Page 1 M.Y. 2012 AILY ODYBUILDERS NSTRUCTIONS SSUE 2012...
Page 2 IVECO S.p.A. Technical Application Strada delle Cascinette, 424/34 10156 Torino (TO) - Italy www.iveco.com Printed 603.95.241 - 2 ed. 02/2012 Revi - 10/2012...
Page 3 AILY Bodybuilders instructions Printed 603.95.241 - 2 Base - 02/2012 UPDATE DATA Section Paragraph Description Revision date Index Modification to text October 2012 3.4.2 Modification to text October 2012 Modification to table 3.11 and text October 2012 3.14.3 Modification to text October 2012 Modification to figure 3.23 5.4.9...
Page 4: Base
Update data Base - 02/2012 Printed 603.95.241...
Page 5: Base
Any modification, conversion or outfitting not listed in this manual and which is not expressly authorised in writing by Iveco shall result in the exclusion of any responsibility for Iveco, and, in particular, where the vehicle is covered by a guarantee, shall result in an immedi- ate lapse of the guarantee.
Page 6 Page header and footer interpretation Section number - Vehicle type Section title page number Basic edition - Print Chapter title month year number Foreword Base - 02/2012 Printed 603.95.241...
Page 7 INDEX OF SECTION Section General specifications Chassis modifications Fitting superstructures Power Take Offs Special instructions for electronic subsystems Appendix A - Daily PASSENGER TRANSPORT Appendix B - Daily CNG and CNG with Recovery Mode Index of section Printed 603.95.241 Base - 02/2012...
Page 8 Index of section Base - 02/2012 Printed 603.95.241...
Page 9: Table Of Contents
Index SECTION 1 General specifications Page Aim of the requirements Technical documentation available via computer IVECO authorisation Request for approval Liabilities Legal provisions Multi Stage Type Approval - Collaboration (only for EU nations, Switzerland and Turkey) Guarantees Quality System management 1.10...
Page 10 GENERAL SPECIFICATIONS AILY Index Base - 02/2012 Printed 603.95.241...
Page 11: Aim Of The Requirements
Aim of the requirements Aim of the requirements The aim of this publication is to supply data, specifications and instructions for fitting out and converting original IVECO vehicles in order to guarantee their operation, safety and reliability. These Requirements also indicate the following for Bodybuilders: the quality level to be attained;...
Page 12: Request For Approval
IVECO as well as regulations in force in the country the vehicle is destined for; any effects on the vehicle’s operation, safety, reliability and, in general, the good performance of the vehicle;...
Page 13: Multi Stage Type Approval - Collaboration (Only For Eu Nations, Switzerland And Turkey)
• appropriate documentation of modifications made, giving clear evidence that the aforementioned laws and regulations have been respected (e.g. type-approval/testing documentation). Before signing the Technical Agreement, IVECO reserves the right to visit the Bodybuilder in order to ensure they are qualified to perform the outfitting/conversion requested by the agreement.
Page 14: Guarantees
IVECO provides for work to be performed correctly have not been respected; original spare parts or components made available by IVECO for specific operations have not been used;...
Page 15: Prevention Of Accidents
In order to comply with directive 2000/53 EC (ELVs), IVECO forbids installation of components containing lead, mercury, cadmium and hexavalent chromium; exceptions are made for the cases allowed for by Annex II of this directive.
Page 16: Vehicle Management C/O Bodybuilder
(vehicle and/or equipment) and check its functionality and safety; perform the checks laid out in the Pre-Delivery Inspection (PDI) list available from the IVECO network for the items regarding the work performed (obviously the other items in the ODI will remain the responsibility of the Dealer as per guarantee booklet);...
Page 17: Vehicles Identification
AILY Vehicles identification 1.13 Vehicles identification The commercial designation of IVECO vehicles is not the same as the type approval (homologation) designation. Two types of commercial designation are shown below with the meaning of the codes used: Class Engine Version...
Page 18: Dimensions And Masses
Greater values in compliance with the weights permitted on the axles may be authorized by IVECO after modifying such components as the chassis, under run-bar, mirrors, etc. Positioning of lights and side mirrors is normally expected for widths up to 2350 mm.
Page 19: Determining The Centre Of Gravity Of The Body And Payload
1-11 GENERAL SPECIFICATIONS AILY 1.15.2 Determining the centre of gravity of the body and payload Positioning on the longitudinal plane The examples given below may be used to determine the position of the superstructure’s centre of gravity and the payload. The technical documentation specific to each model (chassis cab drawing) give the positions permitted with the vehicle in its standard form.
Page 20 1-12 GENERAL SPECIFICATIONS AILY In terms of the effects of dividing the payload on the axles, consider that it is evenly distributed, with the exception of cases where the shape of the loading bed would result in it being distributed differently. Regarding any equipment, the actual position of the centre of gravity must be used.
Page 21: Printed 603.95.241 Base -
1-13 GENERAL SPECIFICATIONS AILY Height of centre of gravity For chassis cab and unladen vehicles, the height of the centre of gravity is given on the specific technical documentation for each model (chassis cab diagram). When the vehicle is complete with a superstructure and fully laden, this height must comply with the maximum values permitted by national or international regulations, particularly ECE Directive 13 on longitudinal stability and ECE Directive 111 on transverse stability while in motion.
Page 22 (for liquids) the density; to recommending due caution in driving behaviour. Any cases that are difficult to assess must be submitted to IVECO for approval. c) Loads that involve high aerodynamic actions To conversions characterised by large height and surface area (e.g.: vehicles with large advertising panels); the height of the centre of thrust determined by high winds must be calculated very carefully.
Page 23: Observing The Permitted Weights
Observing the permitted weights All limits given in IVECO documentation must be respected. It is essential that the maximum weight on the front axle is not exceeded, under any load condition, so as to ensure the correct steering and braking characteristics regardless of the road surface conditions.
Page 24: Instructions For Correct Operation Of Vehicle Components And Accessibility
1-16 GENERAL SPECIFICATIONS AILY Instructions for correct operation of vehicle components and accessibility 1.16 Instructions for correct operation of vehicle components and accessibility When converting vehicles or installing any type of equipment, no alterations must be made which would compromise correct operation of the vehicle assemblies and components in their various work conditions.
Page 25: Conventions
1-17 GENERAL SPECIFICATIONS AILY Convention 1.17 Conventions The following conventions are used in this document: Wheelbase: distance between the centre line of the steering axle and that of the rear axle. This definition differs from the definition of wheelbase indicated in EC Directives. Rear overhang: distance between the centre line of the rear axle and the rearmost point of the chassis side members.
Page 26 1-18 GENERAL SPECIFICATIONS AILY Convention Base - 02/2012 Printed 603.95.241...
Page 27 CHASSIS MODIFICATIONS AILY Index SECTION 2 Chassis modifications Page General standards regarding changes to the chassis 2.1.1 Particular precautions 2.1.2 Characteristics of the material to be used when modifying the chassis 2.1.3 Stress on the chassis Drills on the chassis 2.2.1 Hole positioning and dimensions 2.2.2...
Page 28 CHASSIS MODIFICATIONS AILY Page 2.5.4 Elongation 2-22 Application of the towing hook 2-24 2.6.1 Adjusting the vehicle for towing 2-24 2.6.2 Precautions for installation 2-24 2.6.3 Hook types 2-24 2.6.4 Towing hook for central axle trailers 2-25 2.6.5 Rear cross member in a lowered position 2-27 Application of a supplementary axle 2-29...
Page 29 CHASSIS MODIFICATIONS AILY Page 2.15.4 ESP system downgrading 2-62 2.16 Electrical system: work and current draws 2-64 2.17 Moving components and fastening supplementary units and equipment 2-65 2.18 Road transport of hazardous goods (ADR) 2-68 2.19 Application of a retarder 2-69 2.20 Changes to the under-run protection bar...
Page 30 CHASSIS MODIFICATIONS AILY Index Base — 02/2012 Printed 603.95.241...
Page 31 CHASSIS MODIFICATIONS AILY 2222.2 General standards regarding changes to the chassis General standards regarding changes to the chassis Keep the following in mind: welding is absolutely prohibited on the load bearing structures of the chassis (with the exception of what is specified in paragraphs 2.2.3, 2.4, and 2.5);...
Page 32 5 minutes of applying the paint. For signal level ground connections (e.g.: low absorption sensors or devices), do not use the standardised IVECO points ”m1” (on the engine block, near the starter motor) or ”m2” and make the ground connections of the signal cables on points separate from the power cables and cables used as radiofrequency shields.
Page 33 CHASSIS MODIFICATIONS AILY Table 2.2 - Section dimension and thickness of the chassis A x B x t A x B x t Chassis rear section wheelbase section rear Class Type Wheelbase [mm] overhang area side member overhang area side [mm] [mm] member [mm]...
Page 34 CHASSIS MODIFICATIONS AILY Drills on the chassis Drills on the chassis When it is necessary to fit auxiliary parts or assemblies to the chassis, the existing holes made in the factory should be used if possible. Drilling the flanges of the vehicle side members is strictly prohibited, with the exception of what is indicated in paragraph 3.3.1.
