position of the...

Page 35: ...lue in static conditions cannot be exceeded for any reason whatsoever Note static stress σ allowed on chassis 120 N mm2 In any case respect any more restrictive limits placed by national standards Welding causes material property deterioration therefore when checking stresses in thermally altered zones a resistance reduc tion of 15 must be accounted for 2 2 DRILLS ON THE CHASSIS Installation of au...

Page 36: ...bars 192342 Figure 2 valid with chassis thickness 7 7 mm with chassis thickness 6 7 mm the measurement is equal to 39 mm Screws and nuts We generally recommend the use of the same type and class of screws and nuts as those employed for similar anchorages on the original vehicle see Table 2 3 Table 2 3 Screws resistance classes Resistance class Use Breaking strength N mm2 Yield stress N mm2 8 8 Int...

Page 37: ...tric arc welding and in order to protect electrical components and ECUs 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 negative pole from the battery disconnect the positive pole of the battery without connecting it to earth do NOT short circuit the negative pole ...

Page 38: ...igure 5 Arc weld the area with multiple steps and use base electrodes that are thoroughly dried Avoid power overloads the welds must be free of marginal incisions and slag Start from the opposite end and weld as in the previous item Let the side members cool slowly and in a uniform fashion No cooling with air jets water or other means is allowed Grind off the excess material Mount steel corner rei...

Page 39: ...ired for the painted parts Table 2 4 Class of protection IVECO Standard 18 1600 Prospectus I Class Part requirements Examples of parts involved A Parts in direct contact with atmospheric agents Bodywork Rear view mirrors Windscreen wipers Metallic structured sun visors Metallic bumpers Cab hook lock Door stop device Bodywork fastening elements screws bolts nuts washers etc B B2 Parts in direct con...

Page 40: ...hase description Classes A B 8 B1 5 B2 C D MECHANICAL SURFACE CLEANING 1 Sand shot blasting yes yes yes yes Brushing yes Sandpapering PRE TREATMENT Iron phosphating only for non precoated ferrous materials yes yes yes yes Zinc phosphating yes CATAPHORETIC PAINTING High thickness 30 40 μm yes 2 yes 6 yes 6 yes 6 9 yes 6 Medium thickness 20 30 μm yes 3 Acrylic finishing 35 μm RUST PREVENTER Bi compo...

Page 41: ...ot accepted Tables 2 7 and 2 8 indicate the minimal treatment that modified or added components must receive when it is not possible to have protection that is similar to that of original components Different treatment is allowed if it ensures similar oxidation and corrosion protection Do not used powder varnish directly after degreasing has been performed Lightweight alloy copper and brass parts ...

Page 42: ...eel rim mounting surfaces on the hubs and the contact areas of the locking lugs wheel studs ensure adequate protection of brake discs The electronic components and modules must be removed Engines and their electric electronic components Appropriate precautions must be taken to protect engine wiring and ground contacts the sensor actuator side connectors and wiring side the sensors actuators on the...

Page 43: ...ransformation must provide sufficient guarantees in terms of technology and inspections quali fied personnel appropriate operational processes etc For the 4x4 versions variation in the wheelbase is only allowed with specific approval from IVECO The operations must be performed in compliance with these directives taking into account the suitable adjustments and adapta tions as well as all required ...

Page 44: ...ows flanged head screws may be employed if cutting the frame to be carried out according to indications of the second item in Welding Operations Paragraph Weld ing Page 9 mark a second line of reference points so that the work area is set between the two lines plan for a dis tance of at least 1500 mm upon work completed Carry over the points relative to the cutting area between the two lines proce...

Page 45: ...ons See Chapter 2 8 Page 37 for checks of modifications allowed 2 5 REAR OVERHANG MODIFICATION General information When modifying the rear overhang it is necessary to take note of the variations that this modification inflicts on distribution of axle loads in compliance with loads established by IVECO see Chapter 1 15 Page 11 Limits set by national law must also be respected as well as maximum dis...

Page 46: ... shortening the rear overhang of the chassis When the rear crossbar is too close to another crossbar the latter can be eliminated if it plays no role in suspension support Elongation possible solutions concerning elongations are shown in Figures 2 7 and 2 8 Cuts can be of straight type The minimum dimensions of the reinforcements to apply in the area of modification are shown in Figure 2 3 The sol...

Page 47: ...ss member 91455 Figure 8 1 Added part 2 Reinforcing profile 3 Original rear cross member 4 Any additional cross member When the elongation is rather large the need of an additional crossbar must be evaluated on a case to case basis in order to ensure proper torsional strength of the frame The insertion of an extra crossbar having characteristics similar to the series is necessary however when two ...

Page 48: ...oads keep in mind the precautions given in Paragraph Towing hook for centre axle trailers Page 22 Precautions for Installation The towing hook must be suited for the loads allowed and must be of a type approved by national standards Given their importance related to safety the drawbar couplings must not undergo modifica tions In addition to the requirements of the hook manufacturer it is necessary...

Page 49: ...In cases where the connection flange of the drawbar coupling does not have holes suitable to those on the existing rear crossbar of the vehicle the latter may be authorised for modification upon application of adequate reinforcements The Bodybuilder has the duty of realising and installing the superstructure so as to allow coupling connection and checks without impairment or hazard of sort The tra...

Page 50: ... the drawbar coupling manufac turer and on the part manufacture plate see DIN 74051 and 74052 Towing hooks that bear special approvals and with values greater than those listed in the above standards may be used However these towing hooks may pose restrictions in relation to the type of trailer used e g drawbar length In addition the drawbar may require reinforcement for the towing vehicle as well...

Page 51: ...y be necessary to adopt sections of the counter chassis having a larger size than those normally provided Example of calculations for connection device class for centre axle trailers We shall consider a vehicle with maximum weight of 18 t that must tow a centre axle trailer of 9 t with length of load bed 8 m and theoretical drawbar length of 7 m The data at hand yields R 9 t S equals 0 9 t i e the...

Page 52: ... 3105 1313 33 44 3330 1830 57 70 3690 57 78 4185 2145 78 85 4455 2280 78 95 5 4815 2505 78 85 80E 195x65 4 3105 1313 16 16 16 16 3330 1830 16 16 34 34 3690 16 24 44 44 5 4185 2145 16 19 57 57 4455 2280 19 39 63 70 4815 2505 32 57 78 85 80EP 4 3105 1313 18 39 57 3330 1830 44 63 85 3690 63 78 100 100 5 4185 2145 57 78 100 100 4455 2280 78 85 100 112 4815 2505 78 100 120 120 90E 195x65 4 3105 1313 16...

Page 53: ...5 120E 240x70 5 3105 1313 16 16 16 16 16 16 3690 1740 16 16 16 16 16 16 4185 2055 16 16 40 45 45 45 6 4455 2190 16 16 16 16 16 16 4815 2460 18 25 63 63 63 63 6 7 5175 2685 18 21 63 5670 3000 29 63 100 6570 3500 85 112 135 120EP 5 3105 1313 16 16 16 16 16 16 3690 1740 39 63 85 85 85 85 4185 2055 70 85 115 115 115 115 6 4455 2190 44 70 100 100 100 100 4815 2460 70 100 130 130 130 130 6 7 5175 2685 7...

Page 54: ...70 3000 78 115 115 115 6570 3605 130 150 170 170 150EP 5 3105 1313 16 16 16 16 6 3690 1740 35 57 57 57 4185 2055 85 100 100 100 4455 2190 100 125 125 125 6 7 4815 2460 100 135 135 135 5175 2685 130 150 150 150 7 7 5670 3000 130 170 170 170 6570 2605 170 230 230 230 160E 240x70 5 3105 1313 16 16 16 16 6 3690 1740 16 16 16 16 4185 2055 16 16 16 16 4455 2190 16 25 35 35 6 7 4815 2460 25 57 57 57 5175...

Page 55: ... 180E 262 5x80 in line 217 5x80 7 7 6590 2775 78 100 100 150 180EP 6 3690 1133 16 16 16 16 7 7 4185 1313 16 16 16 16 4590 1650 16 18 18 63 4815 1853 18 35 49 110 5175 2123 49 78 78 133 5670 2235 78 100 100 133 6210 2235 57 85 85 115 6590 2775 130 150 150 211 190E 262 5x80 in line 217 5x80 6 3690 1133 16 16 16 16 7 7 4185 1313 16 16 16 16 4590 1650 16 16 16 16 4815 1853 16 16 16 18 5175 2123 18 35 ...

