Iveco DAILY 4x4, DAILY 4x4 RANGE BODYBUILDER Instructions Manual

DAILY VEHICLE 4X4
R

ANGE

BODYBUILDER

INSTRUCTIONS

LIGHT RANGE

ISSUE 2007

Publication Edited by:
Technical Application
Strada delle Cascinette, 424/34
10156 Turin - Italy

Publication Nr. 603.93.761 - 1

st

Edition

Printed in Italy - 05.07

B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy

Produced by:

Print 603.93.761 Base - May 2007

Update data

DAILY 4x4

Bodybuilders instructions
Print 603.93.761 - 1

st

edition

Base - May 2007

UPDATE DATA

Section Description Page Revision date

Base - May 2007 Print 603.93.761

Update data

This publication provides the data, features and instructions for vehicle fitting and modifications.

It is intended for qualified, skill personnel. The body builder is responsible for designing the fitting, its modification and execution,
and will have to ensure compliance with the provisions both of this publication and the law regulations in force.

Prior to carrying out any work, make sure you have the publication of the vehicle model on which you are about to work. Also make
sure that all the accident-prevention equipment such as, for instance, goggles, helmet, gloves, boots, etc. as well as the working, lifting
and handling equipment are available and in good workingorder. Finally, make sure that you operateon the vehicle in such conditions
as to ensure maximum safety.

The execution of the work by strictly complying with the above provisions, as well as the use of the components shown, ensure that
the work is carried out correctly and safely.

Any change, modification or fitting not covered by this manual and not expressly authorized in written by IVECO will relieve the
latter of any responsibility and make, in particular, the vehicle guarantee null and void.

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.

After every single intervention, the functioning, efficiency and safety conditions established by IVECO shall be restored. Contact the
IVECO service network for vehicle set-up, if necessary.

IVECO shall not be responsible for any change, modification or fitting concerning the vehicle.

The data and information contained in this publication may not be updated due to the changes made by IVECO, at any time, for
technical or commercial reasons, or to make the vehicles comply with the law regulations in force in the different countries.

In case of disagreement between the provisions i ncluded herein and the actual vehicle make-up, contact IVECO prior to carrying
out any work.

General danger

It includes the dangers of above described signals.

Danger of serious damage for the vehicle

Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.

Environment protection

It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.

Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Symbols - Warnings

!

Foreword

It indicates an additional explanation for a piece of information.NOTE

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Foreword

Page header and footer interpretation

Vehicle type

Section title

Section number -

page number

Print

number

Chapter title

Basic edition -

month year

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Foreword

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Index of section

INDEX OF SECTION

Section

General specifications

1

Chassis modifications 2

Fitting superstructures 3

Power Take-offs 4

Specific information and instructions 5

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Index of section

GENERAL SPECIFICATIONS

1-1

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Index

Index

SECTION 1

General specifications

Page

1.1 Aim of bodybuilders instructions 1-3

1.2 IVECO approval for changes and fittings 1-3

1.3 Liabilities 1-4

1.4 Guarantees 1-4

1.5 Request for approval 1-4

1.6 IVECO technical documents available by means of computer 1-5

1.7 Trademarks and Logos 1-5

1.8 Legal Provisions 1-5

1.9 Prevention of accidents 1-6

1.10 Choice of material to use: Ecology - Recycling 1-6

1.11 Vehicle delivery 1-7

1.12 Vehicles identification 1-8

1.13 Dimensions and masses 1-9

1.13.1 General Specifications 1-9

1.13.2 Determining the Centre of Gravity of the Body and Payload 1-10

1.13.3 Observing the Permitted Weights 1-13

1.14 Instructions for the Correct Functioning of the Parts of t he Vehicle and Ac cessibility for Maintenance 1-14

1.15 Quality Syst em management 1-15

1.16 Vehicle maintenance 1-15

1.17 Conventions 1-16

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Index

GENERAL SPECIFICATIONS

1-3

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Aim of bodybuilders instructions

Aim ofbodyb uilder s instructi ons

1.1 Aim of bodybuilders instructions

The purposeof this publication is to provide data,specifications and instructions for the bodybuilding an d conversion of anoriginal

IVECO vehicle to ensure the function ality, safety and reliability of the vehicle and its components.