Page 35 CHASSIS MODIFICATIONS AILY 2.2.2 Screws and nuts In general, it is recommended to make connections of the the same type and class as those foreseen for similar fastenings on the original vehicle (Table 2.4). Screws of class 8.8 and 10.9 must be hardened and tempered and, for applications with diameter 6 mm, it is recommended to ≤...
Page 36 The welds must only be made by qualified personnel with suitable equipment, and always to professional standards (see standard EN 287). Any operation performed that does not comply with the instructions provided by IVECO could seriously damage the on-board systems, jeopardise vehicle safety and cause damage not covered by the warranty.
Page 37 2-11 CHASSIS MODIFICATIONS AILY Welding procedures a) Carefully remove any paint and traces of oxidation from the parts of the chassis involved with the welding as well as those that must be covered with reinforcements. b) Cut the side members with a slanted or vertical cut. The side members must not be cut at the points where the chassis contour and width changes or where stress is greater (e.g.
Page 38 2-12 CHASSIS MODIFICATIONS AILY 2.2.4 Closing holes by welding When making new holes, and if they are too close to already existing holes (see Figure 2.2), the latter can be closed by welding them. To ensure that this operation will be successful: smooth the external edge of the hole;...
Page 39 AILY Rust protection and paint Rust protection and paint NOTE All components assembled on the chassis must be painted according to IVECO Standard 18-1600 colour IC444 RAL 7021 70/80 gloss. 2.3.1 Original vehicle components Table 2.5 shows the protection and painting classes required for the original vehicle components; Table 2.6 shows the classes for non painted or aluminium parts and Table 2.7 shows the parts for the painted classes.
Page 40 2-14 CHASSIS MODIFICATIONS AILY Table 2.6 - Various unpainted, aluminium parts and components - IVECO Standard 18 - 1600 (Table IV) Classes IVECO Type of protection standard B - B1 - B2 Stainless steel ¡ 18-0506 GEO 321-8 GEO 500-8...
Page 41 2-15 CHASSIS MODIFICATIONS AILY Table 2.7 - Painted parts - IVECO Standard 18 - 1600 (Table III) Classes Cycle phase description B § B1¤ Sandblasting/shotblasting MECHANICAL SURFACE yes L yes L yes L yes L Brushing CLEANING¡ yes L Sanding...
Page 42 2-16 CHASSIS MODIFICATIONS AILY 2.3.2 Added or modified parts All the vehicle parts (body, chassis, equipment, etc.) that are added or that are changed must be protected against oxidation and corrosion. Areas without protection are not accepted on ferrous materials. Tables 2.8 and 2.9 indicate the minimum treatments to which the modified or added components must be subjected when it is not possible to protect them using the same protection used for the original components.
Page 43 2-17 CHASSIS MODIFICATIONS AILY 2.3.3 Precautions a) On the vehicle Suitable precautions must be taken to protect the parts for which paint may be harmful for conservation and operation: rubber or plastic flexible pipes for pneumatic and hydraulic systems; gaskets, parts in rubber or plastic; propeller shaft and power take-off flanges;...
Page 44 2.4.2 Authorisation The wheelbase may be changed without specific IVECO approval only when: implementing one of the lengths foreseen in the catalogue for the type of vehicle to be transformed; replicating the structure (side member section; number, type and positions of the cross members), the circuits and systems on the standard chassis corresponding to this length.
Page 45 In general, shortening the wheelbase has a negative influence on braking characteristics. Table 2.11 shows the limits for wheelbase modification. Check with the IVECO - Homologation & Technical Application department about the conditions (brake cylinders, minimum tares, technically permissible weights, tyres, height of the centre of gravity) with which these values are permitted.
Page 46 IVECO for the same wheelbase or the next highest one. Alternatively, if permitted by local regulations, larger sized sections of the sub-frame may be adopted.
Page 47 To prevent consequences on the resistance of the original sections, it is not permitted to apply reinforcement plates directly on the wings of the side members using holes filled with welding. Alternatives may be authorised by IVECO only when demonstrated requirements exist, connected to the subsequent phase of installing the superstructure.
Page 48 When changing the rear overhang, keep in mind the impact this has on the effects of the distribution of useful load on the axles, with respect to the loads specified by IVECO (see chapter 1.15). It is necessary to comply with the limits specified by national regulations as well as the maximum distances from the rear structure edge and the heights off the ground, defined for the towing hook and the under-run protection.
Page 49 2-23 CHASSIS MODIFICATIONS AILY The solution foreseen for elongations greater than 350 mm is shown in Figure 2.10. Figure 2.8 Figure 2.9 Figure 2.10 102427 If the amount of the elongation is considerable, it is necessary to assess on a case by case basis if a supplementary cross member is needed in order to ensure suitable torsional rigidity for the chassis.
Page 50 (chassis cross member, electrical coupling joint, towing hook, chronotachograph, etc...). Please note that the assembly of the chronotachograph, based on current regulations, may only be performed by the IVECO service Network.
Page 51 2-25 CHASSIS MODIFICATIONS AILY Application of the towing hook 2.6.4 Towing hook for central axle trailers A trailer is defined as a central axle type when it has one or more axles close to each other. Particularly due to the effect of the vertical dynamic loads, with this type of trailer, the rear vehicle cross member is subjected to significant stress.
Page 52 2-26 CHASSIS MODIFICATIONS AILY The following table shows the maximum permitted values of S for the tow cross members in production, for central axle trailers. Table 2.13 Model Maximum S (kN) 35S, 35C, 40C 45C, 50C, 60C, 65C, 70C Calculation example for the attachment device class for central axle trailers Considering a 65C15 vehicle with a maximum weight of 6250 kg that must tow a central axle trailer weighing 3500 kg with S = 250 kg, length of the loading surface of 5 m and theoretical drawbar length of 4 m.
Page 53 Rear cross member in a lowered position When it is necessary for the tow hook to have a lower position than what is originally foreseen, IVECO can release authorisation to lower the attachment of the original cross member or to apply a supplementary cross member, which is the same as the original one, in a lowered position.
Page 54 1.15.3. Increase in the towable weight For vehicles suited for the IVECO tow, it is possible to assess, in certain cases and for particular uses, the possibility to authorise towable weights that exceed what is normally permitted.
Page 55 The maximum slope values of the standard propeller shafts must be observed also for the cases when working on the suspensions and rear driving axle. In the case of difficulty, contact the IVECO Technical Application department, and send to it a diagram with the length and slope of the new transmission for a homokinetics check.
Page 56 2-30 CHASSIS MODIFICATIONS AILY For the sliding shafts, the length LG must be evaluated between the cross journal centres and with the sliding branch in the intermediate position. Always check both LG and LZ branches. The maximum operating revs must be deduced from the following formula: = maximum operating revs (rpm) = motor revs (rpm) at maximum power, see Table 2.14 = gearbox ratio in the highest gear, see Table 2.15...
Page 57 2-31 CHASSIS MODIFICATIONS AILY Pipe thickness It is normally not possible to indicate a valid pipe thickness. In fact, the thickness of the pipe depends on the torque to be transmitted by the original shaft, as well as on the constructive setting of the transmission line (driving torque, ratios in the kinematic chain, load on the driving axle or axles).
Page 58 2-32 CHASSIS MODIFICATIONS AILY 2.8.2 Section positioning For transmissions implemented with multiple sections, the individual transmissions must have approx. the same length. In general, the length between an intermediate shaft and a sliding shaft (see Figure 2.15) must not be longer than 600 mm; whereas between the two intermediate shafts this difference must not be greater than 400 mm.
Page 59 Furthermore, for these it is usually not possible to shorten the wheelbase beyond the shortest value foreseen standard (e.g.: tilting). It is recommended to use original IVECO transmissions; if this is not possible crude steel pipes can be used that have a yield point...
Page 60 2.9.1 Intake The characteristics of the engine supply air intake systems and exhaust systems must not be made without IVECO authorisation. Any operations must not change the original intake vacuum values and the exhaust counter-pressure values. Table 2.17 - Maximum permitted counter-pressure at the intake and exhaust at nominal speed and at full load...
Page 61 2-35 CHASSIS MODIFICATIONS AILY Changes to the engine cooling and intake system 2.10 Changes to the engine cooling system The original conditions of proper operation must not be changed, particularly those regarding the radiator, free surface of the radiator, pipes (dimensions and path). In any case, if transformations are necessary (e.g.: changes to the cab) that require work on the engine cooling system, keep in mind that: the useful area for the passage ofair for radiator cooling must not be less than what is implemented for vehicles with standard...
Page 62 This type of transformation is strongly advised against as it involves components of the suspension and chassis anchoring parts that are essential to the vehicle’s active safety. Any company that still intends to carry out this work must provide IVECO with detailed documentation in order to obtain technical approval.
Page 63 To regulate this ratio, proceed as indicated in point 2.15.2, foreseeing a value corresponding to the rigidity characteristics of the new spring for the load to be applied on hole 9. If it is not possible to respect this ratio under all load conditions, contact IVECO for a new check of compliance with the legal regulations.