Page 56: ...x80x8 mm 210x80x8 190x80x8 150x50x8 angle 130x50x8 angle Actual reduction in height mm 40 52 92 104 The possibility of interrupting the combined reinforcement continuity is limited to special cases and must be authorized Similarly when the application of the external reinforcement angle solutions C and D see Figure 3 24 presents difficulties e g presence of suspension supports or of the coupling b...

Page 57: ... mm and should use a material with the minimum requirements set out in Chapter 3 3 Paragraph Choosing the type of connection Page 11 The fastening to the vertical rib of the side members must be done with all the union screws of the crossbar to the chassis of the vehicle integrating them with others whose number and positioning consider the greater time transmitted In principle in the lowerings eq...

Page 58: ...orce must be ensured If the local legal regulations provide it after construction the vehicle must be presented for the required checks Figure 2 13 shows an example of a lowered supplementary crossbar In cases where this solution is chosen on vehicles with short rear overhangs the external connection angle must be made according to the solution proposed therein If after lowering the rear crossbar ...

Page 59: ...rcements In cases where it is necessary to reinforce the standard crossbar and there are no originally reinforced crossbars you will have to resort to the application of C profile within the crossbar an adequate reinforcement even of the connections of the same to the side members of the vehicle C profile within the crossbar with connection to the vertical rib of the side member or to the next cro...

Page 60: ...tow weights than those normally allowed These authorisations include the towing conditions and when necessary provide the instructions relevant to any vehicle modifica tions or work required standard crossbar reinforcements see Figure 2 13 or installation of a reinforced crossbar when available or adjustments to the braking system The drawbar coupling must be suited for the new use and its connect...

Page 61: ...y national laws and the necessity to ensure driving safety and proper vehicle function This includes the need to verify due to the GVW increase the adequacy of the FUP Front Underrun Protection and RUP Rear Underrun Protection type to the new situation and their possible replacement see chapter 2 20 Page 58 and 2 25 Page 61 Any application diagrams sent to IVECO Technical Application to be examine...

Page 62: ... a rear or central third axle the following changes are mandatory use of suitable brake cylinders on the axle for the parking brake adjustment of the brake system It is necessary that of the two ABS solenoid valves on the axle one handles the right wheels of the engine axle and of the added axle and the other one the left wheels a rear The installation of an axle behind the engine axle generally r...

Page 63: ...authorisation from IVECO upon presentation of the supplementary system diagram Suspension The construction quality of all the components must be ensured axle suspension brake assemblies systems etc in order to guar antee the driving safety and the correct functioning of the vehicle Particular attention must be paid to the realization of the suspension given its importance in the vehicle s road han...

Page 64: ...arly when there is a superstructure with high centre of gravity Similar stability measures should be adopted for mixed suspensions on added rear axles Attachments to the chassis The connections for the added axle to the chassis must be able to react directly on all the longitudinal and transversal forces without transmitting them to the engine axle In the points of application of forces spring sup...

Page 65: ...ist implementation depends on issuance by IVECO of the relative permit on which the maximum permissible load on the over loaded axle is indicated the use is limited to short sections of the route and the speed limit set in the specific authorisation Some national laws allow the use of the lifting device even in normal driving conditions as long as the max approved load set for the engine axle and ...

Page 66: ...does this relieve the Outfitter of any work related liabilities Lengths allowed 1 The maximum work lengths that can be produced both for the middle and sliding sections LG or LZ see Figure 2 20 can be determined in relation to the external diameter of the existing vehicle pipe and the maximum running rpm see for mula and Table 2 12 If the shaft length calculated in this fashion is insufficient for...

Page 67: ...ansfer box ratio 0 95 for EuroCargo 4x4 and equal to 1 if missing or for shafts upstream of the transfer box Table 2 12 Engine speed rpm at maximum output power and gear ratio Engine Power HP nMAX rpm Gearbox iG 4 cylinders F4AFE411A 160 2500 5S 42 0 77 6S700 0 79 6AS700 0 79 F4AFE411B 190 2500 6S700 0 79 6AS700 0 79 S1000 0 71 S2500 0 74 F4AFE411C 210 2500 5S 42 0 77 6S800 0 78 6AS800 0 78 9S 75 ...

Page 68: ... from flange to flange must be at least 800 mm for sliding shafts and 700 mm for intermediate shafts Table 2 13 Maximum possible lengths Dimensions of the hook outer diameter x thickness mm Maximum propeller shaft speed rpm 2500 2700 2900 3300 3800 Maximum possible lengths LG to LZ mm 2030 90 x 3 2060 1960 1900 1760 1635 2035 100 x 3 2170 2100 2000 1850 1710 2040 120 x 3 2420 2350 2220 2070 1850 2...

Page 69: ...xle reaction bars The inclination of the rear axle casing must be no more than 5 5 from the horizontal plane When in vehicle loading conditions the flange of the rear axle is lower than that of the gearbox housing flange it is necessary to make the inclination of the rear axle housing and the intermediate shaft greater than that of the engine gearbox axle Vice versa when in vehicle loading conditi...

Page 70: ...e using support plates at least 5 mm thick see Figure 2 23 connected to crossbars with characteristics similar to those specified by IVECO In modifying the wheelbase it is best to plan for disassembly of intermediate shafts when shaft length is less than approximately 800 mm 91453 Figure 23 1 Intermediate shaft 2 Support plate 3 Rest plate 4 Intermediate shaft bearing The considerations made up to...

Page 71: ...4 3 F4AFE411C C 15 4 3 TECTOR 6 CYLINDERS F4AFE611A C 26 5 F4AFE611E C 26 5 F4AFE611C C 26 5 F4AFE611D C 26 5 Intake The air intake must be mounted as to avoid intake of hot air from the engine compartment or dust and water The intake compartment must be sealed airtight and fitted with rubber gaskets that prevent hot air recirculation The gaskets must be of high quality as to support a steady temp...

Page 72: ... from the engine compartment must be guaranteed making sure that there are no hot air pockets of recirculation by adopting guards or deflectors fan performance must not be modified any modifications of the water piping must not compromise complete filling of the circuit done with a steady flow and without any backflow from the intake until the circuit is filled and regular water flow in addition t...

Page 73: ...ine fuel Direct connection to the vehicle tank is allowed under the condition that it occurs independently from the engine fuel supply and the new circuit must be perfectly airtight route piping and wiring layout and installation of brackets and flexible fittings in relation to the spaces available and the influ ence of heat on the chassis parts Avoid any exposed parts that may be dangerous and ad...

Page 74: ...of the evaporator unit and of the bellow inside the cab in cases where not provided directly from IVECO must be planned as not to negatively impact control functions and access to equipment b cab roof installed systems it is necessary to verify that the mass of the equipment does not exceed the weight allowed by the cab in addition the Body builder must define the structural reinforcements to appl...

Page 75: ...lly crafted fixing points on the cab roof sides and using support devices of appropriate sizes If the national standards require it these installations must be controlled by relevant authorities Realization of sleeper cabs The transformation of the standard cab to a special cab or sleeper cab special vehicles public use fire brigade etc can be author ised by IVECO after the evaluation of the suita...

Page 76: ...presented to the competent Body that will inspect the new tyres and the vehicle documents Mounting larger tyres always requires a size check in relation to mechanical components wheel arches etc in the various dynamic steering and vehicle shaking conditions may entail rim replacement with the consequential need to verify the spare tyre holder modification may affect distance from ground of the rea...

Page 77: ...brake cylinders valves etc since they are safety components Any changes to the braking system modification of pipes installation of additional operating cylinders etc requires the authorisation of IVECO Note For new units it is advisable to prefer the same brands as those fitted to the original vehicle If the national standards provide it the vehicle must be presented to the competent authority fo...

Page 78: ...rring to the centre line of the pipe Φ 6 to 35 mm Φ 8 to 55 mm Φ 12 to 85 mm Φ 16 to 85 mm Preparation and assembly IVECO STD 17 2403 Cut the pipe at right angles 15 maximum error using a special tool in order to avoid imperfections that affect the sealing Permanently mark the section of pipe dimension L in Figure 2 24 to be inserted into the coupling to ensure secure sealing Mark the pipe to avoi...

Page 79: ...elop the pipe completely and which may be metal with rubber plastic protection or be made of plastic material Provide appropriate distances between one fastening element and the other generally max 500 mm for plastic pipes and max 600 mm for metal pipes can be considered In order to avoid deformations and tensions at the time of closure of the couplings for the plastic pipes it is necessary to tak...