1.2 IVECO approval for changes and fittings

Changes must be c arried 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;

- work carried out on the braking sy stem;

- work carried ou t on th e suspension system;

- steering wheel modifications;

- changes to the stabiliser bars and suspensions;

- changes to the cab, cab supports, locking and tipping devices;

- changes to the engine intake and exhaust systems

- engine cooling system modifications;

- power unit and driving component modifications;

- work carried out on front and rear axles;

- fitting decelerator brakes;

- fitting power take-offs;

- changing the tyre dimensions;

- coupling device (hooks, fifth wheels) modifications;

- electric/electronic unit modifications.

The other modifications of fittings covered by the following standards and made in compliance with the same do not require specific
approval from IVECO. Any modification or fitting not covered by these standards shall, on the contrary, be authorized by IVECO
in advance.

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Liabilities

Liabilities

1.3 Liabilities

The au t horizations issued by IVECO c on cern solely the technical/conceptual feasibility of the modification and/or fitting to be
made on a genuine IVECO vehicle.
The bodybuilder is responsible for the:

- project of the modification or fitting;

- choice and features of the products used;

- workmanship of the modification or fitting;

- compliance of the project and its implementation with all the instructions provided by IVECO;

- compliance of the project and its implementation with all the current regulations in the country where the vehicle is registered;

- the functionality, safety and reliability and in general the effective performance of the vehicle and also the effects that the changes

and the conversion may have on vehicle performance and specifications.

1.4 Guarantees

The bodybuilder/chassis converter who has built the body or who has modified the chassis must guarantee that the work was
undertaken in a professional manner in full compliance with the specifications contained in this manual. IVECO reserves the right
to declare void its own warranties for the vehicles where:

- these specifications have not been adhered to or where unauthorised equipment was installed, or unauthorised modifications

were carried out;

- an unsuitable frame has been used for the required conversion or application;

- the specifications, standards or instructions issued by the Manufacturer for the flawless execution of the operations have not

been heeded;

- original spare parts or components which the Manufacturer has made available for specific interventions were not used;

- read and respect the safety standards and symbols applied before any operation;

- do not use the vehicle for applications other than those for which it is designed.

Maintaining the functionality of vehicle components.
The effective operation of vehicle components, all component safety and running conditions, com-

pliance with national and international regulations (e.g. EC Directives) and also accident prevention
standards must naturally be guaranteed in all permitted conversions and applications.

All our vehicles are covered by a warranty as laid down in the specific documents.
The bodybuilder must arrange to carry out operations at least in an equivalent manner.

1.5 Request for approval

The requests for approval or support to carry out work or make modifications o r fittings shall be forwarded to the IVECO marke­ting offices in charge.

To obtain the approval, the body builder shall provide adequate documents that illustrate the anticipated implementation, utilization
and conditions of use on th e vehicle. The drawings shall highlight any item differing from the instructions contained in this manual.

The body builder shall submit the modification and/or fitting to the competent authorities for approval.

GENERAL SPECIFICATIONS

1-5

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IVECO technical documents available by means of computer

IVECO techni cal documents availabl e bymean sof compute r

1.6 IVECO technical documents available by means of computer

The following technical documents are available on the Internet at www.thbiveco.com:

- directives for transformation and equipping of vehicles;

- technical cards;

- chassis cab diagrams;

- chassis diagrams;

- other specifications concerning the vehicle range.

The body builder shall submit the modification and/or fitting to the competent authorities for approval.

1.7 Trademarks and Logos

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.

IVECO reserves the right to withdraw the tradenames and logos if the fitting or conversion fails to conform with requirements. The
bodybuilder accepts all responsibility for the entire vehicle.

