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NEW DAILY

–

CHASSIS INTERVENTIONS

CHASSIS INTERVENTIONS

2.13

WORK ON SHEET METAL

–

Printed 603.95.789

–

1 Ed. - Base 02/2014

Work on bodywork (vans)
Fitting baggage racks

The installation must be carried out using the fixing devices specifically envisaged on the roof (low roof and medium roof versions),

bearing in mind the following indications:

●

the fixing element must include the baggage rack anchoring device and ensure the necessary resistance to longitudinal and

crossways forces. 3+3 fixing elements are envisaged for all pitches;

●

to avoid altering the vehicle's cornering stability, the load must not exceed a total of 200 kg;

●

the mass allowed on each fixing element must not exceed 25 kg.

204648

Figure 23

Table 2.15

Dimensions [mm]

Van wheelbase 3000 low roof - short overhang

1760

754

932

1548

Van wheelbase 3520 SL medium roof (H2)

2549

1082

935

1229

Van wheelbase 4100 SC medium roof (H2)

3713

1082

935

1229

Summary of Contents for NEW DAILY

Page 1: ...NEW DAILY BODYBUILDERS INSTRUCTIONS L I G H T R A N G E ISSUE 2014...

Page 2: ...IVECO S p A Technical Application Homologation Strada delle Cascinette 424 34 10156 Torino TO Italy www iveco com Printed 603 95 789 1st ed 02 2014 Images and text IVECO S p A 2014 All rights reserved...

Page 3: ...INES FOR TRANSFORMATION AND GUIDELINES FOR TRANSFORMATION AND VERSIONS UPDATE DATA 5 Printed 603 95 789 1 Ed Base 02 2014 GUIDELINES FOR TRANSFORMATION AND VERSIONS UPDATE DATA Section Description Pag...

Page 4: ...Printed 603 95 789 Base 02 2014...

Page 5: ...ration 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 equipm...

Page 6: ...Printed 603 95 789 Base 02 2014...

Page 7: ...95 789 Base 02 2014 GENERAL INFORMATION 1 CHASSIS INTERVENTIONS 2 APPLICATIONS OF SUPERSTRUCTURES 3 POWER TAKE OFFS 4 ELECTRONIC SUB SYSTEMS 5 ADBLUE AND SCRT SYSTEM 6 DAILY PEOPLE CARRIER A DAILY CNG...

Page 8: ...Printed 603 95 789 Base 02 2014...

Page 9: ...Printed 603 95 789 Base 02 2014 SECTION 1 GENERAL INFORMATION...

Page 10: ...Printed 603 95 789 Base 02 2014...

Page 11: ...ENT 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...

Page 12: ...4 NEW DAILY GENERAL INFORMATION GENERAL INFORMATION Printed 603 95 789 1 Ed Base 02 2014...

Page 13: ...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 ELECTR...

Page 14: ...onents 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 autonomo...

Page 15: ...al 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 B...

Page 16: ...cal 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 p...

Page 17: ...uch 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...

Page 18: ...wheels S Single rear wheels C Twin rear wheels 15 Engine power no x 10 power in HP H Engine type 2 3 F1A Engine combined with engine power code 15 N Natural Power Engine Bi Fuel combined with engine p...

Page 19: ...he 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...

Page 20: ...sidered that this is evenly distributed except in cases in which the shape of the load surface leads to a different load distribution For equipment the centre of gravity is obvious considered for its...

Page 21: ...standards in particular Directives ECE 13 on longitudinal stability and ECE 111 on lateral stability while driving The following cases should be distinguished 1 fixed loads 2 mobile loads 3 loads tha...

Page 22: ...hrust de termined in the case of cross wind must be evaluated very carefully Even with the low centre of gravity a vehicle fitting that has a high surface area may not provide sufficient lateral stabi...

Page 23: ...imits for use and reinforcements to be made to parts of the vehicle These exceptions if they exceed the limits of the law must be authorised by the Administrative Authority In the authorisation reques...

Page 24: ...y builder must position and fasten them in an accessible and secure way in compliance to any national regulations 1 17 GENERAL REGULATION FOR THE PREVENTION OF FIRE RISK Particular attention must be p...

Page 25: ...Printed 603 95 789 Base 02 2014 SECTION 2 CHASSIS INTERVENTIONS...

Page 26: ...Printed 603 95 789 Base 02 2014...

Page 27: ...allation 21 Types of hook 23 Drawbar couplings for centre axle trailers 23 Rear crossbar in lowered position 25 2 7 ASSEMBLING AN ADDITIONAL AXLE 26 2 8 GEARBOX MODIFICATION 26 Lengths allowed 27 Posi...

Page 28: ...NTIONS CHASSIS INTERVENTIONS Contents Printed 603 95 789 1 Ed Base 02 2014 2 19 INSTALLING A RETARDER 59 2 20 REAR UNDER RUN PROTECTION RUP 60 2 21 REAR MUD GUARDS AND WHEEL ARCHES 60 2 22 RAIN FLAP 6...

Page 29: ...s 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 ar...

Page 30: ...onductivity paint 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 standardis...

Page 31: ...3 94 x 56 x 3 3520 840 3520 long overhang 1240 4100 1825 35C lightened camper 3750 1655 144 x 56 x 3 94 x 56 x 3 4100 1825 35C 50C truck 3000 1 1240 174 x 70 x 4 114 x 70 x 4 3450 1355 3750 1655 4100...

Page 32: ...er flaps with exception to what is indic ated in Chapter 3 3 Paragraph Choosing the type of connection When new holes must be made for specific applications installation of shelves corner shelves etc...