Page 64 If it is necessary to have a supplementary heating system, it is recommended to use the types foreseen by IVECO. For vehicles for which IVECO does not foresee these heaters, they must be installed in compliance with the requirements of the equipment manufacturer (e.g.
Page 65 2-39 CHASSIS MODIFICATIONS AILY Figure 2.18 shows a diagram of a supplementary heating system with an additional heater. Figure 2.18 Engine coolant Diesel oil 159346 1. Main heater - 2. Optional supplementary heater - 3. Solenoid valve - 4. Additional heater responsibility of the fitter A.
Page 66 (if not directly foreseen by IVECO) must be designed so that it does not have a negative impact on the functionality of the controls and equipment accessibility;...
Page 67 2.13.1 General information All operations on the driving cab must be previously authorised by IVECO. The changes must not prevent the functionality of the control devices positioned in the area involved with the change (e.g. pedals, linkages, switches, pipes, etc.) nor change the resistance of the weight bearing elements (pillars, reinforcement sections, etc.).
Page 68 Installation of a spoiler or a baggage compartment Upon request, versions created by IVECO based on its own designs and checks are available. If installing ”kits” of another origin, comply with the specific indications provided by the manufacturer.
Page 69 2-43 CHASSIS MODIFICATIONS AILY Figure 2.19 173262 1. Roof panel - 2. Cutting limit area -3. Side headlining - 4. Door compartment ring - 5. Rear internal cross member - 6. Rear wall - 7. Rear door compartment trim - 8. Side trim Operations on sheet metal Printed 603.95.241 Base —...
Page 70 2-44 CHASSIS MODIFICATIONS AILY 2.13.3 Operations on the body (vans and combi) Installation of baggage compartments Installation must be carried out using fixing devices specifically provided on the roof panel (low roof and medium roof versions), taking the following into account: the fastening element must involve the baggage compartment anchoring device and ensure resistance against longitudinal and transversal thrusts.
Page 71 2-45 CHASSIS MODIFICATIONS AILY Operations on the roof panel a) Application of a translucent roof On vehicles not originally equipped with one,, the translucent roof (available from IVECO Parts) can be installed as follows: Table 2.19 Component Part number Quantity...
Page 72 2-46 CHASSIS MODIFICATIONS AILY b) Installation of a hatch A hatch may be installed on the roof panel, providing that the operation does not involve the hoops and that the seal and resistance of the modified part is guaranteed. Figure 2.22 shows an installation example. Figure 2.22 sealant anchoring section...
Page 73 2-47 CHASSIS MODIFICATIONS AILY c) Changes to roof panel height In production, three roof panel versions are available with respective internal heights equal to: low roof = 1595 mm medium roof = 1900 mm high roof = 2100 mm Changing the height of the roof panel is a very complicated and onerous operation: therefore, this operation must be limited to the medium and high roof versions that have the same structure as the roof panel.
Page 74 2-48 CHASSIS MODIFICATIONS AILY d) Opening of side windows The opening of windows in vans requires the specific precautions and techniques specified below. • Cut the plate being careful to maintain a section with a minimum width of: 15 mm (in the case of glass fixed with a gasket); 20÷25 mm (in the case of glass fixed by gluing).
Page 75 2-49 CHASSIS MODIFICATIONS AILY Operations on sheet metal Operations on the structure and the floor In addition to the instructions and precautions suggested up to this point, please remember: when drilling holes on boxed sections, areas where stress is more concentrated must be avoided (A and B pillars, in particular); the holes for anchoring to the floor must be protected and sealed against the infiltration of water, dust and exhaust gas;...
Page 76 2-50 CHASSIS MODIFICATIONS AILY NOTE If working on the bodywork of vehicles equipped with a front suspension with a torsion bar, it is necessary to guarantee accessibility to the position adjustment system. Figure 2.26 Area free of obstructions for accessing the regulation unit 112216 Operations on sheet metal Base —...
Page 77 This type of operation requires confirmation by IVECO regarding the suitability of the original suspension devices. In general, solutions equivalent to those foreseen in normal production for similar versions can be adopted.
Page 78 2-52 CHASSIS MODIFICATIONS AILY 2.13.5 Occupant protection The airbags, the safety belt attachments, the position of the retractors and the pre-tensioners, the anchoring of the seats are an integral part of passive safety. Any change made to these components could jeopardise the protection of the transported passengers and compliance with legal regulations.
Page 79 NOTE The replacement of the tyres with others of a different size or load capacity in comparison to what was foreseen during vehicle approval requires IVECO authorisation and verification of the need to reprogram braking system management. The vehicle must be presented to the competent department for checking the replacement and for updating the registration documents.
Page 80 If it is necessary to remove the wheels to equip the vehicle, when remounting them the contact surfaces between the rim and connection flange must be clean and free of corrosion. Furthermore, the tightening torques according to IVECO standard must be guaranteed (see Table 2.21). Table 2.21 - Wheel tightening torques according to IVECO std. 17-4000...
Page 81 The specifications and material of the new pipes must correspond with those of the originally used pipes. The assembly must be carried out in a manner that ensures that the system is suitably protected. For the supply of materials and their assembly, it is recommended to contact the IVECO Support Service or specialised workshops. Metal pipes...
Page 82 2-56 CHASSIS MODIFICATIONS AILY Plastic pipes They are used on vehicles with air spring suspension for connecting the air springs to the integrated control unit and for controlling the braking corrector. In the case of replacement, keep in mind that plastic material is not permitted: in areas where the temperature could exceed 80 °C, (e.g.
Page 83 2-57 CHASSIS MODIFICATIONS AILY In general, use quick coupling type unions (it is recommended to use the same brands used to originally equip the vehicle). When required due to dimensions (e.g. near curves) unions with a metal insert can be used. Before inserting the pipe into the union, tighten the union itself into the threaded seat of the component (e.g.
Page 84 In that case, the system will deactivate and the predetermined amount of time must pass before restarting the operation. If replacing the modulator (supplied by IVECO Parts already filled with brake fluid in all parts) it is sufficient to perform the manual bleeding procedure, making sure not to empty it and to not cycle the pump or the solenoid valve before filling is complete.
Page 85 2-59 CHASSIS MODIFICATIONS AILY 2.15.2 Braking corrector For vehicles that are still requested without ABS, there are two types of braking correctors: version for the dual braking circuit combined with the single rear wheels (models 29L and 35S); version for the single circuit combined with twinned rear wheels (models 35C). Adjusting the corrector The adjustment is performed originally in the production plant and makes the vehicle suitable for transporting loads or for the application of normal superstructures in compliance with deceleration and traction values required by the relative EC Directives.
Page 86 2-60 CHASSIS MODIFICATIONS AILY Figure 2.29 102436 Single-circuit corrector for model 35C 1. Pressure gauge upstream of the corrector - 2. Pressure gauge downstream of the corrector - 3. Test unions - 4. Breaking corrector - 5. Rod - 6. Main lever - 7. Adjustment lever - 8. Coupling screw - 9. Hole for the application of the calibration load Work on the brake system Base —...
Page 87 The following paragraph describes the main situations that can be determined. NOTE The reprogramming of the control unit or the downgrading of the ESP system can be performed exclusively by the IVECO Support Service. Work on the brake system Printed 603.95.241...
Page 88 Variation of the G.V.W. The variation of the G.V.W. must be authorised by IVECO and is possible only in some particular cases if an ESP system is installed. In cases of compatibility, the system management software must be reprogrammed, in all other cases downgrading is mandatory.
Page 89 These operations may only be carried out if authorised by IVECO and require the reprogramming of the ESP system software. Stabilizer bar modification or replacement The modification or replacement of the stabilizer bars must be authorised by IVECO and may not be done if there is an ESP system.
Page 90 2-64 CHASSIS MODIFICATIONS AILY Electrical system: work and current draws 2.16 Electrical system: work and current draws NOTE For information regarding work on the electrical system, refer to what is described in section 5 - Chapter 5.4. Electrical system: work and current draws Base —...
Page 91 2-65 CHASSIS MODIFICATIONS AILY Moving components and fastening supplementary units and equipment 2.17 Moving components and fastening supplementary units and equipment If it is necessary to move units (various components, fuel tank, spare wheel, etc.) for the installation of particular equipment, the operation is permitted on the condition that: the functionality of the units themselves is not jeopardised;...
Page 92 2-66 CHASSIS MODIFICATIONS AILY The holes to be made for the new positions must be made on the rib of the side member, according to the requirements specified in Chapter 2.2 and, being careful to use already existing holes as much as possible. Figure 2.32 102451 Clutch control tank...
Page 93 If the fuel tank capacity is not sufficient or the tank is not suitable for the fitter’s requirements, a tank of a larger size or with a different shape can be installed. Before replacing it, check that the new tank is compatible with the vehicle’s original configuration. Figure 2.34 specifies the types of IVECO tanks available as an alternative to the original one. Figure 2.34...
Page 94 Hazardous goods must be transported by specifically equipped vehicles and the type of equipment is different based on the said categories. IVECO does not provide ADR versions, although the vehicles are already compliant on the level of some electrical parts, mechanical components and materials inside the cab.