Page 80: ... modulators must be maintained relative to the axis rear wheels The wiring between the sensors on the rear axle and the control unit as well as between the control unit and the modulators must be adjusted using new cables or extension cables with appropriate connectors The brake piping upstream of the modulators must also be adequate Withdrawing air from the cooling system In vehicles with a pneum...

Page 81: ... the air suspension connection 25 Air Drying Unit the APU regeneration volume must be checked 2 16 ELECTRICAL SYSTEM CURRENT INTERVENTIONS AND DRAWS Note For information on work on the electrical system refer to what is described in Section 5 Chapter 5 7 Page 36 2 17 PART RELOCATION AND ANCHORAGE OF ADDITIONAL UNITS AND EQUIPMENT The movement of units various components fuel and urea tanks batteri...

Page 82: ...t see Chapter 1 15 Page 11 Depending on the use of the vehicle applications should always provide a suffi cient margin in their height from the ground The holes to be drilled for the new arrangements should be made on the rib of the side member according to the regulations given in Chapter 2 2 Page 7 and taking care to use the existing holes as much as possible When filling the fuel tank is hinder...

Page 83: ...e of the chassis the minimum space that can not be used by fitting elements is equal to 915 or 1320 mm measured from the centre line of the front axle according to the original placement of the urea tank see Figure 2 29 196786 Figure 29 2 18 TRANSPORT OF HAZARDOUS MATERIALS ADR Depending on the specific ECE TRANS WP 15 213 document and its national implementations dangerous goods are classified un...

Page 84: ... from overvoltage with appropriate connections for use in hazardous environments with fuses or automatic circuit breakers Main power switch excluding the tachograph powered directly from the battery with suitable safety devices placed near the batteries with direct or remote control in the cab and outside Braking Compliance with specific EC Directives Obligation of the anti lock system ABS and a d...

Page 85: ... of the work Please note that any unauthorised work on the original retarder will invalidate the vehicle warranty For the cooling of hydraulic retarders the connection with the corresponding engine circuit is allowed given that this does not result in any case in exceeding the maximum allowed temperature of the fluid in the original system otherwise there must be a separate cooling circuit In case...

Page 86: ... test certificates Note On vehicles with a GVW higher than 14 tons it is necessary to use a rear under run protection similar to the one of vehicles with GVW 18 tons or choose for the opt 4667 provided for vehicles which use a 3rd axis 2 21 REAR MUD GUARDS AND WHEEL ARCHES On cab version vehicles without rear fenders the Bodybuilder must implement solutions equal to those provided by IVECO For the...

Page 87: ...erchangeable equipment hook lifts the connection can be made by means of suitable supports on the counter chassis or directly on the chassis In the latter case use the existing holes on the vertical rib of the side member as much as possible in compliance with Chapter 2 2 Page 7 In implementing the outer protection as required by the regulations e g EC Directive it is permitted to use either a sin...

Page 88: ...h the lower part of the superstructure over 1300 mm from the ground or with the width of the superstructure below the external tyre dimension B Permissible sag under the test load 30 mm on the rear part last 250 mm of the device 150 mm on the remaining parts C Support for fixing the combined lateral protection and the mudguard for the rear wheels ...

Page 89: ...step in the cab is fixed to the FUP the change of its position leads to the replacement of the fixing bracket of the step in order to keep its position unchanged with respect to the cab 2 25 REAR VIEW MIRRORS The table shows the main dimensions of the arms of the approved rear view mirrors according to the maximum width of the com plete vehicle and the position of the driver Table 2 16 Arms for ap...

Page 90: ...62 EUROCARGO Euro 6 CHASSIS INTERVENTIONS CHASSIS INTERVENTIONS 2 25 REAR VIEW MIRRORS Printed 603 95 747 1st Ed Base 12 2013 131013 Figure 33 ...

Page 91: ... Printed 603 95 747 Base 12 2013 SECTION 3 APPLICATIONS OF SUPERSTRUCTURES ...

Page 92: ... Printed 603 95 747 Base 12 2013 ...

Page 93: ...plates rigid junction 16 Mixed connection 17 3 4 CONTAINER APPLICATION 18 Fixed bodies 18 Tipper bodies 20 Heavy duty services 21 Light duty services 22 Roll off containers 23 3 5 TRACTOR FOR SEMI TRAILER 24 3 6 TRANSPORT OF INSEPARABLE MATERIALS TRAILER TRUCKS 24 3 7 INSTALLATION OF TANKS AND LOOSE MATERIAL CONTAINERS 24 3 8 INSTALLING A CRANE 26 Crane behind cab 27 Crane at rear overhang 31 Remo...

Page 94: ...4 EUROCARGO Euro 6 APPLICATIONS OF SUPERSTRUCTURES APPLICATIONS OF SUPERSTRUCTURES Printed 603 95 747 1st Ed Base 12 2013 ...

Page 95: ... reduction of the time of inertia of the reinforcing section involves bending and higher stresses on the main chassis Following are the characteristics of certain materials which were taken into account in some of the applications stated below Table 3 1 Material to be used for the construction of superstructures Std IVECO 15 2110 and 15 2812 Name of steel Breaking strength N mm2 Yield stress N mm2...

Page 96: ...presents a decisive value for the stress of the material the moment of inertia is important mainly for the flexural hardness and for the quota of the bending moment to be taken depending on the connection used Aluminium counter chassis When using materials with different characteristics from those of steel e g aluminium the size and structure of the counter chassis must be appropriately adjusted 1...

Page 97: ... short large and not very convenient dimensions 3 2 ELEMENTS MAKING UP THE COUNTER CHASSIS Longitudinal profiles The side members of the added structure must be continuous extended as much as possible toward the front of the vehicle and towards the rear area of the front spring support in addition they must rest on the chassis and not on the brackets In order to achieve a gradual reduction of the ...

Page 98: ...tical rib of the chassis This can be achieved by inserting an intermediate profile suitably adapted to the side member or by applying an adequately stiffened connecting bracket The shape of the profile section is defined taking into account the function of the counter chassis and the type of overlying struc ture Open C profiles are advisable when the counter chassis needs to adapt elastically to t...

Page 99: ...at are not lower These values can be obtained from the technical documentation of the profile manufacturers Cross members A sufficient number of crossbars possibly to be placed in correspondence with the fastening clamps to the chassis must brace the two sections of the counter chassis The crossbars may be open section e g C or closed section where you would want to impart greater stiffness In the...

Page 100: ...Euro 6 APPLICATIONS OF SUPERSTRUCTURES APPLICATIONS OF SUPERSTRUCTURES 3 2 ELEMENTS MAKING UP THE COUNTER CHASSIS Printed 603 95 747 1st Ed Base 12 2013 166684 Figure 5 193869 Figure 6 1 Counter chassis 2 Diagonals ...

Page 101: ...hat the added equipment transmits to the chassis both in static and dynamic conditions Number size and construction of the anchors reasonably allocated in the length of the counter chassis must be such as to ensure a good connection between the chassis and the counter chassis The screws and the clamps must have material strength class of not less than 8 8 and the nuts must be fitted with systems t...

Page 102: ...gure 3 12 a single resistant section can be considered for the two profiles on the condition that the number and distribution of the connections are such as to withstand the consequent cutting forces The possibility of establishing a single resistant section between the chassis and the counter chassis allows you to achieve greater resistant capacity compared to the connections with brackets or cla...

Page 103: ...ion in case of elastic connection with the chassis We consider two C sections with the following dimensions chassis 250 x 70 x 5 mm counter chassis 140 x 70 x 7 mm and stressed in a section given by the maximum bending moment M f equal to 15 000 Nm perpendicular applied to the plane con taining the rib of the side member From the calculation are obtained the following values chassis It 1 545 cm4 W...

Page 104: ...er to better contain the loads in the transverse direction the brackets are normally applied so that there is a slight protrusion perpendicular to the upper edge of the chassis If instead the brackets must be applied exactly to the wire the side guide for the superstructure must be assured with other devices e g using guide plates connected only to the counter chassis or only to the vehicle chassi...

Page 105: ...on of the torque If necessary the total capacity of the connection can be restored by installing cut resistant hardware in the rear suspension area In versions where the vehicle is lifted by hydraulic stabilisers e g cranes aerial work platforms limit the collapse of the elastic ele ment 30 40 mm to ensure sufficient cooperation of the counter chassis and avoid excessive bending moments on the ori...

Page 106: ...3 Figure 11 1 Chassis 2 Counter chassis 3 Clevis fasteners 4 Closure with anti unscrewing system 5 Spacers 6 Guide plates if necessary Connection with longitudinal and transverse sealing plates rigid junction The type of mounting shown in Figure 3 12 made with plates that are welded or bolted to the counter chassis and fixed with nails or screws to the vehicle chassis ensures a good capacity for r...

