Iveco DAILY M.Y. 2012 Body Builder Instructions
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Iveco DAILY M.Y. 2012 Body Builder Instructions

Iveco DAILY M.Y. 2012 Body Builder Instructions

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D
M.Y. 2012
AILY
B
I
ODYBUILDERS
NSTRUCTIONS
I
SSUE 2011

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Summary of Contents for Iveco DAILY M.Y. 2012

  • Page 1 M.Y. 2012 AILY ODYBUILDERS NSTRUCTIONS SSUE 2011...
  • Page 2 IVECO S.p.A. Technical Application Strada delle Cascinette, 424/34 10156 Torino (TO) - Italy www.iveco.com Printed 603.95.241 - 1 ed. 09/2011...

  • Page 3: Update Data

    AILY Bodybuilders instructions Printed 603.95.241 - 1 Base - 09/2011 UPDATE DATA Section Paragraph Description Revision date Update data Printed 603.95.241 Base - 09/2011...
  • Page 4 Update data Base - 09/2011 Printed 603.95.241...

  • Page 5: Symbols - Warnings

    IVECO is available to provide all and every explanation required to carry out the work and also help you handle the cases not dealt with in this publication.
  • 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 - 09/2011 Printed 603.95.241...
  • Page 7 INDEX OF SECTION Section 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 - 09/2011...
  • Page 8 Index of section Base - 09/2011 Printed 603.95.241...
  • Page 9 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 4-13 4.6.2.1 Mechanical Gearbox 4-13...
  • Page 10 POWER TAKE-OFFS AILY Index Base - 09/2011 Printed 603.95.241...

  • Page 11: General Specifications

    POWER TAKE-OFFS AILY 44444. General Specifications General Specifications Different types of power takeoffs (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 12 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 13 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 14 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 15 (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 16: Power Take-Off From Transfer Box

    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 17: Power Take-Off From Engine

    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 18: Pto Management

    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 19 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. Button (4) controls tipping body lowering: this action will be simultaneous and will be cancelled when the button is released.
  • Page 20 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 21: Mechanical Gearbox

    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 22: Automatic Transmission

    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 - 09/2011 Printed 603.95.241...
  • Page 23 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 24 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 25 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 26 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Index Base - 09/2011 Printed 603.95.241...

  • Page 27: Electronic System

    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 28: Bodybuilder Connectors

    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 29 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 30 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 31 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 32 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 33 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 34: Specification

    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 35 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 36 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 37 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 38 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 39 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 40: Anti-Theft System

    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 41: Electronic Control Units

    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 42 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 43 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 44: General Information

    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 45 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 46 (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 47 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 48 5-24 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Figure 5.15 m6+ms6 140860 m = power grounds ms = signal grounds POSITION OF EARTH POINTS ON VEHICLE m2. Engine compartment ground left chassis side member - m3 + ms3. Engine compartment ground under the servo brake - m4.
  • Page 49 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 - 09/2011...
  • Page 50 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 - 09/2011 Printed 603.95.241...
  • Page 51 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 52: Electromagnetic Compatibility

    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 53 ≥ 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 54 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 55 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 56 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 57 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 58 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 59 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 60: Additional Equipment

    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 61 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 62 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 63: Current Drawing

    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 64 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 65 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 66 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 67 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 68 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 - 09/2011 Printed 603.95.241...
  • Page 69 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 70 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 71 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 72 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 73: Additional Circuits

    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 74 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 75 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 76 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 77 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 78: Side Marker Lights

    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 79 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 80 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 81 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 82 5-58 SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS AILY Electrical System: Modifications and Drawing-Off Power Base - 09/2011 Printed 603.95.241...

  • Page 83: Appendix A - Daily Passenger Transport

    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 84 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Index Base - 09/2011 Printed 603.95.241...
  • Page 85 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 86 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 87: Main Dimensions

    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 88 APPENDIX A - DAILY PASSENGER TRANSPORT AILY A.3.4 Requirements concerning the fire-proofing materials The covering materials used inside the engine compartment must be inflammable and non-absorbent for fuel and lubricants, unless said material is coated with an impermeable layer. The remainder of the materials used for the bodywork must be ”flame retarder” or self-extinguishing, depending on the number of passengers that can be transported and/or the applicable regulations in the country for which the vehicle is intended.
  • Page 89 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Figure A.2 128319 Diagram for installing fixed seat Building the bodywork Printed 603.95.241 Base - 09/2011...
  • Page 90 APPENDIX A - DAILY PASSENGER TRANSPORT AILY Figure A.3 Guide fixing section 128320 Diagram for installing seats on guides Building the bodywork Base - 09/2011 Printed 603.95.241...
  • Page 91 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 92: External Noise

    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 93: Thermal Insulation

    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 94 It is recommended that IVECO be informed of the results obtained and consultancy be sought regarding any modifications for fine tuning.
  • Page 95 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 96: Bodybuilder Connectors

    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 97 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 98 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 99: Appendix B - Daily Cng And Cng With Recovery Mode

    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 100 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Index Base - 09/2011 Printed 603.95.241...
  • Page 101 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 102: Safety Rules

    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 103: General Warnings

    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 104: Tightening Torques

    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 105: Parts List

    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 106 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 107 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 108 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 109 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 110 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 111 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 112 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 113 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 114 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 115 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 116 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 117 B-19 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY B.4.1 Cylinder scheduled overhauling according to ECE/ONU R 110 standards Methane gas cylinders for road vehicles must be inspected EVERY FOUR YEARS by competent authorities responsible for certifying their validity. NOTE The due date is shown on the cylinders and in the documents supplied with the vehicle.

  • Page 118: Cylinder Replacement

    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 119: Fuses And Relays

    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 - 09/2011...
  • Page 120 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 - 09/2011 Printed 603.95.241...

  • Page 121: Power Take-Off

    B-23 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Power takeoff Power takeoff 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 122 B-24 APPENDIX B - DAILY CNG AND CNG WITH RECOVERY MODE AILY Power takeoff Base - 09/2011 Printed 603.95.241...

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