Page 95 For the connection of the management control unit, a bridle must be used on the instrument panel, which can be obtained from the IVECO spare parts service with reference no. 5801619664 (right-hand drive) and 5801619666 (left-hand drive). NOTE For vehicles with an ESP system, see Paragraph 2.15.4.
Page 96 In cab vehicles supplied without mudflaps, these can be positioned by implementing solutions equivalent to what is foreseen by IVECO. For the implementation of the mudflaps, the wheelhouses as well as for the conformation of the superstructure, keep in mind that: the free movement of the wheels must be guaranteed also if chains are used, in compliance with the limits specified in Paragraph 2.13.3;...
Page 97 2-71 CHASSIS MODIFICATIONS AILY 2.22 Mudflaps If required by regulations and if not originally fitted, it is necessary to ensure that the complete vehicle is provided with suitable mudflaps. For the assembly, the distances specified by current regulations must be respected. Side protections 2.23 Side protections...
Page 98 2-72 CHASSIS MODIFICATIONS AILY Chocks Base — 02/2012 Printed 603.95.241...
Page 99 FITTING SUPERSCTRUCTURES AILY Index SECTION 3 Fitting supersctructures Page Construction of the subframe 3.1.1 Material 3.1.2 Section bar dimensions 3.1.3 Aluminium subframe Elements making up the subframe 3.2.1 Longitudinal runner profiles 3.2.2 Cross members Connections between frame and counterframe 3-10 3.3.1 Choosing the type of body mounting 3-10...
Page 100 FITTING SUPERSCTRUCTURES AILY Page 3.10 Recovery vehicles 3-34 3.11 Municipal, fire-fighting and special services 3-35 3.12 Installation of front snowploughs 3-36 3.13 Winch installation 3-37 3.14 Special body conversions 3-38 3.14.1 Chassis-cowls 3-38 3.14.2 Motor homes 3-38 3.14.3 Installation of overhead platformsInstalling an aerial platform 3-39 Index Base - 02/2012...
Page 101 The following are the characteristics of some materials taken into account for some of the applications described below. Table 3.1 - Material to be used for body manufacturing Standard IVECO 15-2110 e 15-2812 Breaking load...
Page 102 The table below illustrates the values for the bulk modulus W for C-section bars recommended by IVECO. The indicated W value refers to the real section and allows for the section bar coupling radii (it can be calculated with some approximation by multiplying by 0.95 the value obtained by considering the section made up of simple rectangles).
Page 103 IVECO. Furthermore, when calculating the minimum size of reinforcing profiles, the allowed stress limit of aluminium must be taken into account as well as the different elasticity modulus compared to steel (approx.
Page 104 FITTING SUPERSCTRUCTURES AILY Elements making up the subframe Elements making up the subframe 3.2.1 Longitudinal runner profiles The side members of the additional structure must be continuous, extended as much as possible toward the front part of the vehicle and toward the area of the rear support of the front spring; furthermore, they must lean on the chassis and not on shelves. In order to create a gradual decrease of the resisting section, the front ends of the profile must be tapered in height to an angle no greater than 30º...
Page 105 FITTING SUPERSCTRUCTURES AILY The shape of the profile section is determined according to the function of the sub-frame and the type of structure above it. Open C profiles are recommended when the sub-frame must adapt elastically to the vehicle chassis, or boxed sections when a greater rigidity of the assembly is required.
Page 106 FITTING SUPERSCTRUCTURES AILY 3.2.2 Cross members A sufficient number of cross members, to be positioned near the fastenings of the chassis, must brace the two profiles of the sub-frame. Cross members can have an open section (e.g. C-section) or a closed section if greater rigidity is required. Use suitable plates when connecting them, so as to provide appropriate resistance (see Figure 3.4).
Page 107 FITTING SUPERSCTRUCTURES AILY Figure 3.7 166685 Self-supporting bodies as subframes When installing self-supporting structures (e.g. vans, tanks) or when the basic structure of the equipment to be installed is already shaped as a sub-frame, the use of a sub-frame (longitudinal profiles and cross members) can be avoided. Elements making up the subframe Printed 603.95.241 Base - 02/2012...
Page 108 Choosing the type of body mounting The selection of the type of connection to be used - if not provided initially by IVECO - is very important in terms of the subframe providing strength and stiffness, for the appropriate body type.
Page 109 (e.g. driving off-road). If the vehicle chassis is already fitted with shelves to connect a tray of a type approved by IVECO, these shelves must be used to that purpose. Shelves applied to the sub-frame or structure must have resistance characteristics no lower than those originally fitted on the vehicle (see Table 2.7 and Table 3.1).
Page 110 3-12 FITTING SUPERSCTRUCTURES AILY 3.3.4 Elastic connections When greater elasticity is required for the connection (e.g. vehicles with highly rigid structure, such as vans, tanks, etc. used on winding roads or poor conditions or off-road, etc.), the fastenings shown in Figure 3.9 must be used in the area behind the cab. In other words brackets fitted with silentblocks (1), Belleville washers (2) in line or in parallel or coil springs (3) must be used.
Page 111 3-13 FITTING SUPERSCTRUCTURES AILY 3.3.5 Connection with U bolts (clamps) The most important mounting of this type is illustrated in Figure 3.10. In this case the Bodybuilder must position a spacer (preferably made of metal) between the wings of the two side members and at the fastening U bolts, so that the wings will not be flexing due to the pull of the U bolts.
Page 112 3-14 FITTING SUPERSCTRUCTURES AILY 3.3.6 Connection with plates for longitudinal and transverse fixing (rigid joint) The type of fastening shown in Figure 3.11, with plates welded or bolted to the sub-frame and fastened with screws or nails to the vehicle chassis, ensures good reaction to longitudinal and transversal forces and greater support to the overall rigidity. Figure 3.11 102462 In order to use these plates correctly, take the following into account:...
Page 113 3-15 FITTING SUPERSCTRUCTURES AILY 3.3.7 Mixed connections According to the indications for the creation of the sub-frame (point 3.1) and the considerations in paragraph 3.3, the connection between vehicle chassis and reinforcing sub-frame can be mixed, i.e. created by using elastic (shelves, U bolts) and rigid (longitudinal and transversal plates) connections rationally.
Page 114 Fastening must be performed by means of suitable shelves fitted to the vertical rib of the side members; if these fastenings are not already fitted by IVECO, they must be created following the indications in point 3.3.3. In order to perform an adequate longitudinal containment, when connecting with shelves or flanges, it is advisable to fit a rigid connection (on each side) on the end of the rear overhang, performed by means of plates or screws on the upper wing of the side member (see Figure 3.11 and 3.12).
Page 115 3-17 FITTING SUPERSCTRUCTURES AILY Building vans A structure made of longitudinal profiles and cross members can be created to connect to the vehicle chassis. For longitudinal profiles, see Table 3.4. Figure 3.14 shows an example, where the longitudinal profiles are completed by cross members and shelves for the entire length in order to limit the height of the structure.
Page 116 3-18 FITTING SUPERSCTRUCTURES AILY When cross members are used for the floor with a distance no longer than 700 mm between them, connected so as to form a sufficiently rigid structure (self standing), the use of longitudinal profiles may not be necessary (see Figure 3.15). To ensure the required stability of the cross members and to avoid excessive rigidity of the chassis in the front part, we recommend taking into account the observations of paragraph 3.4.1.
Page 117 The use of tilting platforms at the rear and on all three sides generally subjects to the frame to considerable stress. Therefore take into account the following indications. a) The use of a stabiliser bar is recommended for models for which IVECO considers it an optional. b) The sub-frame must be: suitable for the vehicle type and for the specific operating conditions.
Page 118 3-20 FITTING SUPERSCTRUCTURES AILY Figure 3.16 166687 1. Subframe - 2. Body mounting brackets - 3. Shear-resistant plates - 4. Hinge constraint Table 3.5 Minimum reinforcing longitudinal Models Modulus of resistance Dimensions (mm) Wx (cm 35C, 40C 80x50x5 45C, 50C, 60C, 65C, 70C 100x60x6 Fitting box bodies Base - 02/2012...
Page 119 The range does not envisage special vehicles for towing semitrailers. However, it is possible to make the conversion using the chassis-cab vehicle, with specific authorization issued by IVECO. This authorisation provides the instructions that the Bodybuilder must follow, the allowed masses and the prescriptions for use.
Page 120 5. Rear wing support - 6. Connection to the chassis Fifth wheel All fifth wheels can be used on IVECO vehicles provided that their load, size and performance capacities are declared by the Manufacturer to be suitable to the specific use.
Page 121 3-23 FITTING SUPERSCTRUCTURES AILY Electric system Perform any modification observing the general precautions under point 5.4. NOTE For vehicles with ESP system, see point 2.15.3. Combining the tractor with the semi-trailer Semitrailers must not have construction characteristics (e.g. excessive chassis flexibility, insufficient braking capacity, etc.) such as to cause negative effects on the driving behaviour of the semitrailer.