Page 33: ...Geomet or zinc coating Geomet treated screws are discouraged when using them in welding opera tions Use flange headed screws and nuts if there is sufficient space Use nuts with an anti unscrewing syst...

Page 34: ...g leafs with the electrodes or pliers Weld operations 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 Cut the si...

Page 35: ...is must be painted in compliance with IVECO Standard 18 1600 Colour IC444 RAL 7021 70 80 gloss Original vehicle parts The following tables show respectively the classes of coating and protection requi...

Page 36: ...ainting See Table III yes 1 Coupling with other materials must not cause the battery effect 2 Coatings free from chromium salts 3 Coatings free of hexavalent chromium Table 2 6 Painted parts IVECO Sta...

Page 37: ...the part to treat Specific phosphates must be used for zinc coated or aluminium sheets Added or modified parts All vehicle parts body chassis equipment etc that are add ons or subjected to modificatio...

Page 38: ...painting is required after wheels are removed it is necessary to Protect the wheel rim mounting surfaces on the hubs and the contact areas of the locking lugs wheel studs ensure adequate protection of...

Page 39: ...he transformation 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 i...

Page 40: ...on supports mark the reference points with a slight punch mark on the top flaps on both side members after having verified that the con junction line is at a perfect right angle with the longitudinal...

Page 41: ...than those or the original wheelbase frame assuming an evenly distributed load and considering the frame as a beam positioned in place of the suspension supports When an elongation is performed starti...

Page 42: ...distribution must ensure that the profile provides the expected reinforcement resistance We recommend creating a cut resistant joint in the area of the rear overhang and for about half of the wheelba...

Page 43: ...0 mm If it is necessary to move the rear crossbar fixed using screws it is necessary to maintain the same type of union as in the series number of screws dimensions strength class If a drawbar shall b...

Page 44: ...o greater than 300 350 mm is shown in Figures 8 and 9 In this case the corner reinforcements which also serve as junction between cross member and frame must have the same width and thickness of the o...

Page 45: ...version chassis cross member electrical coupling union tow coupling chronotachograph etc However bear in mind that fitting the chronotachograph when necessary in relation to current legislation must b...

Page 46: ...es 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...

Page 47: ...requires the use of suitable towing hooks The values of the towed weights and vertical loads allowed are listed on the technical documents of the drawbar coupling manufac turer and on the part manufac...

Page 48: ...centre axle trailers We shall consider a DAILY 65C15 vehicle with maximum weight of 6250 kg that must tow a centre axle trailer of 3500 with S 250 kg length of load bed 5 m and theoretical drawbar le...

Page 49: ...ely Connection of the drawbar in its new position must be performed in the same way and using screws of the same type diameter and resistance class in relation to the original connection Anti unscrewi...

Page 50: ...ure and installation 2 7 ASSEMBLING AN ADDITIONAL AXLE The installation of extra axles on the vehicle is not envisaged 2 8 GEARBOX MODIFICATION Gearbox adjustment following wheelbase modification must...

Page 51: ...igure 16 LG Length of intermediate sections LZ Length of sliding sections LT Total length For sliding shafts the length LG must be evaluated between the universal joint centres and with the sliding st...

Page 52: ...ve axles If using a pipe with a greater diameter than the original thickness should in theory be reduced until reaching the same torsional capacity nevertheless the dimensions of the fork male end nee...

Page 53: ...zontal The intermediate shaft and the axle casing axle must be aligned Angle may vary by a maximum of 1 compared to the engine clutch gearbox axis and this may be achieved by inserting a wedge between...

Page 54: ...Rest plate 4 Intermediate shaft bearing The considerations made up to this point are valid for vehicles with separate gearboxes Furthermore the wheelbase on these vehicles may not be reduced beyond t...

Page 55: ...anical suspension by adding air operated bellows of appropriate dimensions The maximum inflation pressures envisaged by the manufacturer must be strictly observed in order to avoid excessive vehicle s...

Page 56: ...1E C 43 1 9 17 VGT F1CFL411F C 43 1 9 14G WG F1CFA401A A F1CFA401A B 27 P 2 Intake The air intake must be mounted as to avoid intake of hot air from the engine compartment or dust and water The intake...

Page 57: ...a steady flow and without any backflow from the intake until the circuit is filled and regular water flow in addition these modifications must not alter maximum water stabilisation temperature even i...

Page 58: ...pendently 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 availab...

Page 59: ...CONDITIONING PLANT 35 Printed 603 95 789 1 Ed Base 02 2014 204649 Figure 21 1 Main heater 2 Optional supplementary heater 3 Solenoid valve 4 Additional heater installed by body builder A Solenoid valv...

Page 60: ...visaged by IVECO installation 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...

Page 61: ...stance and maintain cab functionality and protections intact In any applications or units or equipment on the roof e g conditioning plant spoilers make sure that the mass of the equipment does not exc...

Page 62: ...NTIONS 2 13 WORK ON SHEET METAL Printed 603 95 789 1 Ed Base 02 2014 204647 Figure 22 1 Roof panel 2 Cutting limit area 3 Side finishing of roof 4 Door support ring 5 Internal rear cross member 6 Rear...

Page 63: ...e baggage rack anchoring device and ensure the necessary resistance to longitudinal and crossways forces 3 3 fixing elements are envisaged for all pitches to avoid altering the vehicle s cornering sta...

Page 64: ...gure 24 shows an installation example 208216 Figure 24 1 Cutting area 2 Anchorage profile 3 Sealant c Modifying the height of the roof Three roof versions are available in production having respective...

