Iveco DAILY 4x4 2020 Body Builder Instructions
  1. Manuals
  2. Brands
  3. Iveco Manuals
  4. Trucks
  5. DAILY 4x4 2020
  6. Body builder instructions

Iveco DAILY 4x4 2020 Body Builder Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

4 x 4
B O D Y B U I L D E R S
I N S T R U C T I O N S
I S S U E 0 8 - 2 0 2 0

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DAILY 4x4 2020 and is the answer not in the manual?

Questions and answers

Related Manuals for Iveco DAILY 4x4 2020

Summary of Contents for Iveco DAILY 4x4 2020

  • Page 1 4 x 4 B O D Y B U I L D E R S I N S T R U C T I O N S I S S U E 0 8 - 2 0 2 0...
  • Page 2 IVECO S.p.A “TECH PE T&H - BODY BUILDER SUPPORT” Lungo Stura Lazio, 49 10156 Torino (TO) - Italy www.iveco.com Printed 692.68.999 – 3 Ed. 08/2020 Images and text: IVECO S.p.A. 2020 All rights reserved.
  • Page 3 UPDATE DATA Section Chapter Description Revision date – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 4 Data and information contained in this publication may be outdated as a result of changes adopted by IVECO, at any time, for tech- nical or commercial reasons or due to the need to adapt the vehicle to new legal requirements.
  • Page 5 INDEX OF SECTIONS GENERAL INFORMATION CHASSIS INTERVENTIONS APPLICATIONS OF SUPERSTRUCTURES POWER TAKE-OFFS ELECTRONIC SUB-SYSTEMS ADBLUE AND SCRT SYSTEM EXPANSION MODULE Hi-MATIC AUTOMATIC GEARBOX – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 6 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 7 SECTION 1 GENERAL INFORMATION – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 8 – Printed 692.68.999 – 3 Ed. - Base 08/2020...

  • Page 9: Table Of Contents

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION Contents Contents 1.16 INSTRUCTIONS FOR PROPER FUNCTIONING OF THE VEHICLE PARTS AND ACCESSIBILITY ......1.1 SCOPE OF THE GUIDELINES .
  • Page 10 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 11: Scope Of The Guidelines

    It should be noted that the collaboration with IVECO is based on the assumption that the bodybuilder uses the maximum of their technical and organisational skills and that operations are technically and perfectly complete.

  • Page 12: Authorisation Request

    ● the implementation; ● the compliance of the design and implementation of any specific indications provided by IVECO and the laws in force in the countries where the vehicle is destined; ● effects on functionality, safety, reliability and, in general, good behaviour of the vehicle;...

  • Page 13: Guarantees

    (e.g. approval documents/test reports). Before signing the Technical Agreement IVECO reserves the right to visit the bodybuilder, in order to verify qualifications to carry out the fittings and/or processing for which the above collaboration is requested.

  • Page 14: Quality System Management

    ● post-sales assistance; ● training and qualification of staff. The availability of ISO 9001 certification, even though not required, is considered very important by IVECO.   1.10 ACCIDENT PREVENTION Do not allow unauthorised personnel to intervene or operate on the vehicle.

  • Page 15: Vehicle Management On The Part Of Bodybuilder

    12.1 V the battery should be replaced. Note The batteries must be maintained at regular intervals (refer to IVECO Std 20-1812 and/or IVECO Std 20-1804) until delivery of the vehicle to the Customer/Dealer to avoid problems of insufficient charging, short circuit or corrosion. IVECO reserves the right to nullify the guarantee on the battery if the prescribed maintenance procedures are not respected.

  • Page 16: Vehicle Names

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION 1.13 VEHICLE NAMES 1.13 VEHICLE NAMES The commercial name of vehicles (DAILY 4x4) does not match that of the type-approval, a complete example of which is provided below. Type approval name DAILY 70C18HA8 CC W ●...

  • Page 17: Identifications

    IVECO trade names or logos. In the event of cowl vehicles, the positioning of the IVECO logo on the engine bonnet must be done only after final paint spraying and must respect the measurements indicated qualitatively in the following figure.

  • Page 18: Rearview Mirrors

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION 1.15 DIMENSIONS AND GROUND 1.15.3 Rearview mirrors Depending on the width of the version, the rear visibility angles imposed by the Regulations can be respected choosing the most appropriate of the three rear-view mirrors with two arms of varying widths available in the catalogue (opt. 8644, 78318). 1.15.4 Determination of the centre of gravity of the superstructure and the payload To determine the position of the centre of gravity of the superstructure and of the payload, proceed according to the following examples.

  • Page 19: Height Of Centre Of Gravity

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION 1.15 DIMENSIONS AND GROUND   Figure 4 261810     Even distribution of load Uneven distribution of load   Figure 5 261811     Even distribution of load Uneven distribution of load (attention to loads on axles and minimum ratio) 1.15.5 Height of centre of gravity For the chassis cab version and no-load vehicle, the value of the height of the centre of gravity is shown on the specific technical...
  • Page 20 ● in considering (for liquids) the density; ● in prescribing the adoption of adequate precautions for driving. Any cases where evaluation is difficult should be submitted to IVECO for approval. – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 21: Adoption Of Stabilizer Bars

    1.15.7 Observance of the permitted masses All the limits shown on IVECO documentation must be respected. It is particularly important to evaluate the maximum ground on the front axle in any load condition, in order to ensure the necessary steering features in all road surface conditions.

  • Page 22: Variations On The Permitted Masses

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION 1.16 INSTRUCTIONS FOR PROPER FUNCTIONING OF THE VEHICLE PARTS AND ACCESSIBILITY 1.15.8 Variations on the permitted masses Special exemptions from the maximum permissible masses may be granted for specific uses, for which, however, there are precise limits for use and reinforcements to be made to parts of the vehicle.

