Iveco DAILY 4x4 Instructions Manual
  1. Manuals
  2. Brands
  3. Iveco Manuals
  4. Scooter
  5. DAILY 4x4
  6. Instructions manual

Iveco DAILY 4x4 Instructions Manual

Hide thumbs Also See for DAILY 4x4:
Table of Contents

Advertisement

Quick Links

D
V
4
4
AILY
EHICLE
X
R
ANGE
B
ODYBUILDER
INSTRUCTIONS
I
SSUE 2007

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DAILY 4x4 and is the answer not in the manual?

Questions and answers

Related Manuals for Iveco DAILY 4x4

Summary of Contents for Iveco DAILY 4x4

  • Page 1 AILY EHICLE ANGE ODYBUILDER INSTRUCTIONS SSUE 2007...
  • Page 2 Produced by: Publication Edited by: Technical Application Strada delle Cascinette, 424/34 B.U. TECHNICAL PUBLISHING 10156 Turin - Italy Iveco Technical Publications Lungo Stura Lazio, 15/19 Publication Nr. 603.93.761 - 1 Edition 10156 Turin - Italy Printed in Italy - 05.07...
  • Page 3 AILY Bodybuilders instructions Print 603.93.761 - 1 edition Base - May 2007 UPDATE DATA Section Description Page Revision date Update data Print 603.93.761 Base - May 2007...
  • Page 4 Update data Base - May 2007 Print 603.93.761...
  • Page 5 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 - ehicle type Section title page number Basic edition - Print Chapter title month year number Foreword Base - May 2007 Print 603.93.761...
  • Page 7 INDEX OF SECTION Section General specifications Chassis modifications Fitting superstructures Power Take-offs Specific information and instructions Index of section Print 603.93.761 Base - May 2007...
  • Page 8 Index of section Base - May 2007 Print 603.93.761...

  • Page 9: Table Of Contents

    Aim of bodybuilders instructions IVECO approval for changes and fittings Liabilities Guarantees Request for approval IVECO technical documents available by means of computer Trademarks and Logos Legal Provisions Prevention of accidents 1.10 Choice of material to use: Ecology - Recycling 1.11...
  • Page 10 GENERAL SPECIFICATIONS AILY Index Base - May 2007 Print 603.93.761...

  • Page 11: Aim Of Bodybuilders Instructions

    Changes must be carried out in accordance with the requirements set out in the following guidelines. The following may be carried out only with IVECO’s approval after submitting a copy of the documentation required for technical evaluation of the proposed change (drawings, calculations, technical report etc.): wheelbase modifications, whereby the value of the newly obtained wheelbase does not fall within the minimum and maximum values available within the IVECO range for the same vehicle;...

  • Page 12: Request For Approval

    The bodybuilder must arrange to carry out operations at least in an equivalent manner. Request for approval The requests for approval or support to carry out work or make modifications or fittings shall be forwarded to the IVECO marke- ting offices in charge.

  • Page 13: Iveco Technical Documents Available By Means Of Computer

    Trademarks, nameplates and denominations must not be modified or displaced in relation to the original design. The appearance of the vehicle must not be changed or modified. The application of trademarks tied to the transformation or trim levels must be authorised by IVECO. They must not be applied near to the IVECO tradenames or logos.

  • Page 14: Prevention Of Accidents

    In order to comply with EC directive 2000/53 (ELVs), IVECO S.p.A. prohibits fitting parts containing lead, mercury, cadmium and hexavalent chrome to vehicles (except for the departures referred to in Attachment II of the above directive).

  • Page 15: Vehicle Delivery

    ”IVECO Pre-Delivery inspection” list (available from the IVECO network) with regard to the items affected by the work done;...

  • Page 16: Dailyx

    AILY Vehicles identification 1.12 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 17: 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. Dimensions and masses Print 603.93.761...