Page 65: ...d expedients indicated below Cut the sheet metal taking care to maintain a profile with a minimum width of 15 mm for fixed window with gasket seal 20 25 mm for a bonded window Create an internal suppo...

Page 66: ...Installing inside shelves must be carried out with great care to ensure suitable stiffness and self support The lower support must involve the floor support structure cross members and longitudinal pr...

Page 67: ...e suspension and the possibility that snow chains may also be present In this regard Figure 27 highlights the cases that may arise and the related maximum possible lowering measurements 173263 Figure...

Page 68: ...o the original parts of the cab and relative suspension ensure the normal oscillations along the vertical longitudinal and transverse plane To help maintain the integrity of the cab it is recommended...

Page 69: ...and related wiring harness installation of components near the dashboard aperture modifications to the steering column replacements or installations of seats a different H point compared to the origin...

Page 70: ...puter speedometer tachograph and speed limiter must be subject to recalibra tion at an authorised IVECO workshop Tyres of different size and type of structure cannot be mounted on the same axle The ty...

Page 71: ...systems Any modification of the braking system MUST be authorised by IVECO If the national standards provide it the vehicle must be presented to the competent authority for inspection Brake pipes It...

Page 72: ...ine exhaust system between the chassis and moving parts where special flexible pipes hoses should be used Operations must provide materials and dimensions Standards DIN 73378 and 74324 Maximum operati...

Page 73: ...screwing Vehicle pipe installation Before use the new pipes must be thoroughly cleaned inside for example by blowing air with a compressor The pipes must be fixed to the frame with elements which enve...

Page 74: ...system switches off and you must wait for the preset time before resuming the operation When replacing the modulator supplied by IVECO Parts already filled with brake fluid in every part it is enough...

Page 75: ...ply to hole 9 the specific adjustment load for each model and each spring after having loaded the drive axle to the refer ence value see Table 2 19 Table 2 19 Models Rear leaf spring Type Load on leve...

Page 76: ...is an electronic function that contributed to the active safety of the vehicle and inasmuch is compulsory under European Regu lations This function ensures control of crossways dynamics and stability...

Page 77: ...ollowing parameters are important vehicle configuration van truck camper wheelbase P T T type of suspension type of gearbox transmission wheel circumference retarder if equipped Every variation of one...

Page 78: ...pecial cases is tins compatible with the presence of the ESP system In the event of compatibility system management software must be reprogrammed in all other cases Derating is compulsory except as in...

Page 79: ...2 19 Page 59 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 4 2 17 PART RELOCATION AND...

Page 80: ...s units Similarly it must act for the installation of tanks compressors etc the distribution of weight must also be taken into account for their placement see Chapter 1 15 Page 11 In all these applica...

Page 81: ...for the specific tank the use of different tanks requires resetting indications for consumption remaining autonomy etc 2 18 TRANSPORT OF HAZARDOUS MATERIALS ADR Depending on the specific ECE TRANS WP...

Page 82: ...ed in ducts protected from shock stones heat etc Circuits protected from overvoltage with appropriate connections for use in hazardous environments with fuses or automatic circuit breakers Main power...

Page 83: ...ction must be performed based on the following formula 204640 Figure 37 ip rear axle ratio Cf Maximum braking torque Nm R radius under load of the used tyre m GVW Gross Vehicle Weight kg Example of ca...

Page 84: ...th standards in force must be demonstrated to the competent authorities by appropriate documentation or test certificates 2 21 REAR MUD GUARDS AND WHEEL ARCHES On cab version vehicles without rear fen...

Page 85: ...etting In permanently applied superstructures e g fixed bodies vans side protection can be applied on the basis of their structure e g frame of the floor beams while for mobile superstructures e g tip...

Page 86: ...62 NEW DAILY CHASSIS INTERVENTIONS CHASSIS INTERVENTIONS Printed 603 95 789 1 Ed Base 02 2014...

Page 87: ...Printed 603 95 789 Base 02 2014 SECTION 3 APPLICATIONS OF SUPERSTRUCTURES...

Page 88: ...Printed 603 95 789 Base 02 2014...

Page 89: ...sealing plates rigid junction 15 Mixed connection 16 3 4 CONTAINER APPLICATION 16 Fixed bodies 16 Tipper bodies 18 3 5 TRACTOR FOR SEMI TRAILER 20 Fifth wheel supporting structure 20 Fifth wheel 21 B...

Page 90: ...4 NEW DAILY APPLICATIONS OF SUPERSTRUCTURES APPLICATIONS OF SUPERSTRUCTURES Printed 603 95 789 1 Ed Base 02 2014...

Page 91: ...ction 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...

Page 92: ...X 7 123 W 126 220 X 60 X 7 127 W 141 220 X 60 X 8 142 W 160 200 X 80 X 8 240 X 60 X 8 161 W 178 220 X 80 X 8 240 X 70 X 8 179 W 201 250 X 80 X 7 260 X 70 X 8 202 W 220 250 X 80 X 8 260 X 80 X 8 221 W...

Page 93: ...ofiles having dimensions similar to those indicated for the steel can be used Typical examples are fixed bodies vans and tanks provided that the supports are continuous and close up or in the immediat...

Page 94: ...adius of 5 mm 91136 Figure 2 In cases in which the components of the cab rear suspension e g deep cabs do not allow the passage of the profile in the entire section this can be realised as in Figure 3...

Page 95: ...there is to be a rubber undercrawl element we recommend characteristics and thicknesses similar to those used for normal production hardness 80 Shore max thickness 3 mm Its use can prevent abrasive ac...