  • Page 23: General Regulation For The Prevention Of Fire Risk

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION 1.17 GENERAL REGULATION FOR THE PREVENTION OF FIRE RISK 1.17 GENERAL REGULATION FOR THE PREVENTION OF FIRE RISK ▶ Assemblies or parts made using flammable material must never be fitted near the vehicle's ex- haust system.
  • Page 24 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS GENERAL INFORMATION – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 25 SECTION 2 CHASSIS INTERVENTIONS – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 26 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 27 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS Contents Contents 2.6.4 Observations on payload ... . 2.6.5 Increase of towable weight ... 2.1 CHASSIS MODIFICATION STANDARDS .
  • Page 28 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS Contents 2.17 PART RELOCATION AND ANCHORAGE OF ADDITIONAL UNITS AND EQUIPMENT ..2.17.1 Horn ......2.17.2 Wheel mount .

  • Page 29: Chassis Modification Standards

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.1 CHASSIS MODIFICATION STANDARDS CHASSIS INTERVENTIONS 2.1 CHASSIS MODIFICATION STANDARDS 2.1.1 General precautions Keep in mind that: ● weldings on the supporting structures of the chassis are absolutely forbidden (except as prescribed in Para- graph"Weldings" ( ➠ Page 8) and in Chapters 2.4 ( ➠ Page 14), and 2.5 ( ➠ Page 17)); ●...

  • Page 30: Characteristics Of The Material Used In Chassis Modifications

       Table 2.1 - Material to be used in chassis modifications Breaking strength Yield stress Name of steel Extending [N/mm [N/mm IVECO Fe E420 Europe S420MC Germany QStE420TM      Table 2.2 - Section dimension and chassis thickness A x B x t...

  • Page 31: Stresses On The Chassis

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.2 DRILLS ON THE CHASSIS 2.1.4 Stresses on the chassis The following stress value in static conditions cannot be exceeded for any reason whatsoever: Note Permitted static stress on the chassis: σ = 100 N/mm In any case, respect any more restrictive limits placed by national standards.

  • Page 32: Screws And Nuts

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.2 DRILLS ON THE CHASSIS 2.2.2 Screws and nuts We generally recommend the use of the same type and class of screws and nuts as those employed for similar anchorages on the original vehicle (see Table 2.3).    Table 2.3 - Screws resistance classes Breaking strength Yield stress...
  • Page 33 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.2 DRILLS ON THE CHASSIS ● if an electric circuit breaker (main switch) is present, wait for it to complete the cycle; ● disconnect the negative pole from the battery; ● disconnect the positive pole of the battery without connecting it to ground; do NOT short-circuit the negative pole; ●...

  • Page 34: Closing Holes By Welding

    Holes of 20 mm diameter can be sealed off by using chamfered washers welded on both sides.   2.3 RUST AND PAINT PROTECTION Note All components mounted on the chassis must be painted in compliance with IVECO Standard 18-1600 Colour IC444 RAL 7021 - 70/80 gloss. 2.3.1 Original vehicle components The following tables show, respectively, the classes of coating and protection required for the original vehicle components, the protections required for the parts not painted or in aluminium and treatments required for the painted parts.
  • Page 35 See Table III Coupling with other materials must not cause the "battery effect". Coatings free from chromium salts. Coatings free of hexavalent chromium.    Table 2.6 - Painted parts - IVECO Standard 18 - 1600 (Prospectus III) Classes Cycle phase description –...

  • Page 36: Added Or Modified Parts

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.3 RUST AND PAINT PROTECTION This operation must be performed when dealing with cutting burr, oxidation, weld slag, or laser-cut surfaces. Two-layer bodywork cycle. Three-layer bodywork cycle. In alternative to single and bi-component paint only for particular bodywork (windscreen wipers, rear-view mirrors, etc.). Only rear/front axles.

  • Page 37: Precautions

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.3 RUST AND PAINT PROTECTION 2.3.3 Precautions a) On the vehicle Appropriate precautions must be taken to protect parts on which paint could be harmful to the conservation and operation thereof: ● hoses for pneumatic and hydraulic systems in rubber or plastic, with particular reference to the braking system; ●...

  • Page 38: Wheelbase Modification

    "datasets" for EVSC and AEBS (see Section 5 - Chapter 5.8 - Paragraph " Safety electronic devices "). Nevertheless, IVECO must issue its authorisation for wheelbases below the minimum or maximum approved standard sizes on the market.

  • Page 39: Impact On Braking

    Quad-Tor = torsion bar ▶ If the wheelbase is to be lengthened beyond the maximum value approved, these steering solutions must be authorised by IVECO. Any type approval tests are charged fully to the Bodybuilder. 2.4.4 Impact on braking Generally speaking, shortening the wheelbase will have a negative effect on braking.

  • Page 40: Verification Of The Chassis Stresses

    - along the entire contour of the wheelbase - until achieving area strength modulus equal to IVECO values for the same wheelbase or for the next admissible greater length. In alternative, for cases allowed by local standards, larger subframe profiles can be adopted.

  • Page 41: Modifications To The Transmissions

    When modifying the rear overhang it is necessary to note the variations that this modification shall inflict on the payload distribution on the axles, in compliance with the loads established by IVECO (see Chapter 1.15 ). Limits set by national law must also be respec- ted, as well as maximum distances from the rear structural edge and distance from ground, defined for towing hook and under-run protection.

  • Page 42: Authorisation

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.5 REAR OVERHANG MODIFICATION In all cases, the parties performing the work shall be liable thereof. 2.5.2 Authorisation Rear frame elongation as well as shortening to the smallest value for each model of the series do not require authorisation if per- formed in compliance with the instructions provided herein.