  • Page 18: Determining The Centre Of Gravity Of The Body And Payload

    1-10 GENERAL SPECIFICATIONS AILY 1.13.2 Determining the Centre of Gravity of the Body and Payload Positioning on the longitudinal plane To establish the location of the centre of gravity of the body and payload the following examples below may be used as guidelines. The technical documentation specific to each model (chassis cab drawing) give the positions permitted with the vehicle in its standard form.
  • Page 19 1-11 GENERAL SPECIFICATIONS AILY In order to determine the payload on the axles, it must be uniformly distributed except when the shape of the loading surface itself entails a different distribution of the load. Regarding any equipment, the actual position of the centre of gravity must be used. When building bodies or containers, loading and unloading systems must be devised which preclude excessive variations in the distribution of the load and/or excessive loads on the axles.

  • Page 20: Figure 1.4

    1-12 GENERAL SPECIFICATIONS AILY Height of the centre of gravity The height of the centre of gravity of the chassis cab is given in the technical documentation specific to each model (chassis drawing). For testing the vehicle complete with superstructure, the bodybuilder must check that the height of the centre of gravity of the equipment including the payload, or of the entire vehicle when fully loaded, falls within the maximum permitted values.

  • Page 21: General Specifications

    Observing the Permitted Weights All the limits specified on the IVECO documents must be complied with. 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 22: Instructions For The Correct Functioning Of The Parts Of The Vehicle And Accessibility For Maintenance

    1-14 GENERAL SPECIFICATIONS AILY Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance 1.14 Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance As a rule, when modifying or installing any type of equipment, nothing must be altered which prevents the correct functioning of assemblies and parts of the vehicle under all operational conditions.

  • Page 23: Quality System Management

    In addition to making the necessary checks on the outfit in keeping with customary working procedures, the bodybuilder shall perform the checks specified in the “IVECO pre-delivery inspection” list, which can be obtained from the IVECO network, for the aspects affected by the modifications performed.
  • Page 24 1-16 GENERAL SPECIFICATIONS AILY Convention 1.17 Conventions In these bodybuilders instructions, the wheelbase is taken as the distance between the centreline of the first steering axle and the centreline of the first rear axle (driven or non-driven). This definition differs from the definition of wheelbase in the CE Directives. The rear overhang is taken as the distance between centreline of the last axle and the rear end of the chassis runner.
  • Page 25 CHASSIS MODIFICATIONS AILY Index SECTION 2 Chassis modifications Page General instructions for chassis modifications 2.1.1 Specific Precautions Protection against Rust and Painting 2.2.1 Original components 2.2.2 Added or modified painted parts 2-10 2.2.3 Precautions 2-11 2.2.4 Exceeding the Limits 2-12 Drilling the Chassis 2-13 2.3.1...
  • Page 26 CHASSIS MODIFICATIONS AILY Page 2.8.2 Determining Driveshaft Positions 2-27 Modifications of the engine air intake and exhaust system 2-29 2.9.1 Intake 2-29 2.9.2 Engine exhaust 2-29 2.10 Modification of the Engine Cooling System 2-30 2.11 Work on the Suspension 2-31 2.11.1 General Specifications 2-31...
  • Page 27 CHASSIS MODIFICATIONS AILY Page 2.18 Retarder Installation 2-82 2.19 Modifications to the Rear Underrun 2-82 2.20 Rear mudguards and wheel boxes 2-83 2.21 Mudflaps 2-83 2.22 Side Guards 2-83 2.23 Chocks 2-85 Index Print 603.93.761 Base - May 2007...
  • Page 28 CHASSIS MODIFICATIONS AILY Index Base - May 2007 Print 603.93.761...

  • Page 29: General Instructions For Chassis Modifications

    CHASSIS MODIFICATIONS AILY 2222.2 General instructions for chassis modifications General instructions for chassis modifications Particular attention must be given to the following points: Welding to the bearing structures of the chassis is explicitly prohibited (with the exception of the items described at points 2.3.4, 2.4 e 2.5);...
  • Page 30 Connect the earth cables within 5 minutes from the application of the paint. Do not use the IVECO standardised M1 (battery earth connection) M2, M8 (earth connection for starter motor depending on the driving position) points for the earth connections for control switches (e.g. sensors or low absorption devices): See IVECO Work- shop manuals.