Page 96: ...connection see the following Figure on the left When you want to achieve greater stiffness in the connection it can be carried out according to the following Figure on the right 193868 Figure 5 Stiff...

Page 97: ...en 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 that prevent unscrewing The first ancho...

Page 98: ...height of the counter chassis profile to equal bending moment acting on the section greater bending moment allowed equal to the dimensions of the counter chassis profile further increase in the resis...

Page 99: ...pring Bear closely in mind that the elastic element characteristics should be suited to the stiffness of the superstructure the wheelbase and the type vehicle use irregular road conditions stiffness m...

Page 100: ...between the wings of the two side members and in corres pondence to the clevis fasteners in order to avoid the bending of the wings under the pull of the clevis fasteners In order to drive and better...

Page 101: ...ut resistant connection between the chassis and the counter chassis or if you want to contain the height of the counter chassis as much as possible e g centre axle trailers crane on rear overhang tail...

Page 102: ...ers 4 Hardware for longitudinal and transverse containment 3 4 CONTAINER APPLICATION Dimensions and centres of gravity Check the correct load distribution and in particular respect the indications reg...

Page 103: ...hown in Figure 13 The front wall of the bodywork must have the necessary strength and toughness to support the forces generated by the transpor ted load in the case of sudden and high decelerations 20...

Page 104: ...mented so as to limit the stress transmitted to the vehicle cab For couplings and fitting reinforcements bear in mind that no welding should be performed on the sheet metal of the cab and only mechani...

Page 105: ...localized load 5 In rear tipping it is recommended that a stabiliser is fitted to guide the container particularly when the lifting cylinder is located behind the cab 6 The lifting device hinge must...

Page 106: ...le 3 6 To implement this it should also be noted that the structure must be suitably dimensioned for vertical and horizontal loads which the fifth wheel transfers the material characteristics of the s...

Page 107: ...l stops it is advisable to follow the manufacturer s instructions The fifth wheel must not be modified in any way since it is of particular importance for vehicle safety Brake system The body builder...

Page 108: ...RT OF INSEPARABLE MATERIALS TRAILER TRUCKS Not provided 3 7 INSTALLATION OF TANKS AND LOOSE MATERIAL CONTAINERS a Installation with a counter chassis The installation of tanks and containers is carrie...

Page 109: ...in the area where the connections are to be applied and the type of functions for which the vehicle is intended b Installation without a counter chassis The application of tanks directly on the chassi...

Page 110: ...ion of the crane must be made with due consideration to its characteristics and in relation to the performance of the vehicle The positioning of the crane and of the payload must be done within the lo...

Page 111: ...ensions for all these applications are given in Table 3 9 The implementation of constant diameter sections for the entire length of the vehicle is recommended The section of the crane counter chassis...

Page 112: ...s of the longitud inal sections are shown in Table 3 10 Considering the particular distribution of weights on the vehicle load concentrated on overhang and to ensure the necessary tor sional stiffness...

Page 113: ...r chassis section Wx cm3 1 with yield point of the material equal to 360 N mm2 35C 40C 114x70x4 32 57 71 E 45C 50C 114x70x4 32 57 71 110 E 60C 65C 70C 174x69x5 23 23 32 42 71 E E To be checked case by...

Page 114: ...not possible the rear overhang will have to be reduced The tail lift must be fastened with a structure that ensures appropriate weight distribution especially in the case of specific outfits with no a...

Page 115: ...ior mechanical characteristics requires verification of the total moment of resistance of the chassis plus counter chassis To ensure the necessary strength and rigidity and especially in the case of o...

Page 116: ...r must equip the vehicle appropriately to ensure stability during bed tilting manoeuvres All equipment and structures must comply with any applicable national legislation 3 11 VEHICLES FOR COUNCIL FIR...

Page 117: ...for transmission of the control it is necessary to follow the indications contained in Chapter 4 1 Page 5 and 4 2 Page 7 with worm screw control the dimensioning of the drive parts must take into acco...

Page 118: ...ion of the superstructure avoid abrupt sections changes create a fastening solution such as that in Figure 3 or in cases of high stress that in Figure 24 in which the first fastening of the counter ch...

Page 119: ...ssis flap section detail The flaps must have a minimum thickness of 4 mm and enough length to cover the side members of the chassis in front of the cab block area and behind the first fastening point...

Page 120: ...34 NEW DAILY APPLICATIONS OF SUPERSTRUCTURES APPLICATIONS OF SUPERSTRUCTURES Printed 603 95 789 1 Ed Base 02 2014...

Page 121: ...Printed 603 95 789 Base 02 2014 SECTION 4 POWER TAKE OFFS...

Page 122: ...Printed 603 95 789 Base 02 2014...

Page 123: ...789 1 Ed Base 02 2014 Contents 4 1 GENERAL SPECIFICATIONS 5 4 2 PTO FROM GEARBOX 7 Transmission PTO data 7 Direct application of pumps 8 4 3 POWER TAKE OFF FROM TRANSFER BOX 8 4 4 POWER TAKE OFF FROM...

Page 124: ...4 NEW DAILY POWER TAKE OFFS POWER TAKE OFFS Printed 603 95 789 1 Ed Base 02 2014...

Page 125: ...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 ta...

Page 126: ...es the shaft ends must be at the same angle see Figure 1 and this angle must not exceed 7 solution Z is preferred to solution W due to the lower loads on the bearings of the power take off and the equ...