Page 122 For transport systems where particular force configurations arise following concentrated vertical loads and dynamic thrust during braking, a preventive check on the vehicle’s suitability must be carried out directly with IVECO. The structure to support the load on the tractor must be of the sub-frame type, while other limits can be defined from time to time.
Page 123 3-25 FITTING SUPERSCTRUCTURES AILY Installation of tanks and containers for bulk materials Installation of tanks and containers for bulk materials Installation of tanks and containers on vehicle chassis is usually performed by applying a suitable sub-frame. Table 3.7 contains the guidelines for the dimensions of the longitudinal runners to be used for the auxiliary frame. Figure 3.18 a) As was mentioned in the case of other applications, the positioning of the mountings through which the forces are discharged is similar here.
Page 124 In particular, choose elastic characteristics for the front anchoring which are suitable to allow the necessary torsional movements of the vehicle chassis; other anchoring solutions must be authorized by IVECO. Self standing tanks can be placed directly on the vehicle chassis if suitable supports are used, located immediately behind the cab and in the rear axle area.
Page 125 Particular cases when the values of the M moment correspond to value ”E” in Table 3.8 (or greater values) must be checked from time to time and must be expressly authorized by IVECO. Figure 3.19 g (W...
Page 126 3-28 FITTING SUPERSCTRUCTURES AILY 3.8.1 Crane behind the driver’s cab a) Fastening of the reinforcing profiles to the chassis must be performed by means of standard shelves (see Figure 3.20), completing them, if necessary, with elastic fastenings (shelves or flanges) in order to maintain unchanged the flexion and torsion characteristics of the chassis as much as possible.
Page 127 3-29 FITTING SUPERSCTRUCTURES AILY When installing the crane on vehicles with deep cab (e.g. 6+1), extend the sub-frame all the way up to the cab (see Figure 3.2), otherwise the rotation field of the crane must be limited according to the crane capacity in order not to exceed the flexing moment allowed by the chassis.
Page 128 3-30 FITTING SUPERSCTRUCTURES AILY 3.8.2 Cranes on the rear overhang It is advisable for this type of application to extend the subframe over the entire length of the vehicle that is available for the body up to the area behind the cab. The dimensions of the longitudinal runners to be used are given in Table 3.10. Considering the particular distribution of weights on the vehicle (load concentrated on the overhang) and in order to ensure the torsion rigidity necessary for a good behaviour on road and during operation of the crane, the sub-frame must be strengthened in accordance to the crane capacity.
Page 129 3-31 FITTING SUPERSCTRUCTURES AILY Figure 3.21 166689 1. Subframe - 2. Shear-resistant plates - 3. Mounting brackets - 4. Crane mounting plates - 5. Stabilizers - 6. Subframe reinforcing area 3.8.3 Removable cranes Installation of removable cranes on the rear overhang can be performed according to the previous paragraph, provided that the type of fastening used between the crane and the sub-frame does not generate additional stress on the vehicle chassis.
Page 130 3-32 FITTING SUPERSCTRUCTURES AILY Installation of tail lifts Installation of tail lifts NOTE When applying tail lifts, observe the maximum allowed load limits on the rear axle of the vehicle and the minimum load for the front axle (see paragraph 1.15). If this is not possible, shorten the rear overhang.
Page 131 5.4). IVECO requires fittings a switch isolating the electric circuit of the tail lift from the vehicle circuit when the tail lift is not operating. Furthermore, the Bodybuilder must take care of any modification of the underrun bar or the placing of a new type of cross member (see paragraph 2.19) as well as respecting the visibility of rear lights, overhang angles and positioning of the towing hook, as established...
Page 132 This equipment must comply with towing weights, vertical loads on the hook and the minimum ratio between front and rear axle weights as defined in the specific authorizations issued by IVECO. The Bodybuilder must also provide plates/labels indicating the specific conditions under which transport is authorized (towing weight, load on hook, maximum operating speed, etc.).
Page 133 3-35 FITTING SUPERSCTRUCTURES AILY Recovery Vehicles 3.11 Municipal, fire-fighting and special services Fitting of vehicles for community work (compactors, compressors, road sprayers) requires the following in many cases: construction of a very robust sub-frame toward the rear and elastic connections to the chassis toward the front of the vehicle; shortening of the rear chassis overhang.
Page 134 (e.g. towing hook). Otherwise the Bodybuilder must install equivalent systems, complying with safety norms and regulations. Due to the limited maximum speed for most IVECO vehicles used as snow-ploughs, an increase of the maximum load allowed on the front axle can be granted upon request.
Page 135 3-37 FITTING SUPERSCTRUCTURES AILY Winch installation 3.13 Winch installation A winch can be applied to the vehicle in the following points: on the front of the frame (front installation); on vehicle chassis behind the cab; between vehicle side members, centre or displace on one side; on the end of the frame.
Page 136 3.14.1 Chassis-cowls They are built specifically to install bodyworks or special versions (store vans, caravans, etc.). Indications and precautions of the technical documentation (chassis diagram) provided by IVECO must be carefully observed. 3.14.2 Motor homes The limits to weights for single axles and overall weight must be strictly complied with, taking into account the number of people on the vehicle and a sufficient margin to load the following: uggage, curtains, sports equipment;...
Page 137 Positioning on the vehicle must comply with the admissible load and distribution limits. Exceptional cases must be assessed from time to time and specific authorisation must be obtained from IVECO. The installation of an overhead platform/basket requires the introduction of a suitable counterframe. In addition to following the general instructions, (see Chapter 3.3 and Table 3.2 and Table 3.3), the Fitter must also:...
Page 138 The installation of this version on vehicles 29L-35S (single wheels) is possible after fitting specific reinforcing straps on the chassis, which can be ordered originally with specific option no. 74131 or at IVECO Parts with spare parts no. 504267869. Figure 3.24...
Page 139 POWER TAKE OFFS AILY Index SECTION 4 Power Take Offs Page General specifications Power Take Off from gearbox Power Take Off from transfer box Power Take Off from drive line Power Take Off from engine PTO management 4-10 4.6.1 General specifications 4-10 4.6.2 PTO mode...
Page 140 POWER TAKE OFFS AILY Index Base - 02/2012 Printed 603.95.241...
Page 141 POWER TAKE OFFS AILY 44444. General specifications General specifications Different types of Power Take Offs (PTO) for motion withdrawal can be mounted to control of the ancillary control units. According to the type of use and the performances required, the application can be performed as follows: the gearbox;...
Page 142 POWER TAKE OFFS AILY PTO transmissions In respect of the transmission manufacturer’s requirements, particular care must be given to the kinematics (angles, rpm, moment) from the PTO to the attached device during the design phase and dynamic behaviour during the production phase. This means that: the forces which will be present during maximum power and torque output conditions must be considered when calculating scaling...
Page 143 Any higher take-off torques, for occasional uses, must be individually authorised by IVECO on the basis of the type of use. The PTO must normally be used with the vehicle parked and must be engaged and disengaged with the clutch disengaged to avoid excessive stress on the synchronisers.
Page 144 As such, it is recommended you read section 4.6 ”PTO management” before proceeding. The control unit must be reprogrammed by following the instructions found in the relevant IVECO manuals, using the diagnostics tool available from Dealers and Authorised Workshops and supplying information on the PTO used.
Page 145 (working periods, pauses etc.) specific to the Power Take Off in question should be respected. PTOs supplied by IVECO have a flange for direct attachment of pumps with UNI 4-hole connectors. The output consists of a 21 ISO 14 splined shaft (Figure 4.4).
Page 146 Any operation carried out on the propeller shaft without obtaining previous authorisation from IVECO will cause the vehicle warranty to immediately become null and void.
Page 147 POWER TAKE OFFS AILY Power Take Off from engine Power Take Off from engine The use of these PTOs is intended for equipment requiring continuous power and with low torque values (e.g. driving AC systems). Power is taken from the front part of the engine via belt drive. The data listed in Table 4.2 refer to take off with a specific pulley designed according to Figure 4.5.
Page 148 PTOs, etc). See the specifications in IVECO Guideline no. 603.95.231 of 12/2010 for description of the characteristics and methods of use. In case (a) where only the PTO is present, a control panel is installed on the instrument cluster (Figure 4.6, page 4-11), which consists •...
Page 149 4-11 POWER TAKE OFFS AILY Figure 4.6 PTO CONTROL PANEL EXPANSION MODULE ACTIVATION BUTTON 147477 Operating tipper box (if present) Button (3) controls tipping body lifting: this action will be simultaneous and will be cancelled when the button is released. A continuous LED light (5) indicates that lifting of the tipper truck is in progress.
Page 150 Expansion Module NOTE - With the PTO installed, the Engine Control Unit can be configured by IVECO service in order to set the engine operating conditions with PTO engaged. - If you wish to install a PTO after market, you must check whether the vehicle is fitted with Cruise Control.
Page 151 If an after market PTO is to be installed, check to ensure that the vehicle is equipped with the Cruise Control option. NOTE After fitting an after-market PTO, refer to the IVECO Assistance Service for updating the engine ECU software via remote service. PTO management Printed 603.95.241...