  • Page 43: Installing The Tow Hook

    (chassis cross member, electrical coupling union, tow coupling, chronotachograph, etc...). However, bear in mind that fitting the chronotachograph, when necessary in relation to current legislation, must be only carried out by the IVECO Service Network. – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 44: Precautions For Installation

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.6 INSTALLING THE TOW HOOK 2.6.2 Precautions for installation The towing hook must be suited for the loads allowed and must be of a type approved by national standards. ▶ Given their importance related to safety, the drawbar couplings must not undergo modifica- tions.
  • Page 45 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.6 INSTALLING THE TOW HOOK   Figure 10 196787  1.  2. Free field for towing hooks Free field for coupling hooks according to standard DIN 74058 ESC-152 In cases where the connection flange of the drawbar coupling does not have holes suitable to those on the existing rear crossbar of the vehicle, the latter may be authorised for modification upon application of adequate reinforcements.

  • Page 46: Tow Hook For Trailers With Central Axle

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.6 INSTALLING THE TOW HOOK 2.6.3 Tow hook for trailers with central axle Centre axle trailers are defined as those that have the drawbar rigidly connected to the frame and the axle (or more close axles) placed at half the length of the same chassis.
  • Page 47 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.6 INSTALLING THE TOW HOOK Figure 11 279565 As original equipment, the DAILY 4x4 vehicles may be equipped ball, hook or mixed type tow hook, i.e. ball type with safety device. These hooks may only be installed on the rear closing cross member of the chassis.  ...

  • Page 48: Observations On Payload

    Chapter 1.15 . 2.6.5 Increase of towable weight As regards tow vehicles, IVECO may evaluate - in certain cases and for particular applications - the possibility to authorise greater tow weights than those normally allowed.

  • Page 49: Assembling An Additional Axle

    The maximum inclination X° of the rear axle casing must be less than 5° in relation to the horizontal. Note It is strictly forbidden to move the transfer box. We recommend using original IVECO drivelines; if this is not possible, the use of raw steel pipes with a yield load of at least 420 N/mm (42 kg/mm ) may be used.

  • Page 50: Modifying The Engine Air Intake And Exhaust Systems

    F1CE0489R*L 1 - 5 Note Any interventions, if authorised by IVECO, must not vary the original intake vacuum and exhaust back pressure values. 2.10.1 Intake The air intake must be mounted as to avoid intake of hot air from the engine compartment, or dust and water.

  • Page 51: Engine Exhaust (Only Euro Iii)

    (min. 150 mm) from electrical systems and plastic pipes (shorter distances progressively require plate guards, thermal insulators or the replacement of plastic pipes with steel ones). Authorisation must always be obtained from IVECO. Furthermore, modifications to the silencer body are not permitted.

  • Page 52: Modifications To The Heating/Conditioning Plant

    We recommend using IVECO type heating systems whenever it is necessary to install an additional heating system. On vehicles where IVECO does not employ these heaters, installation must be done in compliance with the instructions issued by the equipment Manufacturer (installation of heaters, pipes, electric system, etc.) and in relation to the following indications.
  • Page 53 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.12 MODIFICATIONS TO THE HEATING/CONDITIONING PLANT Figure 14 204649   1. Main heater  A. Solenoid valve (3) open   2. Optional additional heater  B. Solenoid valve (3) closed   3. Solenoid valve       4. Additional heater installed by body builder  ...

  • Page 54: Installing An Air Conditioning System

    (in shape and performance) to the standard model envisaged by IVECO; ● installation of the evaporator unit and of the bellow inside the cab (in cases where not provided directly from IVECO) must be planned as not to negatively impact control functions and access to equipment;...

  • Page 55: Bodywork Interventions

    2.13.1 General information Note All interventions on the driver's cab or on the roof must be authorised by IVECO in advance. The modifications must not hinder operation of the control devices located in the area of the modification (e.g. pedals, switches, pipes, etc.) nor alter the strength of load-bearing elements (frames, reinforcement profiles, etc.).

  • Page 56: Interventions On Chassis Cab Vehicles

    On request, versions are available developed for IVECO on the basis of its design and verifications. If "kits" of other origins are fitted, follow the specific indications supplied by the manufacturer.
  • Page 57 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.13 BODYWORK INTERVENTIONS   Figure 16 228310   1. Roof panel   5. Internal rear cross member   2. Cutting limit area   6. Rear wall   3. Side finishing of roof   7. Door area rear finishing   4. Door support ring   8.

  • Page 58: Protection Of The Vehicle Occupants

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.13 BODYWORK INTERVENTIONS d) Creation of sleeper cabs Not applicable   2.13.3 Protection of the vehicle occupants Airbags, safety belt fittings, the positioning of reels and pre-tension devices and anchorage of seats are all an integral part of passive safety.

  • Page 59: Steering Column Adjustment

    Replacing the tyres with others of a different size or load bearing capacity compared to the spe- cifications recorded during vehicle type approval requires IVECO authorisation as well as verific- ation of whether the electronic management of the speedometer, tachograph and speed limiter and traction and braking system requires reprogramming.

  • Page 60: Work On The Braking System

    Furthermore, tightening of the wheel studs to torque must be ensured in compliance with IVECO Standard 17-9219.    Table 2.14 - Wheel tightening torque according to IVECO STD 17-9219 CONNECTING ELEMENTS TIGHTENING...
  • Page 61 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.15 WORK ON THE BRAKING SYSTEM For procurement please contact IVECO Assistance Service, whereas for assembly the directions in IVECO STD 17-2403 must be complied with. ▶ The total or partial painting of the brake pipes must be absolutely avoided and, for this purpose, appropriate masking of the pipes must be provided.

  • Page 62: Esp (Electronic Stability Control)

    (on vehicles with the ABS/ESP system only using special apparatus present in the IVECO Authorized Workshops). Note The fluid discharged from the hydraulic circuit must not be used again. Top up using only new fluid of the prescribed type, con- tained in original, sealed containers that should only be opened when using the fluid.
  • Page 63 (or Body Computer) or the functional degrading of the system. Note Reprogramming the control unit or derating of the ESP system must exclusively be performed by the IVECO Assistance Service. – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 64: Derating Of The Esp System

    Attachment XI of Directive 2007/46/EC. 2.16.3 Wheelbase variation As stated in Chapter 2.4 , the variation of the wheelbase is only permitted upon specific approval of IVECO. In the event of ap- proval the following alternatives may be verified:...

