Iveco NEW DAILY, Instructions Manual

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10
NEW DAILY
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CHASSIS INTERVENTIONS
CHASSIS INTERVENTIONS
2.2
DRILLS ON THE CHASSIS
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Printed 603.95.789
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1 Ed. - Base 02/2014
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if an electric circuit breaker (main switch) is present, wait for it to complete the cycle;
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disconnect the negative pole from the battery;
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disconnect the positive pole of the battery without connecting it to earth; do NOT short-circuit the negative pole;
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disconnect all ECU connectors, proceed with caution and do not touch the ECU connector pins;
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disconnect the ECU from the vehicle for welds close to the ECU;
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connect the welder earth directly to the weld piece;
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protect the plastic pipes from heat and disconnect them if necessary;
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protect the surfaces of the leaf and air springs against any weld splashes when welds are performed nearby;
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avoid touching the spring leafs with the electrodes or pliers.
Weld operations
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Thoroughly remove paint and rust from the chassis where welds will be made, as well as all parts that will be covered by rein-
forcements.
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Cut the side members with a skewed or vertical cut. The side members must not be cut at the points where the chassis con-
tour and width changes or where stress is greater (e.g. spring mounts). The cutting line must not go through the holes on the
side member (see Figure 4).
91446
Figure 4
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Make a 60 degree bevel cut on the internal part of the side member of the parts to be joined, along the entire length of the
weld area (see Figure 5).
91447
Figure 5
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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.
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Start from the opposite end and weld as in the previous item.
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Let the side members cool slowly and in a uniform fashion. No cooling with air jets, water or other means is allowed.