Page 127: ...ed with the clutch disengaged so as to avoid excessive stress on synchronisers When the PTO is used with the vehicle in motion no gearshift must be carried out 166057 Figure 3 1 Cover for power take o...

Page 128: ...e of the additional 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 Observ...

Page 129: ...the time of publication of these Directives the information in this Chapter may have been subject to changes It is therefore recommended that any possible modifications are verified by consulting www...

Page 130: ...is necessary to verify that the vehicle is equipped with opt Cruise Control The PTO can be installed post sales on vehicles equipped with the relative preparations whether or not there is an Expansio...

Page 131: ...f the vehicle is equipped with the Expansion Module the following is to be ordered from IVECO Parts the PTO installation kit the wiring for the electrical connection of the PTO to the pre installation...

Page 132: ...distinction between PTOs for manual or automatic transmission up to two homogenous PTOs can be installed on the vehicle For instructions on how to insert and remove the PTO refer to the Use and Mainte...

Page 133: ...ote Adjustment of engine speed through Cruise Control Working Engine Speed Demand can only be done between 10 and 20 km h depending on the equipment After turning the selector of Figure 7 in the ON po...

Page 134: ...nted 208928 Figure 8 Multiple State Switch example A 12 pin body builder connector B Responsibility of the body builder 1 Pull up in ECU 2 Pull down only for EDC7CI Table 4 3 Resistance Values Ohm R0...

Page 135: ...When the switch position is changed the number of engine revolutions will move to the programmed speed for each switch position By moving the Cruise Control switch to OFF or by pressing the brake peda...

Page 136: ...16 NEW DAILY POWER TAKE OFFS POWER TAKE OFFS Printed 603 95 789 1 Ed Base 02 2014...

Page 137: ...Printed 603 95 789 Base 02 2014 SECTION 5 ELECTRONIC SUB SYSTEMS...

Page 138: ...Printed 603 95 789 Base 02 2014...

Page 139: ...led 12 Disconnecting electronic control units 13 Repositioning electronic control units 13 5 4 ELECTRICAL SYSTEM CURRENT INTERVENTIONS AND DRAWS 13 Ground points 16 Electromagnetic comparability 21 Re...

Page 140: ...4 NEW DAILY ELECTRONIC SUB SYSTEMS ELECTRONIC SUB SYSTEMS Printed 603 95 789 1 Ed Base 02 2014...

Page 141: ...rs listed in the following paragraphs may be used Location of control units 208934 Figure 1 A Instrument panel B Trailer control unit C Steering wheel column and ignition switch D Body Computer E Oil...

Page 142: ...of a special bridle Note Since it is only possible to detect signals and not power from the connectors each interface between configuration and vehicle must take place by means of diodes and relays 2...

Page 143: ...iode Ground is obtained when the parking brake is activated Ground brake engaged Open circuit brake disengaged 6 Battery positive Output max 20 A Positive protected by fuse on Body Computer F34 7 Exte...

Page 144: ...providing a ground vehicle speed is limited to 30 km h Ground speed limitation active 2 Programmable speed lim iter input Max 10 mA By providing a ground the current speed limitation activ ates deacti...

Page 145: ...ected Specification 1 Vehicle speed signal B7 is a square wave signal with equal frequency of the input signal from the pulse generator and variable duty cycle due to the constant tachometry of the ve...

Page 146: ...terface The calculation of the speed following the reading of the B7 signal involves management of both the frequency and duty cycle of the signal as the frequency depends on the vehicle and the duty...

Page 147: ...e input equal to that represented with a max VCC voltage of 5 V and pull up pull down so as not to lower the VON voltage and raise the response time set by the vehicle interface Specification 3 Cruise...

Page 148: ...lace the battery cables parallel to the vehicle s electric cables Use only fuses with the features prescribed for the specific function NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE PRESCRIBED Repla...

Page 149: ...riginal orientation e g to avoid water ingress electronic control units must not be fitted on the counter chassis the cover must always be refitted avoid subjecting electronic control units to knocks...

Page 150: ...ll the chassis to allow the cables path The corrugated tubing must completely protect the entire cable and be connected with heat shrinking or taping to the rub ber caps on the terminals All the posit...

Page 151: ...e ground with the battery discharged in the event of engine start up on vehicles with manual transmission turn the key to ON and wait until all the lights of the motor on the instrument panel disappea...

Page 152: ...egards the signal related ground connections e g sensors or low absorption devices do not use the standardized points Un der no circumstances use standardized points for engine ground connection and c...

Page 153: ...RRENT INTERVENTIONS AND DRAWS 17 Printed 603 95 789 1 Ed Base 02 2014 208940 Figure 11 m2 Engine compartment ground on left chassis side member 1 Engine earth 2 Battery ground 3 Chassis cable ground 2...

Page 154: ...SUB SYSTEMS 5 4 ELECTRICAL SYSTEM CURRENT INTERVENTIONS AND DRAWS Printed 603 95 789 1 Ed Base 02 2014 208942 Figure 13 m4 Engine compartment ground near front right headlight 208943 Figure 14 m5 Engi...

Page 155: ...nside cab on the central body panel below the tachograph m7 Ground inside cab on the central body panel below the tachograph 208945 Figure 16 m8 Cab interior ground front right section The negative le...

Page 156: ...nected to the system ground negative terminal of the battery are to have good conductivity Consequently particular care should be given to terminal parasitic resistances oxidation scratches etc the me...

Page 157: ...itive spikes of 100 V bursts of 150 V They must operate correctly during the phase when voltage drops to 5 V for 40 ms and to 0 V for 2 ms They must also resist the load dump phenomena up to 40 V The...