Page 107: ...crews 2 min 3 screws per plate 1 0 500 8 M14 1 The increase in the number of screws for each plate makes it possible to proportionally increase the distance between the plates a double number of screws may allow a greater distance between the plates In high stress areas e g the rear spring supports the tandem axle springs and the air springs it is necessary to provide a distance between the plates...

Page 108: ...m reinforcement section 60E 65E 75E 80EL up to 3690 21 60E 65E 75E 80EL and 3690 26 80E 90E 100E up to 3690 26 80E 90E 100E and 3690 36 110EL 1 120EL 1 120E 140E 150E 160E up to 3690 40 110EL 1 120EL 1 120E 140E 150E 160E and 3690 46 180E 190EL all 57 Note For the dimensions of the profiles see Table 3 2 Fastening is achieved through specially crafted brackets along the vertical rib of the side me...

Page 109: ...nt elements For special equipment where a reinforcing section of moderate height is needed the structure of the counter chassis can be integ rated by brackets for the anchorage of the bodywork so as to affect the height across the section of the reinforcing longitudinal profile see Figure 3 15 In these cases the rear wheel arches can be inserted into the equipment crankcase 200445 Figure 15 In the...

Page 110: ...y be permitted provided a higher strength counter chassis is used in order to increase the rigidity of the rear end Where long bodies are needed to transport large volumes it is advisable to lengthen the wheelbase of the vehicle 4 Great care must be given to the positioning of the lifting device both in terms of providing support of adequate strength and in order to correctly position the mounting...

Page 111: ...between the front engine axle suspension support and the rear chassis end or apply addi tional plates Special attention must be paid to ensure adequate stability to the vehicle during the rear tipping of the body For vehicles that are transformed even through two rear axes is prescribed that the box section for the longitudinal reinforcement section see Figure 3 3 involves the segment between the ...

Page 112: ...dard tipper wheelbase in addition to the superstructure specially stiffened rear tipping support anchoring should be used so as to contain sag and ensure good stability during operation the rear tipping angle should be between 35 and 45 and the user should be informed that tipping should be done on as flat a surface as possible use the most rigid rear suspension and rear stabiliser bar available w...

Page 113: ...or at least be in contact with an extens ive area of the suspension attachment areas The lifting devices on board crane system must be fixed to the counter chassis as indicated in Chapter 3 8 Page 26 Vehicle stability must be guaranteed in compliance with standard DIN 30722 during loading and unloading operations The use of stabilizers is recommended at the rear end to be used particularly with ro...

Page 114: ...e counter chassis are shown in Table 3 7 Table 3 7 Installation of tanks Model Section modulus Wx cm3 of the minimum section bar of the counter chassis Yield point of the material used 360 N mm2 60E 65E 75E 80EL 46 80E 90E 100E 110EL 120EL 57 120E 140E 150E 160E 89 180E 190E 99 Note For the dimensions of the profiles see Table 3 2 The assembly of tanks or stiff torsional structures in general must...

Page 115: ... the rests must be made to uniformly distribute the load on a suitably wide surface and with bracing to contain longitudinal and transverse forces anchoring must be sufficiently extended in width approximately 600 mm and arranged near suspension mounts maximum distance 400 mm Specifically the front anchoring flexibility must be suited to contain the necessary torsional movements of the chassis oth...

Page 116: ...compliance with statutory requirements national standards e g CUNA DIN and international standards e g ISO CEN and verifying those required for the vehicle While the crane is operating the stabilisers hydraulic if possible must be used and be in contact with the ground Note To ensure stability on vehicles with air suspension it is required to deflate the air bellows completely As a general rule th...

Page 117: ...sis see Figure 3 21 integrating where necessary other elastic fasteners shelves or flanges to maintain the bending and torsional characteristics of the chassis as much as possible The dimensions of the reinforcement sections to be used for this type of connection are shown in Table 3 8 On vehicles for road use only shear resistant connections see Figure 3 23 may be used for fastening the counter c...

Page 118: ...0 260 260 280 280 300 Minimum value of the section modulus of the counter chassis section Wx cm3 60E 65E 75E 80EL 172 5x65x4 A A 31 57 89 105 E 60E 65E 75E 80EL 172 5x65x5 A A 19 46 57 89 E 80E 90E 100E 195 5x65x4 A A 19 46 89 89 119 E 80E 90E 100E 110EL 1 120EL 1 195 5x65x5 A A A 26 46 89 89 119 E 110EL 1 120EL 1 195 5x65x6 A A A A 19 46 89 89 119 150 E 120E 140E 150E 110EW 240x70x5 A A A A A 36 ...

Page 119: ...ng cab version use a section with modulus of resistance Wx not less than 57 cm3 Note For the dimensions of the profiles see Table 3 2 193899 Figure 22 Elastic connections between chassis and counter chassis see Figure 3 10 may be needed to avoid excessive constraint on the chassis torsional movement for application of crane on off road vehicles on the front and middle parts In these cases the cran...

Page 120: ...he crane assembly area In the crane area brace the reinforcement profile sections which have a thickness of less than 5 mm E To be checked case by case Send IVECO technical documentation with verification of stress and stability 1 In the long cab version use a section with modulus of resistance Wx not less than 57 cm3 Note For the dimensions of the profiles see Table 3 2 Should it be necessary to ...

Page 121: ... 11 Considering the particular distribution of weights on the vehicle load concentrated on overhang and to ensure the necessary torsional rigidity for good performance on the road and during the working phase of the crane the counter chassis must be suitably stiffened in relation to the crane capacity Box sections and cross bracings must be used see Chapter 3 2 Page 7 at the rear suspension and fo...

Page 122: ... tested with the rear axle raised in coun tries where travelling with the vehicle in this condition is allowed see Chapter 1 15 Page 11 The axle must be lowered while travelling if the minimum required value is not obtained 200450 Figure 24 1 Counter chassis on the entire body length 2 Plates 3 Brackets 4 Crane connections 5 Stabilisers 6 Connecting corner Table 3 11 Cranes on rear overhang counte...

Page 123: ...ee Table 3 2 Should it be necessary to reduce the height of the counter chassis box section using shear resistant connections between the chassis and counter chassis combined sections may be used instead of the channel section as indicated in Table 3 12 provided that the width of the wing and thickness are not less than those of the section recommended by IVECO Table 3 11 The possibility of using ...

Page 124: ... specific outfits with no adequate counter chassis e g box truck bodies pick up bodies with cross members The dimensions of the sections to be used for the installation of tail lifts are defined as follows using Table 3 13 in the case of standard rear overhangs and with mean bending moments induced by tail lifts as a function of their capacity The table also indicates the capacity values above whi...

Page 125: ... lift is in operation the bodybuilder may use reinforcement struc tures with larger dimensions than those indicated in Table 3 13 Tail lifts must be installed ensuring that the maximum permissible loads on the rear axle or axles of the vehicle are not exceeded and that the minimum load established for the front axle is maintained see Chapter 1 15 Page 11 If this is not possible the rear overhang w...

Page 126: ...16 21 31 4815 2505 16 21 31 75E 80EL 3105 1313 A A A 3330 1830 A A 16 3690 1830 A A 16 4185 2145 A 16 16 4455 2280 A 16 21 4815 2505 A 16 21 75E P 80EL P 3690 1830 16 16 21 4185 2145 16 21 31 4455 2280 16 21 31 4815 2505 16 21 31 80E 3105 1313 A A A A 3330 1830 A A 16 16 3690 1830 A A 16 16 4185 2145 A A 16 16 4455 2280 A 16 16 21 4815 2505 A A 16 21 80E P FP 3690 1830 A 16 16 21 4185 2145 16 16 2...

Page 127: ... A A A A A A 3690 1740 A A A A A A 4185 2055 A A A A A A 4455 2190 A A A A A 16 4815 2460 A A A A 16 21 5175 2685 A A A A 16 21 5670 3000 A A A A 16 21 6570 2735 A A A 21 31 31 120E P FP 4185 2055 A A A A 16 16 4455 2190 A A A A 16 21 4815 2460 A A A 16 16 21 5175 2685 A A 16 16 21 31 5670 3000 A A 16 16 21 31 6570 2735 A 16 21 31 31 46 140E 3105 1313 A A A A A A 3690 1740 A A A A A A 4185 2055 A ...

