Iveco EURO 4, EURO 5 Service Manual

TRAKKER EURO 4/5

BODYBUILDERS INSTRUCTIONS

HEAVY RANGE

EDITION 2008

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

Publication Nr. 603.93.731 - 2 Printed in Italy - 01/08

Edition

Produced by:

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

TRAKKER EURO 4/5

Bodybuilders instructions Print 603.93.731 - 2

edition

Base - January 2008

UPDATE DATA

Section Description Page Revision date

2 Frame Paragraph 2.16 moved to chapter 5 January 2008

3 Structures 3.26: paragraph added 3.5.4.3 January 2008

3 Structures 3.43: paragraph added 3.12.1 January 2008

4 Power take-off Full overhaul chapters 4.6 and 4.7 January 2008

5 Electronic subsystems 5-41: note added to paragraph 5.5.8 January 2008

6 Exhaust systems with SCR Chapters 6.6 and 6.7 added.

Full overhaul chapter 6.5

January 2008

Update data

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Update data

Base - January 2008 Print 603.93.731

Foreword

This manual contains instructions and data for fitting body structures/ancillaries and Vehicle modifications and is intended for

skilled and qualified personnel. The bodybuilder is responsible for the design and fitting and any modifications necessary for the installation. The bodybuilder must

ensure full compliance with the requirements set out in this manual and with national and international regulations (Construction and Use, and EEC Standards) in force.

Before starting any work make sure you are working form the latest Iveco Bodybuilders Instruction manual for the model. Make sure that all safety equipment e.g. eye protection, hard hat, shoe, gloves etc are used. Check that all mechanical equipment e.g. lifts and handling gear is in good working order and is used. Finally work on the vehicle in good conditions and ensure maximum safety at all times.

Any change, modification or installations not covered by this manual and not expressly authorized i n writing by IVECO will relieve the latter of any responsibility and make, in particular, the vehicle warranty null and void.

For installations / modifications and general information not covered by this manual c ontact Iveco. On completion of the installation e.g. body, crane, wheelbase modification the vehicle and systems must be checked to ensurevehicle

operation and safety is as designed by Iveco and has not been compromised. If a vehicle system needs to be set up i.e. engine control for PTO installation then contact your local Iveco Service Department.

IVECO shafl not be responsible for any change, modification or fittings concerning the vehicle. Due to continuing vehicle improvements and changes in regulations which cover or affect the vehicle, the information in this publica-

tion may not always be up to date. If the bodybuilder has any queries regarding the information contained in this manual regarding the vehicle that is to be worked on

he should contact Iveco before starting.

Symbols - Warnings

Danger to people:

failure to fully comply with these precautions can involve serious danger for personal safety.

Danger of serious damage to the vehicle

Partial or complete non observance of these precautions can cause serious damage to the vehicle and invalidate the Iveco warranty.

Warning / Precaution:

failure to fully comply with these precautions can result in serious danger to personal safety and damage to the vehicle with the loss of the vehicle warranty.

This indicates the correct use of materials in order to make the vehicle as environmentally friendly as possible.

Indicates additional information.NOTE

Foreword

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Page header and footer interpretation

Vehicle type

Section title

Section number -

page number

Print number

Foreword

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Chapter title

Basic edition -

month year

INDEX OF SE CTION

Section

General specifications

Chassis modifications 2

Building & Mounting the structures 3

Power Take-offs 4

Special instructions for electronic subsystems 5

Special instructions for -SCR- exhaust system 6

Index of section

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Index of section

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TRAKKER Euro 4/5

Index

GENERAL SPECIFICATIONS

SECTION 1

General specifications

1.1 Aim of bodybuilders instructions 1-3

1.2 IVECO “no objection” for changes and fittings 1-3

1.3 Liabilities 1-4

1.4 Guarantees 1-4

1.5 Request for a “no objection” 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

1-1

Page

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 weights 1-9

1.13.1 General Specifications 1-9

1.13.2 Determining the Centre of Gravity of the Body and Payload 1-9

1.13.3 Observing the Permitted Weights 1-13

1.14 Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance 1-14

1.15 Quality System management 1-15

1.16 Vehicle maintenance 1-15

1.17 Conventions 1-16

Index

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1-2

GENERAL SPECIFICATIONS

RAKKER Euro 4/5

Index

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TRAKKER Euro 4/5

Aim ofb odybuild ers instr uctions

GENERAL SPECIFICATIONS

1-3

1.1 Aim of bodybuilders instructions

The purpose of this publication is to provide data, specifications and instructions for the bodybuildingand con version of an original

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

1.2 IVECO “no objection” for changes and fittings

Changes must be carried out in accordance with the requirements set out in the following guidelines.