  • Page 31: Protection Against Rust And Painting

    AILY Protection against Rust and Painting Protection against Rust and Painting NOTE All components installed on chassis must be painted as per Sta Iveco 18-1600 Colour IC444RAL 7021 brightness 70/80 shore. 2.2.1 Original components In Table 2.1 details the operations for protecting and painting the components of the original vehicle (Table 2.3 for painted parts, Table 2.2 for non-painted or aluminium parts).
  • Page 32 CHASSIS MODIFICATIONS AILY Table 2.2 - Various unpainted and aluminium parts and components - STD 18 - 1600 (Schedule IV) Class IVECO IVECO Type of protection Type of protection standard B - B1 - B2 Stainless steel ¡ 18-0506 DAC 320-8...
  • Page 33 CHASSIS MODIFICATIONS AILY Table 2.3 - Painted parts - STD 18 - 1600 (Schedule III) Classes Description of the cycle phase Description of the cycle phase B § B1 ¤ Sanding/sandblasting MECHANICAL CLEANING MECHANICAL CLEANING yes L yes L yes L yes L Brushing SUPERFICIAL ¡...

  • Page 34: Added Or Modified Painted Parts

    Table 2.4 (painted) and Table 2.5 (unpainted) show the minimum treatments required for modified or added components when it is not possible to provide the same protection as that used on IVECO original components. Different treatments are allowed on condition that the same level of protection against rust and corrosion is guaranteed.
  • Page 35 2-11 CHASSIS MODIFICATIONS AILY 2.2.3 Precautions Suitable precautions must be taken to protect those parts whose preservation and operation could be damaged by paints such rubber or plastic pipes for the air and hydraulic installations; gaskets, parts in rubber or plastic; flanges of the transmission shafts or power take-offs;...

  • Page 36: Exceeding The Limits

    2-12 CHASSIS MODIFICATIONS AILY 2.2.4 Exceeding the Limits In case of special transport with considerable high centre of gravity (e.g. special body versions, advertising vehicles, etc.), from a technical point the values shown in the table may be exceeded, provided the vehicle is driven carefully (e.g. low speed, gradual running direction changes, etc.).

  • Page 37: Drilling The Chassis

    When auxiliary units or components are to be applied to the frame, existing factory-made holes must be used and the following instructions must be applied. Positioning and sizes If it is necessary to make holes in the frame, it is compulsory to ask IVECO for authorisation. 2.3.1 Screws and nuts In general, use connectors of the same type and class as those for similar fixings on the original vehicle (Table 2.7).

  • Page 38: Stresses On The Chassis

    Permitted static stress on the chassis (N/mm Off-road use Daily 4x4 When prescribed by national regulations, the bodybuilder must check that the stress limits are not exceeded. Welding activity will cause a deterioration in the characteristics of the material. Therefore, when checking the stresses in thermically- modified zones, consider a reduction of approx.

  • Page 39: Welding The Chassis

    (see norms EN 287). Any intervention on the system not car- ried out as per instructions provided by IVECO or carried out by unskilled staff, might severely damage the on-board systems, thus adversely affecting vehicle operation safety and efficiency and causing dam- ages not covered by guarantee contract.

  • Page 40: Closing Of Existing Holes

    2-16 CHASSIS MODIFICATIONS AILY b) On the inner side of the side member give the parts that are to be joined a V-shaped chamfer of 60° along the entire length to be welded (see Figure 2.3). Figure 2.3 91447 c) Arc weld in stretches using carefully dried basic electrodes. The recommended electrodes are: For S 500 MC (FeE490: QStE 500TM) Diameter of the electrode is 2.5 mm, current intensity approx.

  • Page 41: Modifying The Wheelbase

    Modifying the Wheelbase Modifying the Wheelbase 2.4.1 General Specifications It is only possible to alter the wheelbase after obtaining specific approval from IVECO. 2.4.2 Authorisation Provided the chassis converter gives sufficient guarantees from the technological and control point of view (qualified personnel, adequate operating processes, etc.).