Page 128: ...A A 4185 1313 A A A A A A A 4590 1650 A A A A A A A 4815 1853 A A A A A A A 5175 2123 A A A A A A A 5870 2235 A A A A A A 21 57 6210 2235 A A A A A A 21 57 6570 2775 A A A A A A 21 57 A The reinforcement section specified for the relevant superstructure is sufficient e g Table 3 4 for normal containers Note For the dimensions of the profiles see Table 3 2 Should it be necessary to reduce the heigh...

Page 129: ...fted is only permitted using stabilisers The Bodybuilder will be responsible for any modification to the under run protection cross member or for installing a different type see Chapter 2 20 Page 58 for preserving visibility of the rear lights for the overhang angles and for the positioning of the tow hook as provided by the respective national requirements Base configuration for tail lifts A base...

Page 130: ... run bar 2 7 pin DIN 72585 connector 3 10 INTERCHANGEABLE OUTFITS The interchangeable outfits can be separated from the vehicle and positioned on four supports while awaiting subsequent handling As a rule the realization envisages the implementation of a counter chassis with longitudinal sections of dimensions based on Table 3 4 Alternatively there are structures that already include the connectio...

Page 131: ... Figures 3 5 and 3 6 Connections to the chassis must be elastic brackets or supports at the front end and stiff at the rear end cleat plates see Figure 3 12 to allow the additional structure to contribute more effectively towards the rigidity of the assembly The rear tilt pivot must be installed on the counter chassis and must be situated longitudinally as close as possible to the rear sus pension...

Page 132: ...ECO Observance of the required load must be documented and guaranteed by the company that carries out the installation 3 15 APPLICATION OF A WINCH The application of a winch on the vehicle can be carried out at the following points on the front part of the chassis frontal on the chassis of the vehicle behind the cab between the side members of the vehicle in a central or lateral position on the re...

Page 133: ...e added structure e g box sections or sections with upper wing turned outwards see Figure 3 28 Table 3 15 Minimum dimensions of the counter chassis profile Models Approximate capacity of the drum m3 Section modulus Wx cm3 of the minimum reinforcement section with a yield point of the material used 360 N mm2 140EK 150E 160EK 3 3 5 83 180K 4 5 92 Note For the dimensions of the profiles see Table 3 2...

Page 134: ... itself Note To guarantee vehicle stability particularly when cornering and on terrain with a transverse incline the surging of the mass inside the drum during mixing drum operation and the consequent transverse displacement of its centre of gravity must be taken into account The additional motor for the mixing drum control requires a suitable suspension system Specific solutions concerning power ...

Page 135: ... Printed 603 95 747 Base 12 2013 SECTION 4 POWER TAKE OFFS ...

Page 136: ... Printed 603 95 747 Base 12 2013 ...

Page 137: ...AGEMENT 11 General information 12 Definitions 13 PTO mode 0 driving mode 13 PTO modes 1 2 3 configurable 14 4 7 STANDARD CONFIGURATIONS 18 Conditions for activating deactivating PTO 19 No PTO installed or PTO predisposition 19 PTO Multipower 19 PTO manual gearbox with electric engagement 20 PTO 1 2 Allison gearbox 20 PTO Transfer box 21 Intermediate engine speed regulator 21 Allison gearbox 22 Usa...

Page 138: ...4 EUROCARGO Euro 6 POWER TAKE OFFS POWER TAKE OFFS Printed 603 95 747 1st Ed Base 12 2013 ...

Page 139: ...he power take off n Engine revolutions per minute i Transmission ratio PT output rpm engine rpm Type of use The maximum torque take off values indicated are with reference to continuous usage up to 60 seconds Torque take off values exceeding the maximum values indicated for occasional limited usage less than 30 s must be approved on a case by case basis in relation to the type of application In th...

Page 140: ...being driven When it is necessary to obtain a different transmission line with spatial inclinations according to angle φ as shown in Figure 4 2 it is important to remember that the kinetic forces of the assembly can only be ensured if the intermediate section has forks offset by the same angle φ and if equal conditions are respected between the angles at the extremities Χ1 and Χ2 For transmissions...

Page 141: ... installation of a PTO post vehicle production requires the reprogramming of gearbox electronic control unit and the Expan sion Module EM as well as interventions on the wiring system Therefore before proceeding please carefully read Chapter 4 6 PTO Management Page 11 Re programming of the electronic control units must be carried out in accordance with the instructions in the IVECO technical manua...

Page 142: ...itional masses must be verified with regard to the inertial effects in order to avoid the induction of resonance conditions in the engine unit within the field of operational engine Observe values in Table 4 1 for torque take offs 4 3 POWER TAKE OFF FROM TRANSFER BOX On vehicles with all wheel drive 4x4 PTOs may be installed on the transfer box The required take off speed may be selected by engagi...

Page 143: ...tion on the transmission must only be carried out by specialist companies approved by the manufac turer Note Any intervention on the propeller shaft without prior authorisation from IVECO will immediately invalidate the warranty Note The power take offs on the line of the universal joint cannot be used in conjunction with EuroTronic transmissions 4 5 POWER TAKE OFF FROM ENGINE In general the use o...

Page 144: ... to 190EL with power outputs from 280 to 320 HP and 4x4 may be equipped with the optional IVECO Multipower PTO which is capable of handling higher torques than other PTO types This unit is fitted on the rear part of the engine and takes drive from the flywheel and is independent of the vehicle clutch drive it is suitable for use with the vehicle running and or at a standstill e g municipal applica...

Page 145: ...that depending on the gearing ratio of the PTO itself see Table 4 4 the pumps of connected accessories may reach high rotational speeds e g an engine speed of 1800 rpm corresponds to a pump speed of 2400 rpm 4 6 PTO MANAGEMENT Interventions that are carried out which do not comply with the following indications may cause serious damage to the on board systems not covered by the contractual warrant...

Page 146: ...e to drive up to three physical PTOs and controls their activation and the deactivation individually The PTO management functionality significantly simplifies conversion as it includes a number of safety and check functions The following two conditions must be met to permit activation of a PTO 1 PTO is mechanically engaged 2 a PTO mode associated with the PTO must be recalled See later for the def...

Page 147: ...a set of para meters to ensure correct PTO operation The PTO Mode offers the possibility of requesting physical activation of the PTO Possible selections Yes No described below It is possible to activate up to three PTO modes simultaneously Physical PTO Activation The physical PTO activation is an integral part of a PTO Mode This includes a set of parameters for mechanical engagement of a PTO Vari...

Page 148: ... 2 medium priority PTO mode 1 low priority PTO mode 0 driving mode Note The Bodybuilder must observe this order of priority when managing the outfitting and interface outfitting This is so as to avoid additional costs for subsequent modifications to the wiring or reprogramming The following table shows the parameters making up a PTO mode These parameters may only be programmed by IVECO Service usi...

Page 149: ...d the engine speed will be limited to Nmax 3 See following paragraph 4 The TIP function pressing momentary action button briefly lets the driver adjust the intermediate engine speed regulator or speed con trol setting in gradual steps by pressing the SET SET buttons briefly 1 sec Pressing at speeds 25 Km h activates the intermediate engine speed regulator while pressing at speeds 25 Km h activates...

Page 150: ...s possible to limit 1 engine torque delivery as a protection against overload 2 engine rpm as a protection against over speed The diagram in Figure 4 8 shows this qualitatively by means of a toque engine rpm curve defined by 16 points a horizontal section representing torque limitation and a sloping section representing over rev adjustment 193880 Figure 5 1 Engine curve 2 Maximum torque straight l...

Page 151: ...ccording to the intended use of the PTO the speed referred to is that of the crankshaft and not that of the PTO for which the rpm must be calculated taking into ac count the reduction ratio see Table 4 3 the limitations torque intersection point and curve gradient may be selected independently of one another It is however advisable to set a combination these parameters may only be activated by IVE...

Page 152: ...tandard factory configurations Table 4 7 PTO Mode Mode 0 Mode 1 Mode 2 Mode 3 Activation from 21 pin connector 61071 No activation necessary Pins 18 and 17 connected Pins 19 and 17 connected Pins 20 and 17 connected Max torque Max engine torque Max engine torque Max engine torque Max engine torque Maximum rpm value settable with SET button NSET_max Maximum speed in relation to maximum engine rpm M...

Page 153: ...brake state Engaged not engaged Clutch pedal state pressed not pressed Pressure switch state open closed Driving state neutral not in neutral reverse Permitted gear set Permitted engine speed Permitted vehicle speed Maximum coolant temperature Maximum clutch slippage percentage Note These conditions may be modified through the IVECO Service Network No PTO installed or PTO predisposition Only the e...