Instruction for added assemblies

Where assembliesare added, the bodybuilder mustprovide the necessary service and maintenance instructions when the vehicle

is delivered.

1.8 Legal Provisions

On completing the vehicle, the bodybuilder/chassis converter must check the work (modifications, body + equipment etc.) to
ensure that the legal provisions required in the country of registration are observed (e.g. weights, dimensions, braking, noise,
emissions etc.).Information regarding these matters may be obtained from the competent Authorities or the IVECO Area Network.

The vehicles manufactured atour plant (except someversions for Extra-European countries) comply with the EC directives. Conver­ted vehicles must also comply with these directives. The only permissible exception is granted where local type approval differs from
EC homologation.

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Prevention of accidents

Preventi onof accide nts

1.9 Prevention of accidents

Do no allow unauthorised personnel to work on or operate the vehicle.

It is forbidden to use the vehicle if its safety devices have been tampered with or damaged.

The structures and devices fitted to the vehicles must comply with the current regulations concerning
the prevention of accidents and safety regulations in force in the countries where the vehicle is to be
used.

All the precautions dictated by technical awareness must be adopted to prevent malfunction and functional defects.

Compliance with th ese regulations will be the responsibility of the manufacturers of the structures and devices.

!

Components such as seats, coverings, linings, protective panels etc. may represent a potential fire haz­ard if they are exposed to an intense heat source.

Arrange for their removal before working with welding equipment and flames.

1.10 Choice of material to use: Ecology - Recycling

Increasingly greater at tention should be paid, at th e study and design stage, to the choice of materials to be u sed.

This is especially the case as regards the aspectsconnected with ecology and recy cling in the light of domestic and international
regulations that are constantly being developed in the sector.

In this connection:

- everyonemust be aware of theprohibitions on using harmfulor potentiallyhazardous materials, such as ones containing asbestos,
lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent ch rome, etc.

- Use materials whose processing produces limited waste and that permit easy recycling after their first use.

- With composite synthetic materials, use components that are compatible with each other, envisaging also their possible utiliz­ation with the addition of other salvaged components. Affix the markings required in compliance with t he current regulations.

- Batteries contain substances that are very hazardous to the environment. When replacing batteries, we advise contacting the
service network, w hich is suitably equipped for battery disposal in compliance with environmental policies and laws.

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).

GENERAL SPECIFICATIONS

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Vehicle delivery

Vehicledelivery

1.11 Vehicle delivery

Prior to delivering the vehicle, the body builder shall:

- verify that the work has been made correctly;

- perform vehicle and/or equipment set-up;

- check the operation and safety of the vehicle and/or equipment;

- prepare and deliver the necessary instructions for service and maintenance of the fitting and any additional u nits to the end custo­mer;

- write the new data down on the special tags;

- confirm that the work carried out complies with the indications provided by the vehicle manufacturer and with the law regula­tions;

- carry out th e chec ks included in the ”IVECO Pre-Delivery inspection” list (available from the IVECO network) with regard to
the items affected by the work done;

- provide a guarantee for the modifications made;

- in the event that the connections originally provided with screws have been mounted and restored, the same screws shall not
be used. In such an instance, and in the event that nails have been replaced with screws, you must check again th e closing of
the connection after travelling approximately 500-1000 km.

- measure the battery voltage. Ensure there is a minimum charge of 12.5 V. If the voltage reading is between 12.1 and 12.49 V,
recharge the battery (slow charge). If the voltage is less than 12.1 V, the battery must be scrapped and replaced with a new one;

- the batteries must be serviced at regular intervals until the vehicle is handed over to th e customer to prevent problems of low
charge, short-circuits or corrosion. IVECO reserves the right to terminate the battery warranty if the maint enance procedures
required by the IVECO network are not observed.