Page 152 If an after market PTO is to be installed, check to ensure that the vehicle is equipped with the Cruise Control option. NOTE After fitting an after-market PTO refer to the IVECO Assistance Service for updating the engine ECU software via remote service. PTO management Base - 02/2012 Printed 603.95.241...
Page 153 4-15 POWER TAKE OFFS AILY 4.6.2.3 Engine speed control for Power Take Off The engine electronic control unit has provision for a function that performs isochronous adjustment of the engine and PTO speed. As a result of this type of connection it is possible to adjust the speed of both directly with the Cruise Control lever (Figure 4.9). Figure 4.9 139390 In addition, the control unit is able to check the set speed and keep or restore the balance according to the applied load.
Page 154 Whenever it is necessary to store engine speed values different from the default values set by IVECO, the system allows the desired values to be programmed for each selector position by following the procedure described in section 4.6.2.3.
Page 155 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Index SECTION 5 Special instructions for electronic subsystems Page Electronic system Bodybuilder connectors 5.2.1 20 pin connector (61071) 5.2.2 12 pin connector (72068) 5.2.3 Antitheft system 5-16 Electronic control units 5-17 5.3.1 Precautions to be taken with the installed electronic control units 5-17 5.3.2 Disconnecting ECUs...
Page 156 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Index Base - 02/2012 Printed 603.95.241...
Page 157 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 55555. Electronic system Electronic system The following shows the location of the electronic control units and connectors that can be installed on the vehicle. Devices or electrical circuits must not be connected directly to the control units described below. It is only possible to use the connectors listed in the following paragraphs.
Page 158 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Bodybuilder connectors Bodybuilder connectors To allow the Bodybuilder to interface correctly and efficiently with the vehicle’s electrical system, specific connection points have been provided to be used for supplementary systems. This provision is necessary to avoid any manipulation of the system, in order to guarantee its functional integrity and therefore the validity of the guarantee.
Page 159 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.2.1 20 pin connector (61071) 20-way connector Figure 5.3 101564 Existing parts on the vehicle Counterpart to be connected Table 5.1 Code number Description 500314817 20-way male holder joint 500314820 Male contact for 0.3 to 0.5 mm cable 500314821 Male contact for 1 to 1.5 mm...
Page 160 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Table 5.2 - Basic functions of 20 pin connector Description Signal Remarks When positive signal is supplied, the starter motor is powered and starts the vehicle engine. Operation takes place only when the key is turned in the barrel.
Page 161 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Table 5.2 - (continues) Basic functions of 20 pin connector Description Signal Remarks Output Ignition live positive protected by a fuse present Ignition-operated positive max 5 A on the Body Computer - F49 Cruise Control negative analogue signal (in parallel controlled from the steering column Input Cruise Control Command...
Page 162 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.2.2 12 pin connector (72068) 12-way connector Figure 5.4 101554 Existing parts on the vehicle Counterpart to be connected Table 5.3 Code number Description 500314814 12-way male holder joint 500314820 Male contact for 0.3 to 0.5 mm cable 500314821 Male contact for 1 to 1.5 mm...
Page 163 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Table 5.4 - Basic functions of 12 pin connector Description Signal Remarks When an earth signal is supplied, vehicle speed is Input limited to 30 km/h Speed limiter max. 10 mA Earth = active speed limitation When earth connected,...
Page 164 5-10 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Specification 1 Vehicle speed signal B7 is a square-wave signal having the same frequency as the input signal (from the pulse generator) and a variable duty-cycle, due to the vehicle’s tachometric constant. Figure 5.5 VEHICLE SPEED SIGNAL Input signal on the pulse transmitter...
Page 165 5-11 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.6 Interface for processor designer Bodybuilders connector Processor signal COMPULSORY separation diode 120377 The Bodybuilder must fit a separation diode so that the V voltage is not lowered. The signal processing designer must ensure an input interface equal to that shown with a max Vdc of 5 volt and “pull-up/pull-down” in order not to lower the V voltage and increase the response time set by the vehicle interface.
Page 166 5-12 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Specification 2 Engine revs signal The engine revs signal is represented by a square wave. Below are the features of the engine revs signal: Table 5.5 Features Condition Minimum Typical Maximum Unit C-IO To container / VBat- 1.85 R-IO...
Page 167 5-13 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Specification 3 Cruise Control via Bodybuilder socket The Bodybuilder must fit the splitter outlined below by connecting it to the 20 way Bodybuilder connector by referring to the pins shown. Figure 5.8 2490Ω 649Ω...
Page 168 5-14 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Provision for an additional central rear door locking system (Vans) The following exist for ”van” versions: option 5864 ”Central door locking + Provision for an additional central rear door locking system”, which provides a socket on the central pillar.
Page 169 5-15 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY An identical connection must also be done for the driver and passenger’s doors by the Bodybuilder to the side doors plug. Driver door and passenger door connecting diagram Figure 5.11 Bodybuilder’s Actuator Pinl: Driver/Passenger Door actuator Pin3: Driver/Passenger Door actuator Driver Door Plug Bodybuilder’s Switch Button...
Page 170 5-16 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.2.3 Antitheft system In combination with central closing, the vehicle can be equipped with a perimeter type anti-theft system controlled from the Body Computer. This system consists of: a key with remote control, buttons for remote locking/unlocking; actuators to close the cab doors, the sliding side doors and the rear doors in the case of a van;...
Page 171 5-17 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Electronic control units Electronic control units 5.3.1 Precautions to be taken with the installed electronic control units In order to avoid any operations that could permanently damage or cause the operation of the vehicle ECUs to deteriorate, it is good practice to: •...
Page 172 Before installing additional heaters, Power Take Offs, speed limiters, anti-theft devices, mobile phones and cooling system compressors that could interact with the above electronic systems, it is advisable to check the feasibility of application with IVECO. It is also necessary for appropriate diagnostic checks to be carried out in order to confirm that the system has been correctly set up.
Page 173 5.3.2 Disconnecting ECUs Work carried out which does not conform with IVECO instructions, or that is carried out by unqualified personnel, can cause serious damage to the on-board systems, compromise driving safety, the good functioning of the vehicle and cause associated damage that is not covered by the contractual guarantee.
Page 174 Work on the system (e.g. removing wiring harness, making additional circuits, replacing equipment, changing fuses, etc.) that is not done in conformity with IVECO instructions or is carried out by unskilled personnel can severely damage the systems (control units, wiring, sensors, etc.), jeopardizing safety and operation of the vehicle besides causing significant damage (e.g.
Page 175 The wiring of the electronic systems (length, conductor type, arrangement, clamping, connecting shield braids etc.) must follow the original IVECO standards. Carefully reset the original system after carrying out any work.
Page 176 (battery charger) to start the engine. If in doubt, contact the IVECO service network. Any damage to electronic control units caused by failure to comply with procedure is not covered by the warranty.
Page 177 5-23 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.4.1 Earth points The vehicle’s original ground connections should not be modified in principle. In the event that such connections need be displaced or addition ground points need be realized, use the holes found on the chassis as much as possible, taking care to: remove the paint on the chassis side and also the terminal side mechanically by sanding and/or by using an appropriate chemical product to create a contact surface without notches or steps;...
Page 178 5-24 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.15 173253 m = power grounds ms = signal grounds POSITION OF EARTH POINTS ON VEHICLE m1. Engine block ground - m2. Engine compartment ground left chassis side member - m3 + ms3. Engine compartment ground under the servo brake - m4.
Page 179 5-25 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.17 128824 m3 + ms3. Engine compartment earth beneath brake servo Figure 5.18 128825 m4. Engine compartment earth near right front light Electrical system: modifications and drawing-off power Printed 603.95.241 Base - 02/2012...
Page 180 5-26 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.19 128826 m5. Engine compartment earth near left front light Figure 5.20 162250 m6 + ms6, m7. Grounds inside cab on the central body under the tachograph Electrical system: modifications and drawing-off power Base - 02/2012 Printed 603.95.241...
Page 181 5-27 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY The negative leads connected to a ground point in the system must be as short as possible and must be connected to each other in ”star” formation, while tightening most be done in an orderly and adequate manner. As far as electronic components are concerned, the following instructions shall also be followed: the electronic control units shall be connected to the system ground when they are equipped with metal cases;...
Page 182 5-28 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.4.2 Electromagnetic compatibility We recommend that electrical, electro-mechanical and electronic devices which comply with the following immunity requirements for electromagnetic emissions, both irradiated and conducted are used: The level of electromagnetic immunity of the electronic devices equipping the vehicle, at a distance of 1 metre from the transmitting aerial must be: 50 V/m immunity for devices performing secondary functions (not impacting on direct vehicle control), for frequencies varying from 20 MHz to 2 GHz;...
Page 183 ≥ 6 mm If in any doubt, call the IVECO Service Network. These levels are granted only if the system comes from ”IVECO Spare Parts” or it has been certified as per ISO, CISPR, VDE international regulations. Whenever equipment is used that runs on mains power (220 V AC) for its primary or secondary source of power, it must be checked to ensure that its characteristics are in line with IEC regulations.