  • Page 42: Modifying The Rear Overhang

    Without prior authorisation, the installation of a tow-hook is permissible only on those cross members which are intended for that use and on those vehicles which IVECO has intended for towing a trailer. The subsequent installation of a tow hook in vehicles for which the installation of a tow hook was not originally contemplated, must be authorised by IVECO.

  • Page 43: Traditional Towing Hooks

    IVECO provides for a towing hook to be installed. The installation of a towing hook on vehicles which IVECO does not provide a towing hook installation then authorisation from IVECO must be obtained before any installation is carried out.
  • Page 44 2-20 CHASSIS MODIFICATIONS AILY Towhook for mid-axled trailers The use of central axle trailers implies the use of tow hooks suitable for this purpose. The values of the trailer loads and of the permissible vertical loads are contained in the technical documentation of the manufacturer of the tow hook or on the production data plate (e.g.
  • Page 45 On vehicles for which towing of a trailer is permitted and in accordance with values laid down by IVECO for each model, towable weights with mid-axled trailers and vertical loads on the drawbar may be defined on the basis of the size of the drilling flange present on the vehicle rear beam (see Table 2.11).

  • Page 46: Hook Types

    Pin hooks (automatic) These are to be fitted on the truck version, subject to using a suitable cross member. Unless supplied directly by IVECO, they will both need to have type approval in compliance with current standards. They must be installed according to the instructions provided by the respective manufacturers.
  • Page 47 1.13.3. Increasing the Towable Mass For those vehicles which IVECO regards as suitable for towing a trailer, a request may be submitted to evaluate the possibility of authorising a towable mass exceeding that which is normally permitted.

  • Page 48: Installing A Supplementary Axle

    This rule must also be applied when any modifications to the suspension and rear drive axle is made. An all cases, contact IVECO and send them a diagram showing lengths and angles of the new proposed suspension for the necessary authorisation.
  • Page 49 2-25 CHASSIS MODIFICATIONS AILY As far as sliding shafts are concerned, length”LG” is measured between the universal joint centres, with the sliding stub in the intermediate position. Always check both sections LG and LZ. The maximum working revs can be obtained using the formula below: = maximum number of transmission shaft revs (r.p.m.) = maximum number of engine revs (r.p.m.), refer to Table 2.12 = gearbox ratio in the fastest gear, refer to Table 2.13...
  • Page 50 2-26 CHASSIS MODIFICATIONS AILY The greater thickness of the tube depends on the class, i.e. on the torque that the original shaft has to transmit and on the design of the driveline (torque, ratios of kinematic chain, power axle load). A reference value for the thickness of the tube of a general validity cannot be given.

  • Page 51: Determining Driveshaft Positions

    It is absolutely forbidden to move the transfer box. The elastic supports must be fitted with supporting plates at least 5 mm thick (see Figure 2.10) joined to cross members with similar specifications to the IVECO specifications. Figure 2.10 102426 1.
  • Page 52 2-28 CHASSIS MODIFICATIONS AILY The use of original drive line from IVECO is recommended for these modifications. Should this not be possible however, hardened steel tubes with a yield point of not less than 420 N/mm (42 kg/mm ) may be used.

  • Page 53: Modifications Of The Engine Air Intake And Exhaust System

    2.9.1 Intake The specifications of the engine air intake and exhaust systems must not be altered without authorisation by Iveco. Operations carried out should not alter the vacuum levels (for the intake) and the original counterpressure levels (for the exhaust).

  • Page 54: Modification Of The Engine Cooling System

    2-30 CHASSIS MODIFICATIONS AILY Modification of the Engine Cooling System 2.10 Modification of the Engine Cooling System The proper functioning of the original system, especially in connection with the radiator, the free surface of the radiator and hoses (dimensions and layout) must not be tampered with. In any case, whenever modifications must be made that entail work on the engine cooling system (e.g., modifications to the cab), the following points must be considered: the useful area for the passage of air for the cooling of the radiator must not be less than that which is available on vehicles with the standard cab.