  • Page 65: Modification Or Replacement Of The Stabilizer Bars

    2.17 PART RELOCATION AND ANCHORAGE OF ADDITIONAL UNITS AND EQUIPMENT 2.16.5 Modification or replacement of the stabilizer bars The modification or replacement of stabilising bars must be authorised by IVECO and is not compatible with the presence of the ESP system. Inasmuch, if authorisation is granted, Derating of this system is compulsory, except as indicated in Attachment XI of Directive 2007/46/EC.

  • Page 66: Transport Of Hazardous Materials (Adr)

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.18 TRANSPORT OF HAZARDOUS MATERIALS (ADR) 2.18 TRANSPORT OF HAZARDOUS MATERIALS (ADR) Each vehicle complies fully with the technical specifications of Regulation 105 - Series 06/01 - attachment "B" of the Agree- ment ADR 2019 - Part 9 (Requirements relating to the construction and approval of vehicles) with regards to the paragraphs: ●...

  • Page 67: Rear Mud Guards And Wheel Arches

    2.21 REAR MUD GUARDS AND WHEEL ARCHES On chassis cab version vehicles without rear mudguards, the bodybuilder must implement solutions equal to those provided by IVECO. For the realisation of the fenders, the wheel arch boxes and the shaping of the superstructure, keep in mind that: ●...

  • Page 68: Side Protections

      2.24 REARVIEW MIRRORS Depending on the width of the vehicle outfitting, it may be necessary to use rearview mirrors with an extended arm.   Table 2.16 - IVECO type- approved rearview mirrors Models Maximum body width [mm] IVECO type- approved rearview mirrors...
  • Page 69 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS 2.24 REARVIEW MIRRORS Figure 21 279568 * The distances differ between the left and right rearview mirror – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 70 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS CHASSIS INTERVENTIONS – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 71 SECTION 3 APPLICATIONS OF SUPERSTRUCTURES – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 72 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 73 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES Contents Contents 3.12 FRONT INSTALLATION OF SNOW PLOUGH ATTACHMENTS ....3.1 CONSTRUCTION OF THE SUBFRAME ..3.13 APPLICATION OF A WINCH .
  • Page 74 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 75: Construction Of The Subframe

    Following are the characteristics of certain materials which were taken into account in some of the applications stated below.  Table 3.1 - Material to be used for the construction of superstructures Std IVECO 15-2110 and 15-2812 Breaking strength...

  • Page 76: Aluminium Subframe

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.1 CONSTRUCTION OF THE SUBFRAME Section modulus W Recommended C profile [mm] 31 ≤ W ≤ 33 80 X 60 X 8 100 X 60 X 5 34 ≤ W ≤ 36 100 X 60 X 6 37 ≤...

  • Page 77: Elements Making Up The Subframe

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.2 ELEMENTS MAKING UP THE SUBFRAME When the connection between the chassis and the subframe is such as to ensure the transmission of the shear stresses (connection with plates), in checking the stresses at the two ends of the individual section, the new neutral axis has to be defined on the basis of the different elastic modulus of the two materials.
  • Page 78 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.2 ELEMENTS MAKING UP THE SUBFRAME   Figure 3 193867   1. Normal boxed profiles   3. 15 mm lintel (width of the wing of the profile)   2. Gradual passage from the boxed section to the open section ▶...

  • Page 79: Cross Member

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.2 ELEMENTS MAKING UP THE SUBFRAME can be used, but with moments of inertia and resistance which are the same or higher. These values can be obtained from the technical documentation of the profile manufacturers. 3.2.2 Cross member A sufficient number of crossbars, possibly to be placed in correspondence with the fastening clamps to the chassis, must brace the two sections of the subframe.
  • Page 80 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.2 ELEMENTS MAKING UP THE SUBFRAME Figure 5 261817 Figure 6 261818 – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 81: Self-Supporting Superstructures With Subframe Functions

    (e.g. using guide plates connected only to the subframe, or only to the vehicle chassis. If the vehicle chassis is already equipped with brackets for coupling of a body of a type established by IVECO, these brackets must be used for this purpose.

  • Page 82: Connections With Greater Flexibility

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.3 CONNECTION BETWEEN CHASSIS AND SUBFRAME 3.3.2 Connections with greater flexibility When the connection needs greater flexibility (e.g. vehicles with high stiffness of the superstructure such as vans, tanks, etc., used on winding roads or in poor conditions, vehicles for special use, etc.), hardware similar to the type indicated in Figure 8 should be adopted in the area behind the driver's cab.

  • Page 83: Container Application

    Fastening is achieved through specific pre-installed brackets (3) along the vertical rib of the side members (1) (see Figure 9) and, if these connections have not already been specified by IVECO, they must be made according to the indications provided in Para- graph 3.3.2 "Connection with the brackets"...

  • Page 84: Creation Of Van Versions

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.4 CONTAINER APPLICATION The front wall of the body must have the necessary strength and toughness to support the forces generated by the transported load, in the case of sudden and high decelerations. 3.4.3 Creation of van versions A structure consisting of longitudinal profiles and cross members may be used for connection to the vehicle chassis.

  • Page 85: Tipping Bodies

    The use of rear or three-way tipping bodies generally subjects the chassis to considerable mechanical stress. Therefore, the following indications must be observed. The use of a stabiliser bar on all IVECO models for which it is an optional, is recommended. The subframe must be: ■...

  • Page 86: Tractor For Semi-Trailer

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.5 TRACTOR FOR SEMI-TRAILER   Figure 11 228303   1. Subframe   3. Plates   2. Brackets   4. Retainer with hinge    Table 3.4 Minimum reinforcing profile Models Section modulus W Dimensions [mm] 100x60x6 Note For the dimensions of the subframe sections see Table 3.2.  ...