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Vehicles identification

Vehicl es iden tificati on

1.12 Vehicles identification

The commercial designation of IVECO vehicles is not the same as the t ype approval (h omologation ) designation. Two types

of commercial designation are shown below with the meaning of th e codes used:

GVW

(tx10)

Class Engine

rating

(HP:10)

Version Suspension

3 5 S 1 8 W - -

5 5 S 1 8 W - -

Class Rear wheels GVW (t) Version
S single 3.5 - Truck

DCrewcab6+1

Suspension

- mechanic

GENERAL SPECIFICATIONS

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Dimensions and masses

Dimensionsandmasses

1.13 Dimensions and masses

1.13.1 General Specifications

The dimensions and maximum permissible weight on the axles are indicated on the bodybuilder layout drawings, on techn ical

specification sheets and, in greater details, on the official documentation issued by the Company. The kerb weights refer to vehicles
with standard equipment. Special equipment may involve considerable modification to the weight and its distribution on the axles.

On our vehicles, lights and rear-view mirrors are designed for widths of up to 2350 mm.

Weighing the Chassis

As a result of production factors there could be at a ±5% variation in the published weights for models 35S and a ±3% for models

55S.

It is therefore, advisable to weigh the vehicle in the chassis cab condition before fitting the body and equipment and establish the
weight distribution on the axles.

Body conversions

The body building limits for each model are mainly defined by the following:

- weight distribution on the axles;

- width of the mirrors used;

- position of the rear under run-bar.

Greatervalues in compliance with the weights permitted on the axlesmay be authorized by IVECO after modifying suchcomponents
as the chassis, under run-bar, mirrors, etc.

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Dimensions and masses

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) givethe positions permitted wit h the vehicle in its standard
form. The masses and positioning of the single components of the vehicle are given in the chassis and weight distribution diagram.

respectively L1 = L −

W2 ⋅ L

W

102452

Figure 1.1

W = Body + payload (kg)

W1 = Body and payload acting on front axle (kg)

W2 = Body and payload acting on rear axle (kg)

L1 = Distance of the centre of gravity from the rear axle centre line (mm)

L = Wheelbase (mm)

L

1

=

W

1

⋅ L

W

Example of calculation of the load barycentre position

Consider a 40C13 vehi cle with a wheelbase of 3450 mm with:

1. GWW= 4200 kg (permitted maximum: 1900 kg on the front and 3100 kg on the rear)

2. KERB WEIGHT = 1955 kg (1340 kg on the front axle, 615 kg on the rear)

The permitted maximum load (body + payload) will be W = 4200 - 1955 = 2245 kg. Let us calculate the position of the center
of gravity in which the maximum permitted on the front axle is achieved. Let us assume an uniform distributed load .

In this case, out of 2245 kg. W

1

= 1900 - 1340 = 560 kg will affect the front axle, while the remaining W2= 2245 - 560 = 1685

kg will affect the rear axle.

Thus, the following will be obtained:

1. W

1

= 560 kg

2. L = 3450 mm

3. W = 2245 kg

L

1

=W1x L / W = 860 mm

The center of gravity of the load (Body + payload) must not be more than 860 mm far from the rear axle; o therwise, the front
axle would be overloaded.

GENERAL SPECIFICATIONS

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Dimensions and masses

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, th e act ual 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. Relevant instructions should also be given to the operator.

Uniform load distribution Uneven load distribution

Uniform load distribution Uneven load distribution

(beware of axle loads and minimum axle ratio)

102453

Figure 1.2

Figure 1.3

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Dimensions and masses

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.

These limits are defined in compliance with the national or international regulations (e.g. as amended by the current EC braking
Directive) or requested by the Manufacturer to ensure good handling of the vehicle (e.g. transverse stability of the moving vehicle).