Page 184 5-30 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY c) 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 5.24); in order to avoid interference and malfunctioning, create a path that maintains an adequate distance (min. 50 mm) from pre-existing cabling or from other cables (radio, amplifiers and other electronic equipment), fixed keeping the minimum distance from the metal structure of the cab and using existing holes in the sheet metal;...
Page 185 5-31 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.23 98915 1. Antenna support - 2. Gasket - 3. Fixed joint cover - 4. Fixing screw M6x8.5 (torque to 2 Nm) - 5. Antenna - 6. Roof - 7. Antenna extension lead Figure 5.24 99349 1.
Page 186 5-32 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.25 166094 1. Location of the CB transceiver unit (City Band) Equipment for cellular telephones The transmitter part of the equipment must be installed in a flat, dry area, separate from the vehicle’s electronic components and away from damp and vibrations.
Page 187 5-33 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Electrical system: modifications and drawing---off power Figure 5.26 166093 Blue&Me provision components In the case of shielded vehicles, the ceiling fitting with microphone is supplied in the equipment kit case. If required by the installation in the cab, the microphone can be removed and replaced. It must however be positioned at a point distant from possible noise sources and according to the reception area described in the following picture.
Page 188 5-34 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.28 166096 Blue&Me microphone Table 5.7 Description Cable Ground White Signal + Vdc Shielded Cab cable Convergence cable The microphone connector, cab side cable, is with the associated connectors on the ceiling fitting. GPS reception and satellite navigation equipment The transmitter part of the equipment must be installed in a flat, dry area, separate from the vehicle’s electronic components and away from damp and vibrations.
Page 189 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Car radio installation The original equipment (or aftermarket) IVECO car radio is integrated into the system on the CAN network and allows: message repetition to comfort control panel; volume adjustment according to vehicle speed;...
Page 190 In any case we recommend that the increase in the capacity of the batteries should not exceed 20 to 30% of the maximum values provided as an optional extra by IVECO so as not to damage some components of the system (e.g. Starter motor). If greater capacities are required, use additional batteries making the necessary arrangements for recharging as described below.
Page 191 5-37 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Supplementary batteries The insertion of a supplementary battery into the vehicle circuit requires a separate charging system, integrated with that of the vehicle. In this case, supplementary batteries must be provided with an equal capacity to those fitted originally (110 Ah) for correct charging of all the batteries.
Page 192 The auxiliary alternator shall feature the same characteristics as the standard one, and the cables shall be properly dimensioned. If it is necessary to make modifications to the system that are different to those described in this manual (for example, the addition of more batteries in parallel), the operation must be shared with IVECO. Figure 5.31...
Page 193 5-39 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.4.5 Current drawing The following gives information related to the points where it is possible to draw off the available power and the instructions to observe. Figure 5.32 114081 1. Bodybuilders node - 2. Passage of wires between cab/engine compartment - 3. Bodybuilders’ connector (cab interior) Drawing current from CBA (on battery) The battery is fitted with a control unit to deliver the positive (+) and protect the services (CBA).
Page 194 5-40 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Precautions In general it is wise to: where necessary use appropriate fuses that can be fitted near the tap; protect the added cables in special sheaths or corrugation, installing them in compliance with point 5.4.6. And in fitting the CBA it is necessary to: avoid removing fuses from their position;...
Page 195 5-41 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY The only points (2) and (3) from which current may be taken are shown in the figure. It is absolutely prohibited to take current from points that are not shown. Figure 5.35 162238 1.
Page 196 5-42 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Fuse and relay box under the dashboard Located in a special compartment, shut in a fitted drawer, it is on the left side of the dashboard. The fuse layout is shown in fig. 5.36 (the relays are not visible). Figure 5.36 162235 List of fuses under the dashboard:...
Page 197 5-43 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY List of relays under the dashboard: Table 5.11 Presence EURO5 EUROV Power Protection Capacity Type BIFUEL T01a left low beam headlight - headlight adjuster T01b right low beam headlight T11a left high beam headlight T11b right high beam headlight T12a...
Page 198 5-44 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Fuse box and relay in engine compartment Figure 5.37 162236 Electrical system: modifications and drawing-off power Base - 02/2012 Printed 603.95.241...
Page 199 5-45 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY SCM fuse list: Table 5.12 Presence EURO5 EUROV Power Protection Capacity Type BIFUEL air suspensions ignition switch cab climate control fans and engine coolant supplementary heater braking system (valves) air suspensions SCM1/A - SCM1/B - SCM2 power supply T7 relay (30-87) for power discharge from ignition switch T8 relay (30-87) for fuel pump...
Page 200 5-46 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY SCM relay list: Table 5.13 Presence EURO5 EUROV Power Protection Capacity Type BIFUEL BOSCH cooling pump Baruffaldi coupling from trinary (CNG) side marker lamps gear Baruffaldi coupling horn power discharge from ignition switch fuel pump MAIN RELAY engine start-up prevention...
Page 201 5-47 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY SCM1/B fuse and relay list: Table 5.15 Presence EURO5 EUROV SCM1/B Power Protection Capacity Type BIFUEL T54 relay (30-87) for headlight washers AVAILABLE AVAILABLE optional 4448 for bus AVAILABLE AVAILABLE Presence EURO5 EUROV SCM1/B Power Protection Capacity...
Page 202 5-48 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Passing cables from inside the cab to outside Electric cables may be passed from outside the cab to the engine compartment through five 10 mm diameter holes stamped in the bulkhead coupling near the brake servo. Seal the cable routing point to prevent fumes passing from the engine compartment to the cabin.
Page 203 5-49 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY 5.4.6 Additional circuits They must be separate and protected from the main vehicle circuit with a suitable fuse. The cables used must be of a suitable size for their use and must be well isolated. They must be properly protected in sheaths (not in PVC) or in corrugated pipe ducting in the case of more functions (polyamide type 6 material is recommended for the corrugated pipe) and they must be correctly installed, away from impacts and heat sources.
Page 204 AILY Precautions Incorrect installation of electrical accessories may affect occupant safety and cause severe damage to the vehicle. Contact IVECO if you have any questions. Avoid coupling with signal transmission cables (e.g. ABS), for which a preferential path has been defined for electromagnetic requirements (EMI).
Page 205 If it is necessary to make changes to the system other than those described in this manual (e.g. inclusion of LED lights), the operation must be carried out in conjunction with Iveco. a) Trailer connector added by the Bodybuilder If the vehicle is not ordered with a trailer point, a set may be ordered from parts.
Page 206 1. To be connected to the chassis cable - 2. 13 pin socket for trailer For more details on connections and assembling, ask IVECO for the wiring diagrams. Any damage to the lighting system caused by the failure to comply with the above procedure shall not be covered by the warranty.
Page 207 5-53 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY b) Factory-installed trailer connector (optional item 06520) If the vehicle is ordered complete with the trailer connector, the full circuit will be delivered, which is made up of the electronic control unit (already fitted into place), the set chassis cable and the 13-pole connector. Figure 5.43 13-pole connector Rear lights...
Page 208 The external Bodybuilders shall take care to make the connections and install the lights on the respective added structures (boxes, vans, etc.). To ensure the electrical properties of the female connector contacts remain unchanged over time, leave the cap provided by IVECO in place.
Page 209 As regards the vehicles on which the side dimmers are not compulsorily required, the respective connectors are in any case available. In the event that the side dimmers need be installed, the vehicle shall be delivered to an IVECO service centre, in order to have the body computer enabled.
Page 210 5-56 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.46 Yellow button for resetting disconnector Disconnector Indicator: RED - disconnector open CLEAR (off) - disconnector closed 120375 Circuit breaker reset button and relative indicator on battery control unit (CBA) To restore the vehicle to its original conditions: press the central emergency control again;...
Page 211 5-57 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY External hazard control In some cases, activation of the direction indicators is required according to the functioning of the version. This functionality can be managed by supplying an unstable negative signal (via a button) to pin AD09 of connector D (see fig. 5.47) on the Body Computer.
Page 212 5-58 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Electrical system: modifications and drawing-off power Base - 02/2012 Printed 603.95.241...
Page 213 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Index APPENDIX A Daily PASSENGER TRANSPORT Page Chassis A.1.1 Transport A.1.2 Lifting for transportation by ship, rail etc. A.1.3 Delivery A.1.4 Storage A.1.5 Weights and weighing General rules for fixing the bodywork to the chassis Building the bodywork A.3.1 Main dimensions...
Page 214 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Index Base - 02/2012 Printed 603.95.241...
Page 215 IVECO accepts no claims subsequent to delivery that are not recorded in the specific forms signed by the vehicle transporter. The vehicle identification number must be quoted in any claims: this number may be found on the core of the right side-member, in the wheel arch near the suspension.
Page 216 The structure of the bodywork must be designed as a load-bearing unit together with the chassis; bending, torsional and thrust stresses must be absorbed by the entire structure. This is necessary due to the relative flexibility of the chassis. For further information, contact IVECO Quality Department. Fittings may be fixed to bodywork by welding or using screws.