  • Page 87: Installation Of Tanks And Loose Material Containers

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.7 INSTALLATION OF TANKS AND LOOSE MATERIAL CONTAINERS 3.7 INSTALLATION OF TANKS AND LOOSE MATERIAL CONTAINERS 3.7.1 Installation with a subframe The installation of tanks and containers is carried out, as a rule, using a suitable subframe. The approximate dimensions of the profile to be used for the subframe are shown in Table 3.5.

  • Page 88: Installation Without A Subframe

    Specifically, the front anchoring flexibility must be suited to contain the necessary torsional movements of the chassis; ● other anchoring solutions must be authorised by IVECO. Figure 13 208921 The maximum volume, the degree of filling of the container and the volumetric mass of the transported goods must be defined in observance of the axle weight limits.

  • Page 89: Installing A Crane

    Special cases in which the moment M values correspond to the "E" value in the Table (or for higher values) must be checked indi- vidually each time and must receive specific authorisation from IVECO. Figure 14 230046   g = acceleration of gravity equals 9.81 m/s...

  • Page 90: Crane Behind The Cab

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.8 INSTALLING A CRANE 3.8.1 Crane behind the cab The fastening of the reinforcement sections to the chassis must be carried out using the standard brackets (see Figure 15), sup- plementing them, if necessary, with other fasteners of elastic type (brackets or clamps) in order to keep the flexural and torsional characteristics of the chassis as unchanged as possible.

  • Page 91: Crane On The Rear Overhang

    Close the reinforcement section in the crane assembly area. E = To be checked case-by-case. Send IVECO technical documentation with verification of stress and stability. When a higher section modulus is required for the superstructure also use the latter for the crane.

  • Page 92: Removable Cranes

    Standard vans can only be fitted with tail lifts with capacities limited to 300 kg, and only provided that adequate reinforcements are provided on the chassis. For higher capacities, approval is re- quired from IVECO on a case by case basis. The indications provided below refer to the possible installation on trucks.
  • Page 93 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.9 INSTALLATION OF TAIL LIFTS using Table 3.9, in the presence of trucks with rear overhangs as standard; using the indications provided in Figure 17, with trucks with overhangs not as standard or specific tail lifts (for example, in aluminium).
  • Page 94 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.9 INSTALLATION OF TAIL LIFTS = Weight of tail lift = Tail lift capacity = Distance of the tail lift from the rear axle   The bending moment on the chassis may be obtained using the following ratio: M [Nm] = W •...

  • Page 95: Tipper Bodies (Breakdown Recovery)

    Since, when used to remove snow, the vehicle is weighted at the rear and the maximum speed is limited (e.g. 40 km/h), a small increase in maximum axle load may be allowed upon specific assessment and authorisation by IVECO. – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 96: Application Of A Winch

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.13 APPLICATION OF A WINCH It should be possible to use all the elements of the vehicle front panel (e.g. tow-bar, supports for windscreen cleaner); otherwise, equivalent systems must be provided in compliance with the safety requirements. Observance of the required load must be documented and guaranteed by the company that carries out the installation.

  • Page 97: Special Outfits

    3.15.1 Cowl chassis versions They are made specifically for the installation of special bodies or equipment (shop vans, motor homes, etc.). The indications and precautions shown on the technical documentation (chassis diagram) provided by IVECO must be carefully respected. 3.15.2 Motor homes...
  • Page 98 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS APPLICATIONS OF SUPERSTRUCTURES 3.15 SPECIAL OUTFITS Figure 18 277298 ▶ Adopt solutions which ensure the stability of the vehicle and its safety during the operation. The bodybuilder must therefore: ● Define the type and number of stabilizers; ●...
  • Page 99 SECTION 4 POWER TAKE-OFFS – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 100 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 101 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS Contents Contents 4.1 GENERAL INFORMATION ....4.1.1 Type of use ..... 4.1.2 PTO transmissions .
  • Page 102 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 103: General Information

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS 4.1 GENERAL INFORMATION POWER TAKE-OFFS 4.1 GENERAL INFORMATION For drive take-off necessary for actuation of the auxiliary units, a power take-off (PTO) can be fitted on the transfer box (PTO Power Take Off). When defining the power necessary for the apparatus to be controlled, particularly when the values requested are high, the ab- sorbed power should also be considered during the drive phase (5 to 10% for mechanical transmissions, belts and gears, and higher values for the hydraulic controls).

  • Page 104: Pto Transmissions

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS 4.1 GENERAL INFORMATION 4.1.2 PTO transmissions In full compliance with the specifications provided by the Manufacturer of the driveline, the constant-velocity forces from the power take-off at the relevant apparatus should be carefully considered (angles, rpm, moment) during the design phase as well as the dynamic behaviour in the installation phase.

  • Page 105: Power Take-Off On The Gearbox

    Not applicable on Daily 4x4.   4.3 POWER TAKE-OFF FROM TRANSFER BOX For the installation of a PTO on the transfer box, IVECO provides for the adoption of optional specific flanges.   Figure 3 shows some dimensions of the types envisaged.

  • Page 106: Power Take-Off From Drive Line

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS 4.4 POWER TAKE-OFF FROM DRIVE LINE 4.4 POWER TAKE-OFF FROM DRIVE LINE Not available on Daily 4x4.   4.5 POWER TAKE-OFF FROM ENGINE Not available on Daily 4x4.   4.6 PTO MANAGEMENT In addition to referring to the Use and Maintenance Handbook, it is recommended that the indications listed below are always observed.

  • Page 107: After-Sales Installation Of Pto

    IVECO and any specific instructions that may be required. Note The after-sales installation of a PTO means that once installation is complete, IVECO Assistance Service must be contacted in order for the software of the engine control unit, the BDV control unit and, if present, the automatic transmission control unit to be up- dated via teleservices.
  • Page 108 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS POWER TAKE-OFFS – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 109 SECTION 5 ELECTRONIC SUB-SYSTEMS – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 110 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 111 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS Contents Contents 5.8 MISCELLANEOUS ....5.8.1 Additional circuits ....5.1 ELECTRONIC SYSTEM .
  • Page 112 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 113: Electronic System

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.1 ELECTRONIC SYSTEM ELECTRONIC SUB-SYSTEMS It is strictly PROHIBITED to carry out connections to connectors other than those intended by IVECO and to make any changes to the original electrical system. 5.1 ELECTRONIC SYSTEM ▶...