Page 154: ...120 C Deactivation conditions Engine status OFF Vehicle status not stationary PTO3 Vehicle speed 25 Km h PTO1 PTO2 Coolant temperature 120 C Note These conditions may be modified through the IVECO Service Network PTO 1 2 Allison gearbox Default configuration Note These conditions may be modified in Customer Service Table 4 17 Activation conditions Engine status ON 500 rpm 900 Gearbox status neutra...

Page 155: ...d holding the SET and SET buttons 1 sec adjusts the intermediate engine speed setting or the requested speed control setting continuously The effective rpm value or speed value at the time the SET or SET button is released is stored as the new setting The TIP function for the SET and SET buttons may be disabled This configuration is applicable to all PTO modes simultaneously PTO driving mode 0 and...

Page 156: ... met the Allison transmission control unit automatically engages the PTO Any limitations applicable for the active PTO mode final speed maximum torque etc are also valid during the entire engagement process Certain parameters may be modified by the Allison Customer Service to meet the requisites of the bodybuilder Usage of PTO with vehicle in motion If no limitations are required e g torque limiti...

Page 157: ...lue The procedure for setting the idle speed consists of three steps and may only be performed with a warm engine 1 Enabling idle speed adjustment With the engine running at idle speed press the service brake and hold until the adjustment procedure is complete press and hold the RES button for more then 3 sec then release the idle speed immediately adjusts to the minimum value 2 Adjusting idle spe...

Page 158: ...XPANSION MODULE Printed 603 95 747 1st Ed Base 12 2013 204641 Figure 7 1 PTO switch 2 EM control unit 3 Instrument panel 4 PTO solenoid valve control 5 PTO Pressure switch resp Bodybuilder PTO engagement consent 6 PTO return signal 7 Total rear PTO 8 Lateral PTO ...

Page 159: ...ions can be configured The connections on ST91 ST92 and ST93 must be used as described to ensure PTO activation and visualization on the display of the instrument panel The predefined conditions set for the EUROCARGO Euro 6 are described in Chapter 4 7 Page 18 Connections Table 4 13 PTO mode request 61071 PTO 1 Pin 18 PTO 2 Pin 19 PTO 3 Pin 20 To carry out request close the pins on ground of pin 1...

Page 160: ...26 EUROCARGO Euro 6 POWER TAKE OFFS POWER TAKE OFFS Printed 603 95 747 1st Ed Base 12 2013 ...

Page 161: ... Printed 603 95 747 Base 12 2013 SECTION 5 ELECTRONIC SUB SYSTEMS ...

Page 162: ... Printed 603 95 747 Base 12 2013 ...

Page 163: ...ntrol opt 4115 31 VEHH configuration opt 75182 32 5 5 OPERATOR S FOOTBOARD 34 5 6 ELECTRICAL CIRCUIT MODIFICATIONS 35 General information 35 Wiring harness length 35 Disconnecting electronic control units 35 Repositioning electronic control units 36 5 7 ELECTRICAL SYSTEM CURRENT INTERVENTIONS AND DRAWS 36 General information 36 Precautions for work on the system 36 Precautions for work on the chas...

Page 164: ...4 EUROCARGO Euro 6 ELECTRONIC SUB SYSTEMS ELECTRONIC SUB SYSTEMS Printed 603 95 747 1st Ed Base 12 2013 ...

Page 165: ...rmitted to connect devices or electrical circuits directly to the control units Only the connectors or special interfaces listed in Chapter 5 2 may be used Position of electronic control units 196795 Figure 1 1 IBC3 IVECO Body Controller 2 EM Expansion Module 3 ECAS Electronic Control Air Suspension 4 Central locking 5 VCM Vehicle Control Module 6 EBS Electronic Brake System 7 EDC Engine Diesel Co...

Page 166: ... through the CAN line to process the signals input and output crucial for the interaction between the vehicle s individual systems The Body Controller is located in the cab below the dashboard in front of the passenger seat The fuses and relays and also housed here 197232 Figure 2 Bulkhead coupling passage of electrical wiring The subsystems fitted on the chassis are connected to the control units...

Page 167: ...tronic Chassis Module MET transmits and receives information to and from all the components and sensors located on the chassis e g lighting devices brake system sensors differential lock sensors etc Information is transmitted via the Body Controller to the respective recipient vehicle systems The MET is situated inside the left hand chassis side member in the battery housing area ...

Page 168: ...trols the power take offs and makes it possible to carry out complex applications such as control of the transmission gearbox from external sources TC1 message control of the engine from external sources such as engine speed requests and limits vehicle speed limit start up and engine stop safety rules for waste collection applications optimisation of the brake system for waste collection applicati...

Page 169: ...ST92 ST93 Each of these connectors is described as follows in relation to their respective location see Paragraphs Connectors in cab Page 10 or Connectors on chassis Page 24 To interface with the equipment installed the Bodybuilder must have the corresponding opposite male or female connector and use contacts made with reference to the following diagrams Connectors 61071 72071 72074 72072A 72072C ...

Page 170: ...5 mm2 0 5 mm2 1656 7444 EZ Connector ST40B Cable section Contact code 0 35 mm2 0 5 mm2 1657 6444 EZ 0 75 mm2 1 5 mm2 1657 6544 EZ Connectors in cab The following connectors are located inside the cab 61071 standard connector for bodybuilder 72071 standard connector for bodybuilder 72074 Automatic Transmission 72070 FMS 72072A EM 72072B EM 72072C EM ST40 EM ST40B EM Location of connectors inside ca...

Page 171: ...und start engine signal must be permanently active till engine starter runs Open wire no action 2 Engine stop 0151 10 mA VCM X3 26 Ground stop engine short activation sufficient to stop engine Open wire no action 3 Service brake 1165 200 mA VCM X1 13 0 V service brake not pressed 24 V service brake pressed 4 Vehicle standstill 5515 200 mA IBC3 E 15 0 V vehicle standstill 24 V vehicle moving 5 Park...

Page 172: ...Ground RES activated 16 CC Driver BB 0152 10 mA VCM X3 49 CC activation by Driver or Bodybuilder BB Open wire CC controlled by driver Connected to ground CC controlled by Bodybuilder BB 17 Ground 0000 10 A Wiring Ground 18 PTO 1 sw 0131 10 mA VCM X3 47 EM X3 5 Input signal 3 Open wire PTO mode 1 not activated Ground PTO mode 1 activated Input driven by EM when installed Else input driven by VCM 19...

Page 173: ...1 2 3 On contemporaneous activations of PTO 1 2 3 inputs the VCM intermediate Speed Control Mode is assigned by means of prioritization PTO_3 highest priority PTO_2 medium priority PTO_1 lowest priority CAUTION The Deactivation of a physical PTO is only allowed in load free conditions Therefore the deactivation of a physical station ary non stationary PTO device during driving operation and or wit...

Page 174: ...signal 2 Connected to ground on Open circuit off 6 Reserved 7 Reserved 8 Engine speed signal 5587 10 mA ECM 1 34 Pulse signal 9 External lights 3333 5 A IBC3 E 24 0 V lights off 24 V lights on parking low and high beam 1 VCM default vehicle speed is 6 Km h The value cannot be modified in Customer Service with EASY in the presence of the following options OPT 06821 EN1501 Certain Refurbishing Near ...

Page 175: ...ift se lector the transmission will shift to Neutral If the function is enabled in a forward drive range higher than the maximum specified gear range the TCM will invoke preselect downshifts until the specified gear range is attained The function is disabled when the enabling switch is released 3 142 ALL 42 4 PTO active 143 15 mA ALL 43 For special applications Input from PTO switch Open wire inac...

Page 176: ...wo separate input signals When properly integrated into the vehicle system the enabled function automatically commands the transmission to Neutral when a supplementary vehicle brake is engaged 10 Digital ground 103 ALL 3 It must be used as return for closed on digital ground inputs Do not connect to the battery negative or to other grounds 11 Range indicator 113 500 mA ALL 13 Gearbox ground for ne...

Page 177: ... K15 8879 7 5 A 70605 6 Protected by fuse 7 5 A 12 K30 7772 5 A 70604 3 Protected by fuse 5 A 1 Fleet Management System FMS CAN line is enabled with option 14569 For further information please see Chapter 5 3 Page 28 Optional connector 72072A 6 pin yellow A B 190414 Figure 12 A 41118323 Counterpart to be coupled female B 41118304 Existing part on vehicle male Only available with OPT 4572 EM light ...