Page 158: ...where necessary via a supplementary fuse Any additional power lines must be created respecting the correct sizing of cables and protection 3 The coaxial antenna cable must be positioned taking care t...

Page 159: ...he cable 13 Nut Some specific instructions are given below for each type of equipment Amateur equipment for CB 27 MHz and 2 m band 144 MHz The transmitter part must be installed in a separate area fro...

Page 160: ...els than on the higher ones the antenna should be lengthened 2 if the ROS Stationary Wave Ratio is higher on the higher channels than on the lower ones the antenna should be shortened After having cal...

Page 161: ...steering wheel 2 USB socket For cowl version vehicles the ceiling fixture with microphone is provided in the box of accompanying material If installation in the cab requires it the microphone can be r...

Page 162: ...nted 603 95 789 1 Ed Base 02 2014 208949 Figure 24 1 Driver s side 2 Passenger side 208947 Figure 25 1 Bluetooth microphone Table 5 7 Pin Description Cable 1 Ground White 2 Signal Vcc Shielded The con...

Page 163: ...y 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...

Page 164: ...mum 150 mA 6 Lighting 7 Battery 12V 8 Ground B 1 Right door panel speaker 2 Right door panel speaker 3 Tweeter right column 4 Tweeter right column 5 Tweeter left column 6 Tweeter left column 7 Left do...

Page 165: ...on of additional equipment must include suitable protections and should not overload the vehicle system The connection of the added users to ground must be made with an adequately sectioned cable as s...

Page 166: ...M or gel batteries Ground connection of the additional battery is to be made using a cable of adequate section as short as possible 208936 Figure 27 1 Standard battery 2 Additional batteries 3 Alterna...

Page 167: ...l alternator must be of the traditional type with pin L connected in order to ensure excitation with a current between 150 and 200 mA The diagnostic light is optional but a resistance is still necessa...

Page 168: ...panel 8 Diagnostics Lamp or LED Res current between 150 and 200 mA The installation of additional equipment must include suitable protections and should not overload the vehicle system In cases where...

Page 169: ...ontrol unit in the engine compartment There are two fuses FF and FG installed in CBA2 reserved for the body builders the terminals HI and MI downstream of these fuses are the only two points reserved...

Page 170: ...e 13 Paragraph Precautions for operations on the system And in CBA2 installation it is necessary to avoid removing the fuses from their position put the terminals on the studs and secure them with the...

Page 171: ...sensor F43 20 Windscreen washer F47 25 Driver s side power window F48 25 Passenger s side power window F49 5 Ill Int and CSS Tachograph Telma ECU ECU exp mod Socket to ECU trailer socket 13 poles ECU...

Page 172: ...ys on the engine compartment SCM control unit 208475 Figure 33 Table 5 10 List of fuses on SCM Diesel version Location Amperage A Description F1 40 pneumatic suspensions F2 30 Ignition switch F3 40 Cl...

Page 173: ...ain loads F23 30 Wiping F24 20 Power socket F30 5 Side Marker Lights F81 20 IBS sensor F82 70 Body computer 2nd power supply F83 40 Internal cab fans F84 7 5 Baruffaldi coupling F85 25 Fuel filter hea...

Page 174: ...t T50 Heated windscreen and mirrors T51 Climate control unit compressor T52 Heated rear windows T53 Unit heater T54 TGC T55 TGC T56 TGC T64 Headlight washer T65 Spare Table 5 12 List of fuses on SCM C...

Page 175: ...d seats F61 30 Rear differential lock F62 30 Heated rear windows F63 10 Blow By and climate control unit compressor F64 Spare F65 Spare F66 15 Headlight washer F67 7 5 Trailer socket F68 10 Heated win...

Page 176: ...te control unit compressor T52 Heated rear windows T53 Unit heater T54 TGC T55 TGC T56 TGC T64 Headlight washer T65 Spare Fuses on CBA2 control unit in the engine compartment 209812 Figure 34 Table 5...

Page 177: ...supply CBA2 2 200 Power supply SCM and Body builders 3 500 Starter and Retarder 4 80 Body Computer power supply 5 TGC opt Passage of cables from cab interior to cab exterior In the engine compartment...

Page 178: ...case of external panels use a specific sealant both on the cable and on the panel to prevent water dust and fumes from infiltrat ing Where possible it shall also be provided a different cable path tha...

Page 179: ...t to the route of a cable belonging to the original system make sure that its remains integral and avoid any cuts 209813 Figure 37 Any damage caused by failure to comply with procedure is not covered...

Page 180: ...er configuration rear bridle for trailer socket Installation For proper instillation it is necessary to mount the electronic control unit onto the bracket on the cab version also mount the guard mount...

Page 181: ...railer electronic control unit 4 13 pin trailer socket 5 Tail lights Note The graphic is for illustration purposes only 209815 Figure 40 1 Connector 86046_1 to connect to connector 1 OUT of trailer co...

Page 182: ...he electrical connection of a trailer on the electrical systems introduces a significant increase in the length of the positive and negative wires For practical purposes this means a greater voltage d...

Page 183: ...rubber 3 Table 5 19 Connector ST38 for Side Marker Lamps Pin Cable code Function Cable section mm Max current A 1 0000 Ground 1 10 2 3390 Vehicle right side clearance lights 1 10 3 3390 Vehicle left s...

Page 184: ...indicators turn on the circuit breaker on the battery CBA1 is activated and disables the secondary loads the locks unlock and the out swinging door opens if IVECO original the ceiling lights stay on...