The following may be carried out only with IVECO’s authorisation after submitting a copy (two for English Market) of the documentation required for technical evaluation of the proposed change (drawings, calculations, technical report etc.):

- wheelbase modifications, where the new wheelbase does not fall within the minimum and maximum wheelbase availablewithin theIVECOrangeforthesamevehicle;

- work carried out on the braking system;

- work carried out on the suspension system;

- steering wheel modifications;

- changes to th e stabiliser bars and suspensions;

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

- changes to the intake systems, engine exhaust and SCR components;

- engine c oolin g system modifications;

- power unit and driving component modifications;

- work carried out on front and rear axles;

- fitting additional 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 authorisation fromIVECO. Any modification or fitting not coveredby these standardsshall, on the contrary, be authorized by IVECO in advance

Aim of bodybuilders instructions

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1-4

GENERAL SPECIFICATIONS

Liabilities

RAKKER Euro 4/5

1.3 Liabilities

The authorizations issued by IVECO concern solely the technical/c onceptual 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 operation, 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 the performance and specifications of the vehicle.

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 vehicle/model 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 followed.

- Original spare parts or components which IVECO has made available for specific conversions were not used.

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 accident prevention standards must 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 carry out operations at least in an equivalent manner.

1.5 Request for a “no objection”

The requests for approval or support to carry out work or make modifications or fittings shall be forwarded to the IVE CO 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 the vehicle. The drawings shall highligh t 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.

Liabilities

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TRAKKER Euro 4/5

IVECO techni cal documents avail able by means of computer

GENERAL SPECIFICATIONS

1-5

1.6 IVECO technical documents available by means of computer

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

- bodybuilder instruction manuals;

- specification sheets;

- chassis cab diagrams in .dwg and tiff formats;

- chassis diagrams in tiff formats;

- other specifications concerning the vehic le 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 au thorised 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 vehic le.

Instruction for added assemblies

Whereassembliesare added,the bodybuilder must provide the necessaryservice and maintenance instructionswhen the vehicle

is delivered.

1.8 Legal Provisions

On completing th e 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 regardingthese matters may be obtained from the competent Authoritiesor the IVECO Area Network.

The vehicles manufactured at our plant (except some versions 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.

IVECO technical documents available by means of computer

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1-6

GENERAL SPECIFICATIONS

Preventi onof acci dents

1.9 Prevention of accidents

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 these regulations will be the responsibility of th e manufacturers of the structures and devices.

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

They should be removed before working with welding equipment and flames.

RAKKER Euro 4/5

1.10 Choice of material to use: Ecology - Recycling

Increasingly greater attention should be paid, at th e study and design stage, to the choice of materials t o be used.

This is especially the case as regards the aspects con nected with ecology and recycling in t he light of domestic and international regulations that are constan tly being developed in the sector.

In this connection:

- everyonemust be aware of the prohibitionson using harmful or potentiallyhazardous materials,such as ones containing asbestos, lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent c hrome, etc.

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

- With composite synthetic materials, use c omponents 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 the current regulations.

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).

Prevention of accidents

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TRAKKER Euro 4/5

Vehicledelivery

GENERAL SPECIFICATIONS

1-7

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 units t o 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 all legal requirements;

- carry out the checks included in the ”IVECO Pre-Delivery inspection” list (available from the IVECO network) w ith 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 must not be used. In such an instance, and in the event that rivets have been replaced with screws, you must again check the tightness of the c onnection after travelling approximately 500-1000 km, to ensure it is to the correct torque.

- measure t he 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 vo ltage is less than 12.1 V, the battery must be scrapped and replaced with a new one.

Vehicle delivery

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1-8

GENERAL SPECIFICATIONS

Vehicl es ide ntifi cation

RAKKER Euro 4/5

1.12 Vehicles Identification

The commercial designation of IVE CO vehicles does not coincide with the ty pe approval designation. Following are two examples of commercial designation of Trakker Range vehicles complete with an explanat i on of the codes

utilised.