Figure 1.4

Verification with full load:

102454

Ht =

Wc . Hc + Wb . Hb

Wc + Wb

Hb =

(Wc + Wb) . Ht − Wc . Hc

Wb

Wc = Chassis cab vehicle kerb weight

Hc = Height of centre of gravity of chassis cab vehicle (laden condition)

Wb = Body and payload

Hb = Height of centre of gravity of body and payload in relation to ground

Wt = Vehicle weight when fully loaded

Ht = Height of centre of gravity of vehicle with full load

To check the vehicle with its body but no payload, use the above formula but for Ws use only the vehicle unladen weight (The
position for Hv will depend on the load and deflection of the suspension).

The height of the centre of gravity indicated in Table 2.6 represents values which are not to be exceeded for each given equipment
level. These values have been c alculated only in terms of the transverse stability of the vehicle and are applicable to a mid wheelbase.
Any other possible restrictive specification, e.g. braking regulation , should be taken into consideration.

The values given in Table 2.6 refer to the body with fixed payload. In versions where the payload tends to move sideways (e.g.
suspended loads, fluid loads etc.) especially when turning, higher dynamic transverse forces is generated which makes the vehicle

less stable. This must be taken into consideration when providing vehicle operating instructions or for possible reduction in the
height of the centre of gravity.

GENERAL SPECIFICATIONS

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Dimensions and masses

Using Stabiliser Bars

Supplementary stabilising or anti-roll bars, where available, spring reinforcements or the application of rubber components (in

compliance with point 2.11) may increase the height of the centre of gravity of the payload which must be defined as each occasion
arises. The modification must be carried out after careful consideration has been given to the specifications of the version, to the
wheelbase and to the distribution of the cross-stresses acting on the suspension both at the front and at the rear of the vehicle.
It must be borne in mind that it is often advisable to modify the rear axle only since a modified front axle would give the driver a
false sense of stability making it more difficult to perceive the safety limits. Modification to the front axle may be made where the
load is positioned behind the cab (e.g. crane) or where the superstructures are very rigid (e.g. van conversion).

1.13.3 Observing the Permitted Weights

All t h e limits specified on the IVECO documents must be complied with. It is essential t hat 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.

Particular attention must be taken with vehicles where the load is concentrated on the rear overhang (e.g. cranes, tail lifts, trailers)
and to vehicles with short wheelbases and a very high centre of gravity.

Ensure transverse loads are properly distributed when positioning auxiliary components an d superstructures. A +4% variation on
the rated load (50% of load on the axle) is permissible for each wheel (for example: permissible load on axle 3000 kg; 1440 to 1560
kg allowed for each wheel side); in compliance with load allowed by tyres, without affecting braking properties and vehicle driving
stability.

Apart from different specifications for specific vehicles, the following may be taken to be the minimum weights for the front axle:
30% of the total vehicle weight (with uniformly distributed loads and w ith loads concentrated on the rear overhang).

The rear overhang of the body must be built in strict observance of the permitted axle loads, the minimum load required on the
front axle, the limitations in length, the positioning of any tow hook and of the rear under-run guard stipulated by the relevant
National and EC regulations.

Variations in the Permissible Weight

Special exceptions to the maximum permissible weights may be granted for particular applications for which, however, precise

limitations regarding the use will be imposed in addition to possible vehicle reinforcements.

Such exemptions, if they exceed the limits imposed by law, must be authorised by the Government Administrative Authority.

The request for authorisation must include:

- vehicle type, wheelbase, identification number, designated use;

- unladen weight on the axles (e.g. vehicles equipped with crane) including positions for the centre of gravity of the payload;

- proposals concerning the reinforcement of the vehicle components where necessary.

The reduction in the permissible weight on the vehicle (derating) may involve changing various components such as suspension,
brakes etc) and may require recalibration of the load sensing valve where one is fitted. In these circumstances necessary instructions
may be provided.

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Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance

Instructionsforthe Correct F unctioningofthe Parts ofthe Vehicleand AccessibilityforMaintenance

1.14 Instructions for the Correct Functioning of the Parts of t he Vehicle
and Accessibility for Maintenance

As a rule, when modifying or installing any type of equipment, n o th ing must be altered which prevents the correct fu n ctioning

of assemblies and parts of the vehicle under all operational conditions.