Page 185: ...ilder can mount a remove controlled door on the body in combination with a centralised remove control central door locking system lock unlock opt 5865 Antitheft system Predisposition for an additional...

Page 186: ...ed signal 3 Pin 3 rear door actuator 4 Pin 4 door closed signal Closed circuit when the door is closed Open circuit when the door is open For the system to function properly it is essential to have a...

Page 187: ...ntitheft system In combination with the central locking the vehicle can be equipped with an alarm system controlled by the Body Computer and a peripheral system This system consists of a key with remo...

Page 188: ...ELECTRICAL SYSTEM CURRENT INTERVENTIONS AND DRAWS Printed 603 95 789 1 Ed Base 02 2014 Closed circuit when the door is open 208229 Figure 49 1 Bonnet open sensor 2 Engine bonnet socket 3 Alarm siren...

Page 189: ...Printed 603 95 789 Base 02 2014 SECTION 6 ADBLUE AND SCRT SYSTEM...

Page 190: ...Printed 603 95 789 Base 02 2014...

Page 191: ...ts 3 Printed 603 95 789 1 Ed Base 02 2014 Contents 6 1 GENERAL INFORMATION 5 6 2 THE NITROGEN OXIDE CATALYTIC REDUCTION PRINCIPLE 5 6 3 INSTRUCTIONS 6 Materials 6 AdBlue tank 6 Moving AdBlue system co...

Page 192: ...4 NEW DAILY ADBLUE AND SCRT SYSTEM ADBLUE AND SCRT SYSTEM Printed 603 95 789 1 Ed Base 02 2014...

Page 193: ...and additive is then fed to the catalytic converter and chem ically transforms NOx into nitrogen and water harmless to the environment In order to comply with Euro VI new assemblies DOC passive DPF C...

Page 194: ...not be interrupted using the battery manual switch or the ADR switch the AdBlue pipes must always be emptied to prevent any crystallization or damage from freezing the DM screw threads must be treated...

Page 195: ...the chassis with specific brackets any modifications must be authorized by IVECO The Heating Pot Supply Module must be positioned above the centre of gravity of the tank Heating Pot Supply Modules ot...

Page 196: ...ents urea from collecting syphons inside respect the original incline of the filler in relation to the ground any variation in this value must be authorized by IVECO Note The parts in plastic must be...

Page 197: ...the AdBlue freeze the siphon should have an internal collection volume of 12 cm3 and is to be located below the reference distance of the DM for example S 10 mm S 189106 Figure 4 1 AdBlue tank 2 Pump...

Page 198: ...5 789 1 Ed Base 02 2014 208933 Figure 5 A Config 1 DAILY 35S Wheelbase 3520 mm Gsx B Config 2 DAILY 40C 50C Wheelbase 3520 mm Gsx C Config 3 DAILY 40C 70C Wheelbase 4100 mm Gsx Gdx D Config 4 DAILY 35...

Page 199: ...d of 200 mm and ensure distance from any heat sources The pipes can be modified by using only specific tools and fittings which must comply with Standard SAE_J2044 for the most appropriate choice and...

Page 200: ...ols 189108 Figure 7 1 Plastic pipe mounting pliers Part 99387101 2a Clamping jaws for AdBlue pipe Part 99387102 2b Clamping jaws for water pipes Dis 99387103 3a Support for fitting NW6 for AdBlue pipe...

Page 201: ...Printed 603 95 789 Base 02 2014 APPENDIX A DAILY PEOPLE CARRIER...

Page 202: ...Printed 603 95 789 Base 02 2014...

Page 203: ...on and vehicle capacity 6 Driver s seat characteristics 6 Requirements of materials relating to fire protection 7 Structure and securing the seat mounts 7 Rear baggage compartment 11 Side access 11 Re...

Page 204: ...4 NEW DAILY DAILY PEOPLE CARRIER DAILY PEOPLE CARRIER Printed 603 95 789 1 Ed Base 02 2014...

Page 205: ...ot recorded on the designated forms countersigned by the transporter For any claim please provide the vehicle identification number this number is on the core of the right chassis side member in the w...

Page 206: ...DYWORK CONSTRUCTION This chapter provides instructions for the construction of the bodywork with the most important technical and regulatory aspects Defining the bodywork is left to the Body builder s...

Page 207: ...and resistant to fuel or lubricant unless the material has been covered with a water proof layer The rest of the bodywork materials must be flame retarder or self extinguishing depending on the number...

Page 208: ...8 NEW DAILY DAILY PEOPLE CARRIER DAILY PEOPLE CARRIER A 3 BODYWORK CONSTRUCTION Printed 603 95 789 1 Ed Base 02 2014 173264 Figure 1 Seat securing floor frame...

Page 209: ...NEW DAILY DAILY PEOPLE CARRIER DAILY PEOPLE CARRIER A 3 BODYWORK CONSTRUCTION 9 Printed 603 95 789 1 Ed Base 02 2014 173265 Figure 2 Example Fixed seat installation diagram see Drawing 5801805133...

Page 210: ...10 NEW DAILY DAILY PEOPLE CARRIER DAILY PEOPLE CARRIER A 3 BODYWORK CONSTRUCTION Printed 603 95 789 1 Ed Base 02 2014 173266 Figure 3 Example Runner seat installation diagram see Drawing 5801752010...

Page 211: ...t any interference with these elements the AdBlue tank must be shifted slightly along the chassis side member In this case in order to use pipes which are longer but generally available from IVECO Par...