  • Page 55: Work On The Suspension

    If the modification of the specifications of the rear spring does not require changing loads on both axles and total weight, the brake load apportioning valve must be adjusted by an IVECO dealer. So as not to alter the vehicle’s braking capacity, it is necessary to observe the ground load / brake pressure ratio (under various load conditions) given on the rating plate of the brake load apportioning valve.

  • Page 56: Heating/Air Conditioning System Modifications

    IVECO. For vehicles on which IVECO has not anticipated the use of supplementary heaters, the installation should be carried out in com- pliance with the supplier’s instructions (i.e. heater arrangement, piping, electrical system etc.) and following the directions given below.

  • Page 57: Installing An Air-Conditioning System

    (see point 2.16.3). Provide the new circuitry with a protection fuse; in liaison with IVECO, establish a method for installing the compressor; if it is fitted to the engine, use the original IVECO com- pressor;...

  • Page 58: Cab Modifications

    2.13.1 General Specifications Any work on the driver’s cab must be authorised previously by IVECO. Modifications must not prevent operation of the control devices located in the area affected by the modifications (e.g. pedals, linkages, switches, pipes etc) or alter the strength of the load- bearing elements (uprights, reinforcement sections etc.). Due care must be taken when carrying out work that may affect the cooling system and air inlet pipes of the engine.

  • Page 59: Roof Panel Modifications

    Fitting a spoiler The various versions designed by IVECO can be obtained from the local IVECO dealership with relevant instructions for installation. It is recommended that these versions are used as they are specifically checked.
  • Page 60 2-36 CHASSIS MODIFICATIONS AILY Figure 2.11 Section A-A Section B-B Section C-C 1. Roof panel - 2. Limit cutting area - 3. Roof panel side covering - 4. Doorway ring - 5. Internal rear crosspiece - 6. Rear wall - 7. Doorway rear covering - 8. Side covering Cab Modifications Base - May 2007 Print 603.93.761...

  • Page 61: Occupant Protection

    The seats have been fixed to the floor structure in compliance with legal requirements on locking systems. Moving or fitting additional seats requires making suitable fixing areas in the structure under the floor, similar to the IVECO installation, in order to ensure compliance with the legal requirements.

  • Page 62: Changing The Size Of The Tyres

    Replacing the tyres with others of different sizes or with a different loading capacity with respect to those considered at the time of vehicle type-approval must be approved by IVECO and it is also necessary to check for the need to reprogram the EBL or EBS system.

  • Page 63: Modifications To The Braking System

    Any modification to the braking system requires authorisation from IVECO. It is recommended that when new units are fitted they should be the same makes as those fitted to the original vehicle.

  • Page 64: Fitting Pipes On The Vehicle

    2-40 CHASSIS MODIFICATIONS AILY 2.15.3 Fitting pipes on the vehicle New pipes must be thoroughly cleaned inside before use (e.g. by blowing through with compressed air). Pipes shall be secured into their correct positions and the fasteners must fully wrap the pipes: they may be made either of metal, with rubber/plastic protections, or plastic.
  • Page 65 2-41 CHASSIS MODIFICATIONS AILY Manually bleeding air from the hydraulic brake system There is one bleed screw on each brake calliper. Carefully repeat the following operations on each of the callipers (the following sequence must be used - rear right, rear left, front left, front right): check the brake fluid level in the reservoir on the power brake, top up to the maximum level;...
  • Page 66 2-42 CHASSIS MODIFICATIONS AILY Bleed air from the hydraulic braking system using MODUS or E.A.SY. on vehicles with ABS/ABD/EBD On vehicles equipped with ABS/ABD/EBD systems, the traditional, manual bleeding operation described above may not be sufficient. The presence of air causes the brake pedal stroke to be longer, with possible uncharacteristic operation of the system. Manual operations must be carried out, which will be driven by the program in ”MODUS”or “E.A.SY.”.