Page 178: ...ion Vehicle Control module Brake system ECAS when installed Body Controller System Tachograph Detailed information for each system is available via CANopen see EMCY 0x1014 object Requirements for Functional Safety When Bodybuilder application is interfacing the vehicle for Safety related functions then IVECO supports the Bodybuilder application with a Vehicle CAN fully operational output For Safet...

Page 179: ...e code Max Load Connected to Remarks 1 Request gearbox in neutral signal 0992 10 mA 1 EM X3 18 Only supported with OPT 6821 and AutoGbx Only if Bodybuilder Enable is also active 72072A 3 Signal change needed earliest 1 second after K15 ON Ground active low side switch 2 Bodybuilder Emergency Signal 0993 10 mA 1 EM X3 19 Input to activate the Vehicle StoppedState values only with Body builder Enabl...

Page 180: ...EN1501 for adjustment contact IVECO CS organisation 0 V Off Frame not ready 24 V On Frame ready 14 Low accelerator pedal idle switch 6993 1 A EM X4 31 Indicate that Accelerator pedal idle switch 0 V OFF low idle switch not active 24 V ON low idle switch active 15 At least one PTO is engaged 6994 1 A EM X4 32 Indicates at least one PTO is engaged Signal based on PTO feedback signal s 0 V OFF no PTO...

Page 181: ...art all Nodes command is received Rem During this StoppedState phase the affected CANopen signals received on BB CAN are ignored 3 The stopping brake can only be activated with vehicle speed less than 2 km h On EBS vehicles a new Stopping Brake request is serviced only when engine is running When Stopping brake being active the engine could be stopped and Stopping brake remains engaged The Stoppin...

Page 182: ... functions of 72072C Pin Description Wire code Max Load Connected to Remarks 1 K30 7796 10 A 1 K30 Protected by fuse 10 A 2 Ground 0000 Ground 3 CO CANopen operational 0975 0 5 A EM X4 28 LSO Low Side Output activated in the case of CO initiated typically 3 seconds after K15 ON for adjustment contact IVECO CS Open circuit CANopen not operational 0 V CANopen operational 4 Bodybuilder CAN CAN H EM X...

Page 183: ...ule request 0131 VCM X3 47 2 PTO Expansion Module request 0132 VCM X3 46 3 PTO Expansion Module request 0123 VCM X3 45 4 K line for Expansion Module diagnostics 2996 72069 11 Connector ST40B PTO cab harness cable EM cab cable cut out 4 pin 197422 Figure 17 Connector ST40B basic functions Pin Description Wire code Max Load Connected to Remarks 1 PTO Expansion Module request 0131 EM X3 05 2 PTO Expa...

Page 184: ...Figure 19 A 504111928 Counterpart to be coupled female B 41118387 Existing part on vehicle male Only available with OPT 0384 EM full installed Basic functions of connector 72072D Pin Description Wire code Max Load Connected to Remarks 1 K30 7795 10 A K30 Protected by fuse 10A 1 2 Ground 0000 Ground 3 CO enable CANopen 0975 0 5 A EM X4 28 LSO Low Side Output activated in the case of CO initiated ty...

Page 185: ... Pin Description Wire code Max Load Connected to Remarks 1 PTO feedback signal 6131 10 mA 1 EM X3 08 Connect to ground to read PTO feedback signal 2 PTO activation via electromagnetic valve 9131 1 5 A EM X1 01 OFF 0V valve not activated ON 24V valve activated Max load in Lite 2 0 A 3 PTO Press Switch 0391 10 mA 1 EM X3 11 4 Ground 0000 Ground 1 During the K15 OFF phase the input will not be activa...

Page 186: ...the sleep current Trailer connectors If an adjustment of the tow vehicle with continuous braking is necessary use two 7 pin connectors 72000 and 72001 or alternat ively a single 15 pin connector ISO 72010 on the last crossbeam of the chassis If the trailer is designed for a 12 Volt supply an optional connector with 13 pins 72016 must be used Trailer connector 7 pin 113252 Figure 21 Basic functions...

Page 187: ...ght 2283 6 A MET B1 Trailer connector 15 pin 113251 Figure 22 Basic functions of the 15 pin connector 72010 for trailers Pin Description Wire code Max Load Connected to Remarks 1 Left trailer indicator 1180 6 A MET C04 2 Right trailer indicator 1185 6 A MET B03 3 Trailer rear fog light 2283 6 A MET B01 4 Ground 0000 11 A Ground 5 Daylight running lights left trailer clearance light 3332 6 A MET A0...

Page 188: ...on its operation the movements made and the driving style of the driver In the case of Trakker Euro 6 the main information can be displayed directly on the radio screen if this is the type designed for such purpose If the vehicle does not have such a solution detailed information about rpm engine torque water and oil temperature mileage type of route and driving times consumption speed and braking...

Page 189: ...if you have installed an interface that does not support this standard The telematic devices connected to the FMS connector wanting to use the Remote Tachograph Download Data functionality must be set to use the source address F0 if you do not operate in this way on the message error 13 relative to problems on the CAN network could appear on the tachograph 5 4 CONFIGURATIONS FOR TAIL LIFTS Base co...

Page 190: ...or preventing start up with tail lift engaged 25551 Relay for tail lift indicator lamp inserted 50003 Electronic instrument panel for instrument and warn ing lights display 52219 Switch for activating tail lift 52502 Key controlled switch for services with start up 70000 Fuse holder 6 86116 Body Computer multiplex control unit 86132 VCM Vehicle Control Module control unit ...

Page 191: ...described previously consists of specific wiring and a supplementary remote control unit which may be connected in the vicinity of the tail lift When the switch to activate the rear lift is pressed the standard remote control unit is disabled and the supplementary unit only is enabled The original state is restored when the switch is pressed again 200438 Figure 24 25546 ECAS control switch from bo...

Page 192: ...ation for tail lifts Page 40 Refer to the following diagrams for the VEHH configuration without and with ECAS VEHH tail lift without ECAS 200439 Figure 25 25550 Contactor for preventing start up with tail lift engaged 25571 Contactor for VEHH tail lift control 50003 Electronic instrument panel for instrument and warn ing lights display 52219 Switch for activating tail lift 52502 Key controlled swi...

Page 193: ...l lift engaged 25551 Relay for tail lift indicator lamp 25571 Contactor for VEHH tail lift control 25573 ECAS control switch with VEHH tail lift engaged 50003 Electronic instrument panel for instrument and warn ing lights display 52219 Switch for activating tail lift 52502 Key controlled switch for services with start up 70000 Fuse holder 6 86116 Body Computer multiplex control unit 86132 VCM Vehi...

Page 194: ...t an operator at the outside so as the operation can only be activated in its presence it is necessary to prepare the electrical system according to the diagram of Figure 5 27 200441 Figure 27 22050 Bell EN1501 in operation 25139 Maintenance control switch EN1501 53620 Switch parking brake engaged 58740 Parking brake engaged signal warning light 61011 Container for a 3 A diode 70000 Fuse holder 6 ...

Page 195: ...positioning Multiplex system electronic control units 1 If the length is excessive fold the wires without forming rings as this could cause undesired electromagnetic effects The wiring which is very stiff and for this reason it must be replaced with shorter wiring when it cannot be folded 2 If the wiring length is not sufficient it must be replaced Only use genuine IVECO spare parts contact the IV...

Page 196: ...he use of cables and connections with colours codes identical to those used on the original vehicle makes installation correct and facilitates any repair work Note For more detailed information regarding the electrical system of the vehicle refer to the specific Repair Manuals printed 603 95 624 EUROCARGO 6 10 t Euro 6 printed 603 95 633 EUROCARGO 12 18 t Euro 6 and printed 603 95 708 EUROCARGO 4x...

Page 197: ...wired exclusively on the specific receiver additional ground connections may distort the output signal from this sensor The cable bundles for low signal intensity electronic components must be arranged parallel to the metal plane of reference that is adherent to the chassis cab structure in order to minimise parasitic capacities space the path of the cable bundle added to the existing one as much ...

Page 198: ...t be connected to the system ground when equipped with metal housings the negative cables of the electronic control units are to be connected to a system ground point connected to the negative terminal of the battery the analogue grounds sensors while not being connected to the system ground negative terminal of the battery are to have good conductivity Consequently particular care should be given...

Page 199: ...ol for frequencies vary ing from 20 MHz to 2 GHz 100 V m immunity for devices primary secondary functions not impacting on direct vehicle control for frequencies varying from 20 MHz to 2 GHz The maximum excursion allowed for transition voltage with equipment powered by 24 V is 80 V measured on the terminals of the artificial network L I S N if tested on the bench Alternatively if tested on the veh...