Page 212: ...o make a distinction between the rear area in the centre of the last but one row of seats at the height of the passenger s ears front area at the height of the driver s ears In these conditions the re...

Page 213: ...eas where noise insulation is not required for example near the electric retarder polyurethane foam can be used for thermal insulation as long as it has characteristics similar to those described Some...

Page 214: ...acity Function 1 150A Power supply CBA 2 2 200A Power supply SCM and Body builders 3 500A Starter and Retarder 4 80A Body Computer power supply 5 Battery master switch To reset the original vehicle co...

Page 215: ...es Open wire no action Ground speed limitation activated deactivated 3 Outswinging door status Max output 10 mA interfacing with decoupling diode Signals when the door is open Open circuit door open G...

Page 216: ...f the mechanical gearbox braking progression and no excessive effort on the pedal progressive clutch action progressive steering action without resistance or knocks maintaining vehicle trajectory with...

Page 217: ...Printed 603 95 789 Base 02 2014 APPENDIX B DAILY CNG AND CNG WITH RECOVERY MODE...

Page 218: ...Printed 603 95 789 Base 02 2014...

Page 219: ...leaks 6 In the event of fire 6 B 3 SYSTEM INTERVENTIONS 6 General warnings 6 Repainting outfitted chassis 7 Tightening torques 7 List of components 8 Emptying the gas circuit 11 Replacing the VBE sole...

Page 220: ...4 NEW DAILY DAILY CNG AND CNG WITH RECOVERY MODE DAILY CNG AND CNG WITH RECOVERY MODE Printed 603 95 789 1 Ed Base 02 2014...

Page 221: ...acteristics of highly flammable compressed gas do not permit the outfitting or conver sion of vehicles for fire fighting applications or for use in potentially critical environments eg airports refine...

Page 222: ...type approval Take into consideration the following warnings before performing interventions on the engine concerning or involving components of the fuel supply system Before performing any work you m...

Page 223: ...r medium pressure hose to the fitting on the cylinder head Figure B 1 67 73 6 7 7 3 Connection M12x1 for stainless steel pipe on pressure reducer 33 37 3 3 3 7 Connection M12x1 for stainless steel pip...

Page 224: ...h helical coils made of AISI 321 stain less steel internal diameter 6 5 mm covered with a AISI 304 stainless steel braid covered by a heat shrink sheath fittings made of AISI 303 stainless steel High...

Page 225: ...nstructions refer to the Paragraph Repair interventions on fittings ad pipes Page 18 Figure B 18 For reasons of safety both when outfitting and during maintenance it is PROHIBITED to use the gas pipes...

Page 226: ...ILY CNG AND CNG WITH RECOVERY MODE B 3 SYSTEM INTERVENTIONS Printed 603 95 789 1 Ed Base 02 2014 117682 Figure 4 T ADJUSTABLE FITTING AISI 316 TJ stainless steel ogive joint 117683 Figure 5 T INTERMED...

Page 227: ...sary to discharge the entire system including the cylinders This must be decided on a case by case basis depending on the importance and type of work being done In case of uncertainty always opt for t...

Page 228: ...nt or open flames at a distance of less than 5 m from the cylinders Shut off power to the vehicle s electrical system at the master power switch if present Disconnect cables from the battery Ground th...

Page 229: ...ocks Perform the partial emptying operations described in the previous paragraph Check that the taps 5 of the solenoid valves 4 on all the cylinders 3 are closed cock 5 set to C and proceed as de scri...

Page 230: ...ft 1 If there is no pressure proceed to completely disassemble the coil shaft 1 with its O Ring 3 87391 Figure 11 Remove the piston 3 shutter 5 and spring 2 from the coil shaft 1 taking care not to lo...

Page 231: ...led for replacement refit the disassembled parts or their replacements as described in the following paragraph Inserting the mobile equipment of the solenoid valve 87391 Figure 12 Fit the piston 3 int...

Page 232: ...nut 1 with the relative O Ring 2 and tighten it to a torque of 7 Nm Restore electric connection to the coil 4 Repeat the previous operations for all cylinder VBE valves Replacing the VBE solenoid val...

Page 233: ...EM INTERVENTIONS 17 Printed 603 95 789 1 Ed Base 02 2014 117664 Figure 15 Remove the screws 2 and take out the guard 1 117665 Figure 16 Unscrew the couplings 1 and 7 and disconnect the piping 2 and 6...

Page 234: ...a torque of 270 10 Nm Note While doing so take care not to damage the VBE valve s fuse plate with the wrench 99355018 Repairs on pipes and fittings If there is a gas leak from the pipe or from the fi...

Page 235: ...appropriately adjusting the cylinder to avoid pre tensioning the piping Keeping the pipe in its seat screw on the union 4 and tighten it to the prescribed torque Unscrew the union 4 and check the fast...

Page 236: ...s is to prevent the gas escaping outwards and the dispenser being removed from the filling valve after refilling Note The presence of a malfunctioning flow valve or solenoid valve can lead to incorrec...

Page 237: ...ders that have been subject to impact during a vehicle collision must be inspected by a body approved by the manufac turer unless otherwise specified by the competent authority These cylinders can be...

Page 238: ...pter Refitting To refit carry out the removal operations in reverse order observing the following instructions Place the cylinders in the framework with the VBE valves pointing in the right direction...

Page 239: ...89 1 Ed Base 02 2014 B 7 POWER TAKE OFFS The procedures for the engagement and disengagement of power take offs are similar to those described in Section 4 for diesel engine vehicles unless it is nece...

Page 240: ...Printed 603 95 789 Base 02 2014...

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