  • Page 67: Instructions For Adjusting The Braking Load Proportioning Valve

    2-43 CHASSIS MODIFICATIONS AILY 2.15.4 Instructions for adjusting the braking load proportioning valve Load proportioning valve version Two types of load proportioning valve are used: with torsion bar - pushrod for vehicles without ABS and with spring for vehicles with ABS. The former are single circuit while the latter are double crossover circuit.
  • Page 68 2-44 CHASSIS MODIFICATIONS AILY Figure 2.14 119381 1. Control link - 2. Load proportioning valve - 3. Torsion bar Load the rear axle to the values shown in Table 2.16. The weight must not be less than the minimum value indicated by the manufacturer (Figure 2.16).
  • Page 69 2-45 CHASSIS MODIFICATIONS AILY Figure 2.15 (Demonstration) 45025 Connect pressure gauge (3) to the pressure point upstream of the load proportioning valve. Connect pressure gauge (2) to the pressure point downstream of the load proportioning valve. If the pressure gauges are not equipped with automatic bleed valves, bleed them manually by means of the rings on the pressure gauges.
  • Page 70 Loosen the clamping screw 8 of the proportioning valve adjustment lever 7. Apply adjustment load specific to each model to hole 9, after loading the engine axle to the specified reference value. Check the IVECO workshop manuals for the required values. Figure 2.17...
  • Page 71 2-47 CHASSIS MODIFICATIONS AILY Figure 2.18 119383 An example of a load apportioning plate for a 55S18W vehicle Changing the Size of the Tyres Print 603.93.761 Base - May 2007...

  • Page 72: 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. short-circuiting with the risk of fire and destruction of the vehicle) that is not covered by warranty.
  • Page 73 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. Engine starting Never start the vehicle by towing.

  • Page 74: Earth Points

    The battery must in any case by recharged subsequently by disconnecting form the circuit using the correct slow, low current recharging procedure. Do not use other devices (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 75 2-51 CHASSIS MODIFICATIONS AILY Figure 2.20 m6+ms6 m3+ms3 m7+ms7 120364 m = power grounds ms = signal grounds GROUND POINTS AVAILABLE ON THE VEHICLE m2. left chassis side member engine compartment ground - m3+ms3. engine compartment ground under the power brake m4.

  • Page 76: Figure 2.22

    2-52 CHASSIS MODIFICATIONS AILY Figure 2.22 119372 m3 + ms3. Engine compartment earth beneath brake servo Figure 2.23 119373 m4. Engine compartment earth near right front light Electrical System: Modifications and Drawing-Off Power Base - May 2007 Print 603.93.761...

  • Page 77: M7+Ms7

    2-53 CHASSIS MODIFICATIONS AILY Figure 2.24 119374 m5. Engine compartment earth near left front light Figure 2.25 Figure 2.26 114176 114177 m7 + ms7 m6 + ms6 m7 + ms7. Left side cab interior earth on m6 + ms6. Right side cab interior earth on dashboard carrier dashboard carrier Electrical System: Modifications and Drawing-Off Power...
  • Page 78 2-54 CHASSIS MODIFICATIONS AILY Figure 2.27 120382 m8. Earth on frame behind cab Figure 2.28 120383 m9. Earth on left rear crossmember Electrical System: Modifications and Drawing-Off Power Base - May 2007 Print 603.93.761...
  • Page 79 2-55 CHASSIS MODIFICATIONS AILY The negative leads connected to a system ground point shall be as short as possible and connected with one another according to a ”Y” or ”X” arrangements. Therefore, they shall be tightened as orderly and properly as possible. 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 80: Electromagnetic Compatibility