  • Page 114: Bodybuilder Connectors

    Note Given the multiplicity of vehicular variants and of associated wiring, the present chapter only provides information concerning the basic version of the electrical system; please contact the IVECO Assistance Service should you require more specific information. The vehicle's electrical system contains specific connectors for connecting the bodybuilder installations; access to these allows the system's functional integrity and validity of the warranty to be preserved.

  • Page 115: Connector 72105A, Black, 32-Pin, Dwg

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS   Figure 3 230828  1. Connector ST13 5.2.1 Connector 72105A, black, 32-pin, dwg. 5802442666 Figure 4 262203    Table 5.1 - dwg. 5802291186 (Bodybuilders side) Code Description terminal 41200694 EZ Male contact for 0.35 to 0.5 mm² cable 41200695 EZ Male contact for 0.75 to 1.00 mm²...
  • Page 116 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS    Table 5.2 - Basic functions of the 32-pole connector 72105A Cable Connected Description signal Remarks code The engine starts only when the key is turned in the ignition block (K15 ON) Input Engine start up 8888...
  • Page 117 If the "parking brake engaged" signal indicates "ground", it means the parking brake has not been fully released. Therefore a residual braking torque on the rear axle cannot be excluded. IVECO does not recommend use of the signal as an indication of a stationary vehicle.
  • Page 118 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS Obligatory insertion of a 10 kOhm pull-up resistor between 72105A / pin 11 (signal K15) and 72105A / pin 05 as outlined in Figure 5.   Figure 5 262160  1.  2.
  • Page 119 Pin 4   Should you wish to change the value of the 2nd speed limiter, using the tool available at the IVECO Assistance Service, please note that: ● The accuracy of the speed limiter is reduced at low vehicle speeds.
  • Page 120 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS   Mandatory insertion of a 5 k Ω pull-up resistor in addition to a diode as outlined in Figure 8. The pull-up resistor and the diode must be fitted by the bodybuilder. The resistor must be inserted between 72105A / Pin 16 and 72105A / Pin 11.
  • Page 121 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS   Figure 9 230830   1. Speed signal (terminal B3) of the movement sensor fitted   2. Temporal diagram and form of the pulse speed signal on the reduction unit (terminal B7) from tachograph   a.
  • Page 122 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.2 BODYBUILDER CONNECTORS ● C_IO: capacity between input and output (in the event of output stage: C_IO is valid if the output stage is turned off) ● I_Out: output current ● I_Out_SC: output current ●...
  • Page 123    Table 5.6 Resistance Values [Ohm] 2000 For this purpose IVECO recommends use of a relay (not identical to that for the Cruise Control interface) which enables utilization of the same functions available on the steering wheel lever. The Cruise Control option must be configured on both the ECM and BCM systems.

  • Page 124: Electronic Control Units

    K15 Remote control is activated. If, in spite of such requirements, engine operation must still be possible, IVECO recommends using the RunLock function offered by the Ex- pansion Module (if present): refer to Chapter 7.3 ( ➠ Page 5).

  • Page 125: Disconnecting The Electronic Control Units

      5.3.3 Repositioning the electronic control units IVECO recommends avoiding modifications which entail the repositioning of the electronic control units. However, if repositioning is unavoidable, please follow the instructions below: ● the electronic control units must be positioned on the chassis or in the cab and secured with a fastening similar to the original one (i.e.

  • Page 126: Precautionary Measures When Working On The System

    ▶ Any electrical work which does not comply with regulations may cause significant damage (e.g. short circuits with the possibility of fire and destruction of the vehicle) and authorises IVECO to annul the warranty. Before removing any electrical/electronic equipment, disconnect the ground cable from the battery negative terminal.

  • Page 127: Precautionary Measures When Working On The Chassis

    "); the related wiring harnesses should not be coupled to the electronic circuits that already exist on the vehicle in order to avoid electromagnetic interference. Ensure that the wiring of the electronic devices (length, type of conductor, dislocation, strips, cable shielding connection, etc.) com- ply with the original IVECO provision. ▶ Carefully restore the original system after any operations.
  • Page 128 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 13 191316  1.  2. Ground connections: (A) connection is correct; (B) connec- Correct cable fastening to the ground point using: (A) tion is incorrect screw, (B) cable terminal, (C) washer, (D) nut  3.
  • Page 129 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 15 243714 Power ground in battery compartment   Figure 16 262235 Power ground on left side member – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 130 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 17 243716   Power ground on fire guard M3/MS3. Signal/power ground on fire guard   Figure 18 243717 Power, engine compartment ground near front right head- light – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 131 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 19 243718 Power, engine compartment ground near front left head- M10. Power, engine compartment ground near front left head- light light   Figure 20 243719 Power ground, in the cab, wall below dashboard Power ground, in the cab, wall below dashboard MS6.
  • Page 132 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 21 208945 Power ground, in the cab on the side panels   Figure 22 262232 MS8. Signal ground, in the cab, below the floor mat – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 133 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM   Figure 23 262233 M11. Power ground on side member   Figure 24 262234 M12. Power ground on engine crankcase, left side M14. Power ground on side member M13. Power ground, engine compartment, left side 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 a "star"...

  • Page 134: Electromagnetic Compatibility

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.4 ELECTRICAL SYSTEM Figure 25 191317 "STELLA" connections of various negatives with the system ground Figure 26 191318 Shielding by means of a metal braid of a cable leading to an electronic component 5.4.6 Electromagnetic compatibility It is recommended that electrical, electro-mechanical and electronic devices which comply with the following immunity require- ments for electromagnetic emissions, both irradiated and conducted, are used, as shown below.
  • Page 135 191312 a ≥ 6 mm The values in the table are only to be considered respected if the device comes form "IVECO Spare Parts" or it has been certified as per the international standards ISO, CISPR, VDE etc. Whenever equipment is used which 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 136: Receiver-Transmission Systems

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS The most frequent applications include: ● Amateur receiver-transmitter units for CB (City Band) and 2 m bands; ● Bluetooth pre-installation for mobile phones ● GPS reception and satellite navigation equipment ●...