For example:

- Ready access to all parts requiring inspection or maintenance and periodic servicing must be provided. In the case of closed body
types suitable opening doors must be provided.

- For tilting cabs, adequate space permitting tilting must be assu red. In the case of structures which involve the space above the
driver’s cab, adequate space for the passage of intake air must be guaranteed.

- Service access to chassis/driveline components must be retained. For instance repairing the gearbox or clutch must be possible
without necessitating the removal of major components of the added structure.

- The cooling system (radiator cowling, radiator, air passages, cooling circuit etc.), fuel supply (pump position, filters, pipe diameter,
etc.) and the engine air intake must not be altered.

- The anti-noise panels must not be altered or moved in order to prevent changes in the approved noise levels of the vehicle.
Should it be necessary to make openings (e.g. for the longitudinal runner of the body to pass through) these must be properly
closed off using material with inflammability and soundproofing characteristics equivalent to those used originally.

- Adequate ventilation of the brakes and battery case (especially in the case of vans) must be guaranteed.

- When positioning the mudguards and wheel arches, the rear wheels must be free to rebound even when used with chains.

- When the vehicle has been set up, for safety reasons, headlight attitude must be checked and adjusted as necessary. Perform
the adjustment ac cording to the instructions provided in the use and maintenance manual.

- In the case of parts which are supplied loose (e.g. spare wheel, chocks) it will be the responsibility of the bodybuilder to position
and secure them in an accessible and safe manner in compliance with possible national laws.

GENERAL SPECIFICATIONS

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1.15 Quality System management

For some time IVECO has been promoting Quality System development and trainin g for bodybuilders.

This is a requirement due not only to compliance with domestic and in ternational regulations on product liability, but also the growing
demand for increasingly higher quality levels. The creation of new forms of organization in the various sectors and the quest for
increasingly more advanced levels of efficiency.

IVECO believes it essential for bodybuilders to be equipped with an organization where the following are defined and available:

- Organization charts for functions and responsibilities.

- Quality system.

- Quality goals.

- Technical design documentation.

- Process and control phases with relevant resources.

- Product improvement plan, obtained also with corrective actions.

- After sales service.

- Staff training.

- Manufacturer liability documentation.

1.16 Vehicle maintenance

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 t h e
aspects affected by the modifications performed.

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Convention

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 ornon-driven). This definition differs from the definition of wheelbase in th e CE Directives.
The rear overhang is taken as the distance between centreline of the last axle and the rear end of the chassis runner. For dimensions
A, B and t of the frame and counterframe section please refer to the figure below.