    Use electrical/electronic equipment in compliance with the EC Directives on electromagnetic compability, i.e use suitable compo- nents for vehicle applications ”e.” marked (the EC marking is not sufficient). If in any doubt, call the IVECO Service Network. Electrical System: Modifications and Drawing-Off Power Base - May 2007 Print 603.93.761...
  • Page 81 ≥ 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 interna- tional regulations. In case of systems which use the primary or secondary civil electric network (220V AC) as a supply source, the relevant characteristics have to comply with the IEC regulations.
  • Page 82 2-58 CHASSIS MODIFICATIONS AILY Amateur equipment for CB and 2m band. The installation of CB (27 MHz) and 2m (144 MHz) sets must use the power system provided on the vehicle. The connection is made to terminal 30 of connector ST40. The systems must be legally type-approved and fixed (not portable).
  • Page 83 2-59 CHASSIS MODIFICATIONS AILY Use existing holes for routing the cable. Take all the necessary precautions for protecting the body if additional hole have to be drilled (use anti-rust paint, sheath, etc.). Ensure a good connection with the vehicle earth both at the base of the antenna and at the device fixing to ensure maximum power transfer.
  • Page 84 2-60 CHASSIS MODIFICATIONS AILY Figure 2.33 119358 1. Location of the CB transceiver unit (City Band) Two-way systems for GSM/PCS/UMTS mobile phones Cellular telephone systems must be installed using the power system provided in the vehicle. Connect to terminal 30 via a supple- mentary fuse.
  • Page 85 2-61 CHASSIS MODIFICATIONS AILY Follow the precautions below when connecting and arranging the wires: Use a top quality cable particularly as concerned to the protective shielding. The cable route must be at a suitable distance (minimum 50 mm) from pre-existing wiring. Ensure the minimum distance from the metallic structure of the cab.
  • Page 86 The radio comes in two configurations: Radio with CD player Radio with CD+MP3 player The IVECO radio is built into the system on the CAN network and allows: Message repetition to comfort control panel Volume adjustment according to vehicle speed...

  • Page 87: 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 capa- cities are required, use additional batteries making the necessary arrangements for recharging as described below.
  • Page 88 2-64 CHASSIS MODIFICATIONS AILY Supplementary batteries The addition of an auxiliary battery to the vehicle circuit shall provide for a separate recharging system, which shall be integrated with the vehicle one. In this case, auxiliary batteries with the same capacity as the original ones (110 Ah) should be provided, to ensure correct recharging of all the batteries.
  • Page 89 The auxiliary alternator shall feature the same characteristics as the standard one, and the cables shall be properly dimensioned. In the event that modifications other than the ones described in this manual need be made to the system (e.g. adding several batteries in parallel), the operation shall be carried out together with the IVECO experts. Figure 2.35...

  • Page 90: Current Drawing

    2-66 CHASSIS MODIFICATIONS AILY 2.16.4 Current drawing Precautions: The points where current can be drawn and the instructions to be followed are described below. Protection fuses MUST be used and fitted next to the point where the power is taken. The added cables shall be protected by running them inside special sheathes or corrugated pipes.
  • Page 91 2-67 CHASSIS MODIFICATIONS AILY A distribution and protection control unit ( CBA) is installed on the battery. This is fitted with a power take-off for body builders. The body builders’ node is installed on stud no. 6 of the CBA. Figure 2.38 BATTERY BATTERY...
  • Page 92 2-68 CHASSIS MODIFICATIONS AILY Fuse and relay box under the dashboard It is located in a special compartment, which can be closed by means of a snap-in drawer. Figure 2.39 114180 Only fuses of the prescribed type and rated current values shall be used - Danger of fire. The fuses shall be replaced only after the cause of their actuation is eliminated.
  • Page 93 2-69 CHASSIS MODIFICATIONS AILY Fuse and relay box in the engine compartment (CVM) Figure 2.40 114179 Table 2.20 Fuse Utilization Rated capacity Ignition spark plugs 60 A Not used 40 A Not used 30 A Not used 30 A Siren 30 A Ignition switch 30 A...
  • Page 94 2-70 CHASSIS MODIFICATIONS AILY Table 2.21 Relay Utilization Rated output Right and left high-beam headlights 20 A Warning horn 20 A Fan electromagnetic coupling power supply (Baruffaldi) 20 A Fan electromagnetic coupling power supply (Baruffaldi) 20 A Side lights 50 A Heater or air conditioner fans 20 A EDC 16 (main relay)
  • Page 95 2-71 CHASSIS MODIFICATIONS AILY Optional fuse box (engine compartment) Figure 2.41 114080 Table 2.23 Relay Drawing ref. Utilization Rated output Rotary lights 20 A Working lights 10 A Free Air conditioning compressor actuation 20 A Baruffali cut-out 20 A Power takeoff actuation enable 20 A Air conditioning compressor 20 A...
  • Page 96 2-72 CHASSIS MODIFICATIONS AILY Body builders’ connectors (cab interior) The new Daily is fitted with two connectors to be used by body builders to interface with the vehicle electrical system. Figure 2.42 The connectors are located behind the passenger side compartment in an easily accessible area.
  • Page 97 AILY Maxifuse and megafuse fuses Fuse holder are available at the IVECO shops, to protect high-absorption current drawing. They shall be positioned (as near the battery drawing terminal as possible) by the body builder depending on the space available on the vehicle.