  • Page 137: Amateur Equipment For Cb (27 Mhz) And 2 M Band (144 Mhz)

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS   Figure 29 99349   1. Antenna connector   9. Connector (N.C. SO - 239) transreceiver side   2. Ground wire   10. Test executed sticker   3. Insulator   11. The 100 pF condenser must be soldered on the lower pin   4.

  • Page 138: Bluetooth Pre-Installation

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS 5.5.2 Bluetooth pre-installation The Bluetooth setup consists of: ● specific control unit, positioned above the radio and hidden by a plastic cover; ● buttons on the steering wheel; ● ceiling fixture with microphone; ●...
  • Page 139 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS   Figure 31 208947   1. Bluetooth microphone   Figure 32 208949   1. Driver's side   2. Passenger side    Table 5.9 Description Cable Ground White Signal + Vcc Shielded The connector of the microphone connection, on the cab wiring side, is located in correspondence with the ceiling connectors. –...

  • Page 140: Gps Receiver And Satellite Navigation Units

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.5 RECEIVER-TRANSMISSION SYSTEMS 5.5.3 GPS receiver and satellite navigation units Install the transmitting part in a flat, dry area, separate from the electronic components of the vehicle, away from humidity and vibrations. In the case of a pulse transmission system, it must be at a distance of at least 1 meter away from other devices. The GPS antenna must be installed so as to have the maximum visibility possible of the sky.

  • Page 141: Additional Equipment

    In any case, when increasing battery capacity, it is advisable not to exceed 20-30% of the maximum values provided as optional by IVECO, so as not to damage some of the components (e.g. starter motor). When higher capacities are necessary, use additional batteries, making the necessary provisions for recharging as indicated below.

  • Page 142: Current Draws

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.7 CURRENT DRAWS 5.7 CURRENT DRAWS In general it is advisable to: ● use suitable protection fuses in the vicinity near the current draw; ● protect cables inserted into designated sheathing or corrugated cables, installing according to the indications provided in Chapter 5.4 ( ➠...

  • Page 143: Fuses

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.7 CURRENT DRAWS   Figure 35 209810  HI. Current take off point protected by fuse FF  MI. Current take off point protected by fuse FG Fuses FF and FG have a flow rate of 30 A each. If necessary, they can be replaced with ones of a higher capacity respecting the indication of a maximum total current draw (sum of the two fuses) equal to 130 A Note Each connection on the CBA2 must strictly maintain the integrity and correct positioning of the protective cover.
  • Page 144 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.7 CURRENT DRAWS    Table 5.10 - List of fuses on CBA1 Location Amperage [A] Description Power supply CBA2 Power supply SCM and bodybuilders Starter and Retarder Body Computer power supply TGC (opt)   b) Fuses on the CBA2 control unit Figure 37 209812...

  • Page 145: Passage Of Cables From Cab Interior To Cab Exterior

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS 5.7.2 Passage of cables from cab interior to cab exterior In the engine compartment, close to the brake-servo, through the five premade 10 mm holes in the bulkhead, it is possible the to pass the electric cables from the cab to the engine compartment.
  • Page 146 ● Incorrect installation of electrical accessories may affect occupant safety and cause severe damage to the vehicle. Contact IVECO if you have any questions. ● It is necessary to avoid coupling with the signal transmission cables (e.g. ABS), for which preferential routing has been provided in order to meet electromagnetic requirements (EMI).

  • Page 147: Interventions For Modifying Wheelbase And Overhang

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS 5.8.2 Interventions for modifying wheelbase and overhang Should it be necessary to lengthen the wires on the chassis owing to the new dimensions of wheelbase and overhang, a watertight junction box must be used which has the same characteristics as those used on the standard vehicle. The electrical components used such as wires, connectors, terminal blocks, conduits etc.
  • Page 148 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS   Figure 41 262155   1. Trailer electronic control unit   3. Guard   2. Support bracket   4. Chassis side member – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 149   2. Connector to connect to chassis cable   3. 13-pin trailer socket 72016 trailer control unit For further details on connections and installation, request wiring diagrams from IVECO. ▶ Any damage to the light system caused by failure to comply with procedure indicated above is not covered by warranty.

  • Page 150: Installation Of Lateral Side Lights (Side Marker Lamps)

    ST38 connector on the chassis (see Figure 44). In order to keep the electrical characteristics of the contacts of the female socket unchanged, the hood supplied by IVECO must be left attached.
  • Page 151 The side markers are mandatory for vehicles with a total length exceeding 6 m. Installation of side markers requires the intervention of the IVECO Service Network in order to enable the Body Computer.   – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 152: Reverse Gear Signal

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS 5.8.5 Reverse gear signal For safety reasons, certain vehicle versions must emit an external reversing warning sound which is activated when the vehicle is reversing. This safety device may be originally requested as opt. 7638, regardless of the type of gearbox used. Application is recommended inside the rear cross member of the licence plate holder, as in Figure 45.

  • Page 153: Antitheft System

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS    Table 5.16 - Connector for reverse gear signal Cable Connected Description Max. current [mA] Remarks code The signal comes from the control unit in cab +12 V = reverse gear engaged Reverse 1614 500 - 1000...
  • Page 154 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ELECTRONIC SUB-SYSTEMS 5.8 MISCELLANEOUS   Figure 47 271321  1.  3. Bonnet open sensor Alarm siren  2. Engine bonnet socket For the operation mode refer to the Use and Maintenance Manual. – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 155 SECTION 6 ADBLUE AND SCRT SYSTEM – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 156 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 157 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ADBLUE AND SCRT SYSTEM Contents Contents 6.1 GENERAL INFORMATION ....6.2 THE NITROGEN OXIDE CATALYTIC REDUCTION PRINCIPLE ....6.2.1 Main components of the SCRT system .
  • Page 158 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ADBLUE AND SCRT SYSTEM – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 159: General Information

       6.1 GENERAL INFORMATION To comply with Euro VI Regulations on engine gas emissions, IVECO has developed the "SCRT" (Selective Catalytic Reduction Technology) system, consisting of the combined action of a diesel particulate filter (DPF) and post-treatment of exhaust gas (SCR).