Page 217 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Building the bodywork Building the bodywork This chapter provides instructions for assembling the bodywork, with the main technical aspects and regulations. The definition of the bodywork is left to the Bodybuilder’s decisions, according to requirements. A.3.1 Main dimensions For all vehicles, the entry and exit angles must be greater than or equal to 7˚.
Page 218 Seat supporting structures, and their fixing Changing the seat positioning or creating special solutions (e.g. wheelchair transport) is possible subject to IVECO authorisation. Direct anchoring of seats to the floor or the wheel arches is not permitted and as such a specific structure (framework) must be provided for to distribute the load across the whole floor surface.
Page 219 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Figure A.2 173265 Diagram for installing fixed seat (see drawing 504208108) Building the bodywork Printed 603.95.241 Base - 02/2012...
Page 220 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Figure A.3 Guide fixing section 173266 Diagram for installing seats on guides (see drawing 504208109) Building the bodywork Base - 02/2012 Printed 603.95.241...
Page 221 APPENDIX A - DAILY PASSENGER TRANSPORT AILY A.3.6 Rear baggage compartment The baggage compartment volume depends on the maximum weight technically permissible for the vehicle and its axles; the size and position must be validated by structural tests and calculations. A.3.7 Side access door Creation of the door frame must guarantee that the structure in the area of the frame itself be non-deformable.
Page 222 A-10 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Noise emissions and thermal insulation Noise emissions and thermal insulation The Bodybuilder must ensure that the finished vehicle complies with the recommendations relating to noise emissions, specific for each case, and is also obliged to have the vehicle approved/reapproved, if necessary. A.4.1 External noise According to Directive 2007/34/EC, noise emissions for Daily ”People Carrier”...
Page 223 A-11 APPENDIX A - DAILY PASSENGER TRANSPORT AILY A.4.3 Soundproofing insulation In order to achieve good insulation, care must be taken to ensure installation of the soundproofing materials is as continuous as possible, avoiding any interruptions; it is very important that the communicating hatchways between the passenger compartment and the engine compartment, gearbox, rear axle etc., be well sealed.
Page 224 It is recommended that IVECO be informed of the results obtained and consultancy be sought regarding any modifications for fine tuning.
Page 225 A-13 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Electrical power draw---off Electrical power draw-off A.5.1 People transport version CBA The CBA distribution and protection control unit for passenger transport versions is fitted with a disconnector to turn off loads in emergencies. Figure A.5 119378 Table A.2...
Page 226 A-14 APPENDIX A - DAILY PASSENGER TRANSPORT AILY After disconnecting the loads, to restore the vehicle to its original conditions: press the central emergency control again; open the bonnet and press the yellow button on the CBA to reset to the disconnector; Turn the key to STOP;...
Page 227 A-15 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Table A.4 - Basic functions of the 12 pin connector for People Transport Description Signal Remarks A repeater led may be supplied with an Hazard warning light Output intermittent positive signal, in time with the repetition max.
Page 228 A-16 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Road tests Road tests a) The following checks must be performed, with the vehicle stationary, prior to beginning functional testing: • tyre pressure; • oil level in the engine, gearbox and axle, brakes and steering, water in the cooling tank, state of the batteries and level of battery fluid;...
Page 229 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Index APPENDIX B Daily CNG and CNG with Recovery Mode Page General information Safety rules B.2.1 During refuelling B.2.2 In the event of leaks B.2.3 In case of fire Operations on the system B.3.1 General warnings...
Page 230 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Index Base - 02/2012 Printed 603.95.241...
Page 231 Natural gas is compressed in cylinders for transport and use on the vehicle; hence its name of CNG, Compressed Natural Gas. In the Daily vehicle range, CNG and CNG with Recovery Mode positions represent IVECO’s contribution to a transport system that is as eco-friendly as possible.
Page 232 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Safety rules Safety rules B.2.1 During refuelling • The gas is usually compressed to 200 bar during refuelling. Small amounts of natural gas may be released during this operation. The cooling that follows its rapid decompression may cause frostbite symptoms if it comes into contact with the skin.
Page 233 After valve replacement or any repair to the high pressure system, a HYDRAULIC LEAK TEST (300 bar) must be carried out by an IVECO DEALERSHIP able to issue a test certificate if the outcome is positive.
Page 234 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.3.3 Tightening torques TORQUE PART Methane gas system 24 ÷ 26 2.4 ÷ 2.6 High-pressure hose connection (M12x1) to refuelling filler (Italy) - Figure B.2 33 ÷ 37 3.3 ÷ 3.7 High-pressure hose connection (M12x1) to refuelling filler (CEE) - Figure B.2 33 ÷...
Page 235 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.3.4 Parts list Medium-pressure gas line Figure B.1 117679 1. Tublex-product code - Manufacturing date - Lot. The gas hose connecting the reducer to the rail is a flexible AISI 321 stainless steel helical structure, internal diameter of 6.5 mm, protected by a AISI 304 stainless steel braid in turn coated when a shrink-wrap sheath and AISI 303 stainless steel fittings.
Page 236 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY VBE solenoid valve connection lines The VBE solenoid connection pipes are in AISI 304 steel without welded joints, with outer diameter of 6 mm and bore of 4 mm. Fittings Figure B.3 117681...
Page 237 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Figure B.4 117682 ADJUSTABLE ”T”-FITTING Front tipped, AISI 3 16 TJ stainless steel Figure B.5 117683 INTERMEDIATE ”T”-FITTING AISI 316 TJ stainless steel front tipped fitting. Figure B.6 117714 STAIGHT FITTING AISI 316 TJ stainless steel front tipped fitting.
Page 238 B-10 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.3.5 Emptying the gas system Before performing significant operations (such as welding) or servicing the engine, the gas circuit must be completely ventilated with air. It is usually sufficient to partially empty the system (i.e. to empty the pipes and leaving the cylinders as are) but the entire system (pipes and cylinders) may need to be emptied in some cases.
Page 239 B-11 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Partial emptying procedure Figure B.7 117659 1. Pressure reducer - 2. High-pressure gas pipe - 3. Cylinder - 4. VBE solenoid valve - 5. Manual valve A. Open valve - C. Closed valve. This operation only ensures ventilation of the system downstream of the cylinders.
Page 240 B-12 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Removing solenoid mobile equipment and/or cylinder replacement Figure B.8 117660 • Disconnect the electrical connection from the coil. • Unscrew the outer nut of coil (1) with its O-Ring (2). Figure B.9 117661 •...
Page 241 B-13 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Figure B.11 87391 • Remove the piston (5) with shutter (4) and the spring (2) from the coil holder sleeve (1) being very careful not to misplace the pin (3) fastening the shutter to the piston.
Page 242 B-14 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Introduction to solenoid valve plunger Remove the empty coil sleeve (1) with the o-ring. Figure B.12 87391 • Insert the piston (5) in the shutter (4) and lock it with the pin (3). •...
Page 243 B-15 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Figure B.14 117663 • Check that coil (4) does not present signs of damage. Replace the coil if necessary. • Fit the washer (4, Figure B.10) and the coil (4, Figure B.14) on the sleeve (1, Figure B.10). •...
Page 244 B-16 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Figure B.16 117665 • Loosen the fittings (1 and 7) and disconnect the pipes (2 and 6) from the VBE valve fittings (3). Disconnect the electrical connec- tion (5) from the coil (4). Figure B.17 117666 •...
Page 245 B-17 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.3.7 Repair interventions on fittings and pipes If gas leaks occur from the pipe or fittings, replace the pipe assembly. The pipe is not provided with the fittings and these must be obtained separately.
Page 246 B-18 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Cylinders Cylinders Figure B.19 117674 1. Cylinder - 2. Solenoid valve. The methane (CNG) is stored in compressed form at a pressure of 200 bars in a certain number of cylinders positioned in the chassis and protected by metal guards.
Page 247 B-19 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.4.1 Periodic overhauling In accordance with the ECE/ONU R110 regulation, gas cylinders for automotive use must be checked AT LEAST EVERY 48 MONTHS from the date of initial registration, unless otherwise specified. Said overhauling must be carried out by an authorised body which is recognised by the regulating Authority.
Page 248 B-20 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.4.2 Cylinder replacement Removal Before disconnecting the cylinders, empty the system completely following the procedure described in the ”Emptying the gas system” chapter. Figure B.20 117664 • Remove the screws (2) and remove the cover (1). Figure B.21 117715 •...
Page 249 B-21 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Fuses and relays Fuses and relays B.5.1 Fuse box and CNG relay under dashboard See specific section 5.4. Fuses and relays Printed 603.95.241 Base - 02/2012...
Page 250 B-22 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Bodybuilder connectors Bodybuilder connectors NOTE For information on Bodybuilders’ connectors, see Section 5 - Paragraph 5.2. Bodybuilder connectors Base - 02/2012 Printed 603.95.241...
Page 251 B-23 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Power Take Off Power Take Off The PTO engagement and disengagement procedures are analogous to those described in Section 4 for diesel engine vehicles, except for the need (during engagement) to run the engine at 1200 rpm prior to pressing the button in Figure 4.6 on the PTO control panel.
Page 252 B-24 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Power Take Off Base - 02/2012 Printed 603.95.241...

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