  • Page 98: Additional Circuits

    The fuse must be connected as close as possible to the current take-off point. 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 99: Operations To Adjust Overhang

    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 body builder If the vehicle is not ordered with a trailer point, a set may be ordered from parts.
  • Page 100 - 5. Cable to be fitted onto the chassis 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 101 2-77 CHASSIS MODIFICATIONS 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 2.49 Electronic control unit 13-pole connector...

  • Page 102: Side Marker Lights

    The external body builders 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 103 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 104: Repositioning Parts And Mounting Auxiliary Assemblies And Equipment

    2-80 CHASSIS MODIFICATIONS AILY Electrical System: Modifications and Drawing---Off Power 2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment Whenever, in the course of modifying the vehicle, it should become necessary to reposition assemblies such as the fuel tank, batteries or the spare wheel, such relocation is permitted provided that the functioning of these parts is not impaired and provided that the same type of connections as originally in use are re-employed.
  • Page 105 2-81 CHASSIS MODIFICATIONS AILY Fuel tank Figure 2.52 120365 The use of fuel tanks other than the original tanks will lead to incorrect readings for fuel reserve, fuel consumption, range etc. on the control panel. The new electrical systems architecture will process the fuel gauge level signals by associating the emptying concept as for the fuel tank original fitted.
  • Page 106 2-82 CHASSIS MODIFICATIONS AILY Electrical System: Modifications and Drawing---Off Power 2.18 Retarder Installation Not applicable to the vehicle. 2.19 Modifications to the Rear Underrun Our vehicles are fitted with a rear underrun bar in accordance with EC Directives. The maximum permitted distance from the bar to the rearmost part of the body is 400 mm, deducting the distortion found during approval tests (10 mm on average).
  • Page 107 Rear mudguards and wheel boxes When vehicles are supplied without mudguards, the bodybuilder must fit them using similar installations as used by IVECO on similar vehicles. In making the mudguards, wheel arches, as well as the shape of the body, bear in mind that: Ensure the wheels can turn even in the full bump condition with snow chains fitted, in compliance with the limits shown in the documentation supplied by IVECO.
  • Page 108 2-84 CHASSIS MODIFICATIONS AILY Electrical System: Modifications and Drawing---Off Power 2.22 Side Guards In some countries national or EC regulations require that the vehicle is fitted with side guards. The Bodybuilder who finishes off the vehicle must ensure compliance with the required regulations. On permanently fitted structures such as fixed platform or box bodies etc, side guards can be fitted directly to their basic structure (floor frame, crossmembers).
  • Page 109 2-85 CHASSIS MODIFICATIONS AILY Chocks 2.23 Chocks Usually these are fitted directly at the factory. Should this not be the case, or if it is necessary to change their original position, the Bodybuilder must work out a new arrangement in compliance with local regulations. The new position must ensure reliability and safety as well as easy access for operation by the user.
  • Page 110 2-86 CHASSIS MODIFICATIONS AILY Chocks Base - May 2007 Print 603.93.761...

This manual is also suitable for:

Daily 4x4 range bodybuilder

Table of Contents

Save PDF