Figure 1.5

120360

CHASSIS MODIFICATIONS

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Index

Index

SECTION 2

Chassis modifications

Page

2.1 General instruct ions for chassis modifications 2-5

2.1.1 Specific Precautions 2-5

2.2 Protection against Rust and Painting 2-7

2.2.1 Original components 2-7

2.2.2 Added or modified painted parts 2-10

2.2.3 Precautions 2-11

2.2.4 Exceeding the Limits 2-12

2.3 Drilling the Chassis 2-13

2.3.1 Screws and nuts 2-13

2.3.2 Characteristics of the material to be used when modifying the chassis 2-13

2.3.3 Stresses on the chassis 2-14

2.3.4 Welding the Chassis 2-15

2.3.5 Closing of existing holes 2-16

2.4 Modifying the Wheelbase 2-17

2.4.1 General Specifications 2-17

2.4.2 Authorisation 2-17

2.4.3 Consequences for steering 2-17

2.4.4 Effect on Braking 2-17

2.5 Modifying the Rear Overhang 2-18

2.5.1 Authorisation 2-18

2.6 Installing a Towing Device 2-18

2.6.1 General Specifications 2-18

2.6.2 Traditional towing hooks 2-19

2.6.3 Hook types 2-22

2.6.4 Lowered Rear Cross Member 2-22

2.7 Installing a Supplementary Axle 2-24

2.8 Modifying the Drive Line 2-24

2.8.1 Permitted lengths 2-24

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Index

Page

2.8.2 Determining Driveshaft Positions 2-27

2.9 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

2.12 Heating/Air conditioning system modifications 2-32

2.12.1 Installation of a Supplementary Heating System 2-32

2.12.2 Installing an Air-Conditioning System 2-33

2.13 Cab Modifications 2-34

2.13.1 General Specifications 2-34

2.13.2 Roof Panel Modifications 2-35

2.13.3 Occupant protection 2-37

2.14 Changing the Size of the Tyres 2-38

2.15 Modifications to the Braking System 2-39

2.15.1 General remarks 2-39

2.15.2 Brake pipes 2-39

2.15.3 Fitting pipes on the vehicle 2-40

2.15.4 Instructions for adjusting the braking load proportioning valve 2-43

2.16 Electrical System: Modifications and Drawing-Off Power 2-48

2.16.1 Earth points 2-50

2.16.2 Electromagnetic compatibility 2-56

2.16.3 Additional equipment 2-63

2.16.4 Current drawing 2-66

2.16.5 Additional Circuits 2-74

2.16.6 Operations to adjust overhang 2-75

2.16.7 Provision for trailer 2-75

2.16.8 Side Marker Lights 2-78

2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment 2-80

CHASSIS MODIFICATIONS

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Index

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

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Index

CHASSIS MODIFICATIONS

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General instructions for chassis modifications

2222.2

General i nstruction sf orch assis modif ications

2.1 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);

- Holes in the flanges of the side members are not permitted (except for the items described at point 2.3.4);

- Where riveted connections exist and can be modified as explained below, these can be replaced by flanged-head screws and
nuts of min. c lass 8.8 or by hex screws of the next greater diameter and self locking nuts. Screws greater than M12 must not
be used (max. diameter of hole 13 mm) unless otherwise specified.

- In cases where t h e original joints were detached and rejoined with bolts it is forbidden to reuse the same bolts. In th is event
and when rivets are replaced with bolts, the bolt torque must be checked after the vehicle has been driven approximately 500
÷ 1.000 kms.

2.1.1 Specific Precautions

!

During the welding, drilling, grinding and cutting operations when working in the proximity
of brake lines and particularly if these are of plastic material or electric wiring, care must be
taken to ensure their protection. Where necessary they should be removed (comply with the
provisions given at points 2.15 and 2.16).

Figure 2.1

91444

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General instructions for chassis modifications

Regarding the electrical equipment remember to:

a) Take precautions concerning the alternator and the electrical/electronic components. In order to avoid damaging the diode

rectifier, never disconnect the batteries (or open the isolator) when the engine is running.
If the vehicle has to be tow started make certain that the batteries are connected. Should it be necessary to quick charge
the batteries, disconnect them from the vehicle circuit.
In order to run the engine with external means and in order to avoid current peaks which might damage the electric/elec­tronic components, do not use the ”start” function in conjunction with external charge devices if such devices are equipped
with this function. Starting will have to be carried out only with the external battery trolley ensuring correct polarity.

b) Checking the earth connections.

As a general rule the original earth connections of the vehicle must not be changed. If it is necessary to move these connec­tions or to implement further earth points use the existing holes on the chassis as far as possible and:

- Remove, mechanically, and/or with an appropriate chemical product, th e paint on the chassis side and on the terminal side
creating a resting plane free from indentations or ridges.

- Apply appropriate high conductivity paint between the cable terminal and the metal surface (e.g. galvanizing paint IVECO
Part number 459622 by PPG).

- 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 Work­shop manuals.

With regard to the electronic devices, avoid linking earth connections between the devices; only use single wireearths with optimised
lengths (as short as possible).

c) Electric wiring

For further information regar ding the braking and electronic system, refer to point 2.15 and 2.16.