  • Page 160: Instructions

    The following instructions are intended for the AdBlue injection system of the Bosch DeNO 5.2Q type. Note The materials and layouts of normal IVECO production are specifically approved; all other circumstances of variation must be spe- cifically authorized. If changes are made to the chassis which involve this system, the following procedure must be followed under all circumstances: ●...

  • Page 161: Adblue Refuelling Filler

    The tank is secured to the chassis with specific brackets; any modifications must be authorised by IVECO. ● The Pump / Tank (1) assembly can only be disassembled by IVECO Authorized Workshops and must be repositioned as per the type-approved layout and general production; any modifications must be authorised.
  • Page 162 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS ADBLUE AND SCRT SYSTEM 6.4 MOVING ADBLUE SYSTEM COMPONENTS   Figure 3 208932   1. SCR catalytic converter   5. AdBlue delivery pipe   2. Pumping module (SM)   6. DPF Particulate filter   3. AdBlue tank   7. Dosing module (DM)   4.
  • Page 163 SECTION 7 EXPANSION MODULE – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 164 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 165 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS EXPANSION MODULE Contents Contents 7.1 GENERAL INFORMATION ....7.2 WIRING DIAGRAM ....7.2.1 20-way EM connector, black (61071B) .
  • Page 166 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS EXPANSION MODULE – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 167: General Information

      7.2 WIRING DIAGRAM To ensure the functional integrity of the electrical system, IVECO has pre-installed specific connection points to be used for the added systems (see Chapter 5.4 - Paragraph "Current draws and fuses" ). The Expansion Module control unit terminals are available via the two optional connectors 61071B and 72075B (also see Section 5 - Figure 2).

  • Page 168: 20-Way Em Connector, Black (61071B)

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS EXPANSION MODULE 7.2 WIRING DIAGRAM 7.2.1 20-way EM connector, black (61071B)   Figure 2 101564     Existing part on vehicle (male) Counterpart to be coupled (female)    Table 7.5 Code Description 500314820 EZ Male contact for 0.35 to 0.5 mm² cable 500314824 EZ Male contact for 0.75 to 1.5 mm²...
  • Page 169 If Additional Light 1 or Blue Light 1 are activated by Customer Service, then full vehicle CAN operation 72075B / 12 is no longer available (see Chapter 7.3 ( ➠ Page 10)). In order to avoid any problems IVECO requests that the relay is disassembled for full vehicle CAN operation.  ...

  • Page 170: 12-Way Em Connector, Black (72075B)

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS EXPANSION MODULE 7.2 WIRING DIAGRAM ▶ The functions related to the PTO are not available. 7.2.2 12-way EM connector, black (72075B)   Figure 3 101554    Existing part on vehicle (male)    Counterpart to be coupled (female)    Table 7.7 Code Description...

  • Page 171: 9-Way Em Connector, Yellow

    LSO activated with CO unit activation (generally ~ 3sec after K15) CO enabled CIA413 0975 0.5A EM X4/28 contact IVECO Customer Service for the adjustment Open circuit = CANopen not operational Ground = CANopen operational Bodybuilders CAN H 6110 n.a.

  • Page 172: Additional Functions

    Safety / Alarm (engine switching off or reduction in engine speed and possible flashing of low beam/high beam lights). Additional Lights (flashing on the roof, scene lights or rear lights). For more in-depth information on configuration and use, please refer to IVECO Customer Service. – Printed 692.68.999 – 3 Ed. - Base 08-2020...
  • Page 173 APPENDIX C Hi-MATIC AUTOMATIC GEARBOX – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 174 – Printed 692.68.999 – 3 Ed. - Base 08/2020...
  • Page 175 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS Hi-MATIC AUTOMATIC GEARBOX Contents Contents C.1 GENERAL INFORMATION ....C.2 LAYOUT ......C.3 REQUIREMENTS .
  • Page 176 DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS Hi-MATIC AUTOMATIC GEARBOX – Printed 692.68.999 – 3 Ed. - Base 08-2020...

  • Page 177: General Information

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS Hi-MATIC AUTOMATIC GEARBOX C.1 GENERAL INFORMATION Hi-MATIC AUTOMATIC GEARBOX C.1 GENERAL INFORMATION This document addresses the main specifications correlated with the presence of the Hi-MATIC automatic gearbox on the vehicle as well as the indications that must be followed before outfitting commences. See the Bodybuilders' Manual on vehicles equipped with mechanical gearbox for other information.

  • Page 178: Requirements

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS Hi-MATIC AUTOMATIC GEARBOX C.3 REQUIREMENTS C.3 REQUIREMENTS C.3.1 Gearbox release lever Figure 2 210249 The lever can be positioned in a different location that its original mounting position, as long as: ● it compulsorily remains inside the cab; ●...

  • Page 179: Propeller Shaft

    DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS Hi-MATIC AUTOMATIC GEARBOX C.3 REQUIREMENTS C.3.3 Propeller shaft Figure 4 261978 The automatic gearbox requires a specific propeller shaft for length and for the coupling joint (1). Any modifications which involve changes in one or more of these characteristics (e.g. wheelbase modification), are the full respons- ibility of the person who makes these modifications.

  • Page 180: Cooling

    Slight displacements are allowed without any advance authorisation by IVECO only for needs of access during outfitting installation, making sure that no pipes are disconnected.

Table of Contents

Save PDF