Page 200: ... μH 0 11 μF Broad band almost peak 80 66 52 52 36 36 Not ap plicable dBμV conduit Broad band peak 93 79 65 65 49 49 conduit Narrow band peak 70 50 45 40 30 36 Use electrical electronic equipment in compliance with the UNECE directive on electromagnetic compatibility Only components with certified approval and with mark e are allowed the CE marking is not sufficient By way of example the mark presc...

Page 201: ...nd protection 3 The coaxial antenna cable must be positioned taking care to use a low loss top quality product with the same impedance as the transmitter and the antenna see Figure 5 29 in order to avoid interference and malfunctioning create a path the shortest possible which maintains a suitable dis tance min 50 mm from pre existing cabling or from other cables radio amplifiers and other electro...

Page 202: ...ea from the vehicle s electrical components if the transmission is impulsive it must be at a distance of least 1 meter away from other devices The ROS value Stationary Wave Ratio must be as close as possible to the unit the recommended value is 1 5 while the maximum acceptable value must never be greater than 2 The ANTENNA GAIN values must be as high as possible and guarantee a sufficient level of...

Page 203: ... 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 and never underneath any metal which makes up part of the cab structure Moreover the ROS value Stationary Wave Ratio must be as close as possible to the unit the recommended value is 1 5 while the maximum must never b...

Page 204: ...additional batteries it is possible to use 1 recombination batteries AGM or gel 2 traditional batteries In both cases it is necessary to adequately separate the batteries from the environment of the vehicle occupants by means of an appropriate container that ensures sealing in case of emission of vapours for example in the event of a fault in the alternator voltage regulator explosion of the batte...

Page 205: ...trument panel All the lines downstream of all batteries are to be adequately protected under any fault condi tion Failure to ensure adequate protection may pose a fire hazard and a danger to persons Additional alternators The installation of additional batteries involves the verification of the ability of the alternator to charge If the results of this verific ation are negative an alternator with...

Page 206: ...e adding batteries in parallel it is neces sary to share the operation with IVECO Additional electrical units Particular attention must be paid when installing cooling units that use a second alternator mounted on the engine additional gen erator as a power source These generators provide depending on the number of turns a voltage of the order of 270 540 V which goes through the wir ing to the coo...

Page 207: ... 0 2 0 1 0 143 12 9 6 4 2 6 1 3 170 15 3 7 7 3 1 1 5 Battery level status It is approximately derivable by the following table where there is a direct link open circuit voltage of the battery level battery voltage V charge level 12 2 50 12 3 50 12 4 65 12 5 75 12 6 90 Note To check the level it is necessary to accurately measure the voltage with the battery terminals disconnected and possibly at l...

Page 208: ...d at maximum current available to the relative rotating speeds that is the sum of the max currents on the mission in an hour Potential for recharge and optional is the available potential from which was removed the actual vehicular consumption Available potential at idle mode is the maximum available current at idle speed Example 1 Vehicle with 143 Ah battery and 70 A alternator Door To Door missi...

Page 209: ...aw current from the pass wall from the lateral lights systems and from the additional fuse box points A A highlighted in figure 5 36 Note The fuse holder placed on the side of the battery casing must not be changed or moved The current drawing is possible from 1 cable box 2 connector 61071 3 main current switch 4 main power contactor if installed 1 2 3 4 5 204639 Figure 36 1 Cable box 2 Additional...

Page 210: ...wo pole switch that disconnects the battery from the chassis allowing the operation of the tachograph body computer cooling unit bed module and instrument panel For special modifications e g transport of fuel transport of dangerous substances it may be necessary to use a safety switch that isolates the batteries and the alternator from the rest of the system Specific solutions must be authorised b...

Page 211: ...be always performed as close as possible to the draw terminal on the batteries 191313 Figure 38 A Maxifuse B Battery case C Megafuse Maxifuse Capacity Reference number of IVECO electrical kit accessories Fusebox body design number Cable cross section KIT 40 A 4104 0110 KZ 500317518 10 mm KIT 60 A 4104 0111 KZ 500317518 10 mm Megafuse Capacity Reference number of IVECO electrical kit accessories Fu...

Page 212: ...n joints equivalent to the original ones protected with sheaths not PVC or intubated in polyamide conduits of type 6 installed protections from shock heat rubbing with other components in particular with the sharp edges of the bodywork secured separately with insulated cable clamps e g made of nylon and at adequate intervals approx 200 mm The passage through crossbars and or sections must provide ...

Page 213: ...ic battery charging to maintain efficiency Plug and terminal connections must be protected resistant to weathering and executed using components of the same type as those utilised originally on the vehicle In the event that a component has to be installed just next to the route of a cable belonging to the original system make sure that its remains integral and avoid any cuts Any damage caused by f...

Page 214: ... Wire code Max Load Connected to Remarks 1 Ground 0000 10 A Ground 2 Side lights left sides 3332 5 A MET P A07 24V Daylight running lights on signal when K15 OFF and parking lights on K15 ON and parking high beam low beam lights on 3 Side lights right sides 3331 5 A MET P A08 24V Daylight running lights on signal when K15 OFF and parking lights on K15 ON and parking high beam low beam lights on 4 ...

Page 215: ... Printed 603 95 747 Base 12 2013 SECTION 6 SPECIAL INSTRUCTIONS FOR SCR EXHAUST SYSTEM ...

Page 216: ... Printed 603 95 747 Base 12 2013 ...

Page 217: ... SYSTEM Contents 3 Printed 603 95 747 1st Ed Base 12 2013 Contents 6 1 GENERAL INFORMATION 5 6 2 THE NITROGEN OXIDE CATALYTIC REDUCTION PRINCIPLE 5 6 3 INSTRUCTIONS 6 Interventions on AdBlue tank 6 Moving AdBlue system components 8 Operations on pipes for AdBlue and heating water 10 ...

Page 218: ...4 EUROCARGO Euro 6 SPECIAL INSTRUCTIONS FOR SCR SPECIAL INSTRUCTIONS FOR SCR EXHAUST SYSTEM Printed 603 95 747 1st Ed Base 12 2013 ...

Page 219: ...SM Supply Module to a DM Dosing Module which injects AdBlue into the exhaust pipe The mixture of exhaust gas and additive is then fed to the catalytic converter and chemically trans forms NOx into nitrogen and water harmless to the environment In order to comply with Euro VI new assemblies DOC passive DPF CUC and sensors are used which act as parameter control functions Main components of SCRT sys...

Page 220: ...AdBlue fittings water fittings electrical connectors assembly electrical connectors water fittings AdBlue fittings the seal of the DM flange on the ATS side must be replaced each time the DM is disassembled the seal may only be used once the after run phase must not be interrupted using the battery manual switch or the ADR switch the AdBlue pipes must always be emptied to prevent any crystallizati...

Page 221: ...tank 2 Heating coil 3 AdBlue temperature sensor 4 Float At the end of any operations which involve the AdBlue tank make sure that the tank ventilation pipe is not closed the tank contains at least 5 litres of AdBlue to ensure the dosing module is cooled the tank does not contain more than 85 of AdBlue corresponding to the maximum reading of the level sensor with re spect to the tank total volume s...

Page 222: ...ting C AdBlue delivery union D AdBlue return union E Electrical connector Moving AdBlue system components In order to comply with Euro VI requirements the positioning of the main components of the AdBlue system has been optimised In particular the SM and the DM have been inserted into the AdBlue tank and silencer respectively see figure below giving bene fits in terms of space and reduced length o...

Page 223: ... to move the AdBlue tank it must be made sure that the installation heights of SM module of the pip ing keep on complying with the conditions shown in figure 5 except that the position of the DM module should never be changed see chapter 2 9 Paragraph Engine exhaust In the diagram it can be seen that the pipes provide an adequate siphoning system in order to prevent any damage occurring fol lowing...

Page 224: ...e NOx sensor cable Operations on pipes for AdBlue and heating water No folding of the pipes is allowed only operations to lengthen and shorten the pipes are allowed Note In order to limit the loss of load only one lengthened stretch is allowed per pipe The maximum permitted length for the pipes between the pumping module and the dosing module is 3 metres The pipes may be modified using specific eq...

Page 225: ...re an accurate cutting area insert the fittings into the cut parts of the pipe making use of specific tools pliers drift spindle to enlarge the pipe and collar See following Figure It is compulsory to work in a completely dust free environment to prevent dust from reaching the injectors and subsequently clogging them Pipe assembly tools 189108 Figure 7 1 Plastic pipe mounting pliers Part 99387101 ...

Page 226: ... Printed 603 95 747 Base 12 2013 ...

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