CAB VERSIONS

TRACTORS

Cab Range Power Configuration

RANGE-CAB

AD = Active Day short AT = Active Time long

260 /PT14

400 T 54TW

PTT-Cab versions

(n˚/10 → hung in ton)

PTC-Tractors

(with semitrailers)

(n˚/10 → hung in ton)

TRAKKER

VERSION

B=Mixertruck T=Tractor

Engine power

(n˚ x10→ HP)

W = All-wheel drive WT = All-wheel drive tractor

SUSPENSION

version

B T

Suspension

/P = Rear tyre (tandem 21 ton, 6x4 and 8x4)

Vehicles identification

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TRAKKER Euro 4/5

Dimensionsand weights

GENERAL SPECIFICATIONS

1-9

1.13 Dimensions and weights

1.13.1 General Specifications

The dimensions and maximum permissible weight on the axles are indicated on drawings, on technical specifications and, in

greater details, on the official documentation issu ed by IVECO. The kerb weights refer to vehicles with standard equipment. Special equipment may involve considerable modification to the weight

and its distribution on the axles. Lights and rear-view mirrors positioning on ou r vehicles is designed for widths of 2,550 mm. This dimension may also be applied

to special body versions with a width of 2,600 mm (e.g. refrigerator vans).

Weighing the Chassis

As a result of production factors there may be a variation in weight of approx. 5%.

It is, therefore, advisable to determine the weight of the vehic le with its cab before fitting the body and equipment and establishing their distribution on the axles.

1.13.2 Determining the Centre of Gravity of the Body and Payload

Positioning on longitudinal plane

To establish the location of the centre of gravity of the body and payload the following examples below may be used as guidelines.

The technical documentation specific to each model (chassis cab drawing) give the positions permitted with the vehicle in its standard form. The weight and positioning of the single components of the vehicle are given in the chassis and weight distribution diagram.

Dimensions and weights

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1-10

GENERAL SPECIFICATIONS

RAKKER Euro 4/5

Figure 1.1

A = Rear axle or tandem mid axle W = Payload + body W

= Share of payload on front axle

= Share of payload on rear axle (or tandem)

= Distance of centre of gravity from centre-line

of rear axle (or tandem centre-line)

L = Actual wheelbase

Example to determine the position of the centre of gravity of the payload plus body

Vehicles with 2 axles; v ehicles with 3 axles with an equal load on the two rear axles

L1=

W1⋅ L

respectively L1=L-

W2⋅ L

91132

Figure 1.2

Example to verify compliance of admitted weight on the axles

W = Payload plus body W

= Proportion of payload on front axles

= Proportion of payload on rear axles (tandem axles)

= Distance of centre of gravity from mid point of rear axles

L = Effective wheelbase

4-axle vehicles with identical loading of each front a nd rear axle

W1⋅ L

L1=

respectively L

=L-

W2⋅ L

91131

Dimensions and weights

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TRAKKER Euro 4/5

GENERAL SPECIFICATIONS

1-11

In order to apportion 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.

As for equipment, the actual location of the centre of gravity is used. When building bodies or containers, loading and u n loading systems for the tran sported goods must be devised which preclude

excessive variations in the distribution of the load and/or excessive loads on the axles, also giving the relevant instructions to the users.

The bodybuilderwill also need to install suitable payload securing systems on th e body so that transport can be madewith the utmost safety.

Figure 1.3

Uniform distribution of the load Non-uniform load distribution

Uniform distribution of the load Non-uniform load distribution (pay attention to loads

on axles and minimum ratio)

91134

Dimensions and weights

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1-12

GENERAL SPECIFICATIONS

RAKKER Euro 4/5

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 wh en 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 t o ensure good handling of the vehicle (e.g. transverse stability of the moving vehicle). In order to comply with the current EC Directive, IVECO providesinformation for the various models (wheelbaseand specific body)

on computer, regarding:

- Height of centre of gravity of chassis cab (e.g. chassis cab diagram, braking data);

- Maximum height of centre of gravity of complete vehicle at full load (e.g. national type-approval document);

- Braking capacity of each single axle (e.g. braking data).

Figure 1.4

Verification with full load:

91135

Wv · Hv + Ws · Hs

Ht =

Wv = Chassis cab vehicle kerb weight Hv = Height of centre of gravity of chassis cab vehicle (laden condition) Ws = Body and payload Hs = 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 fully laden to gvw

Wv + Ws

(Wv + Ws) · Ht − Wv · Hv

Hs =

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

Dimensions and weights

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TRAKKER Euro 4/5

GENERAL SPECIFICATIONS

1-13

Using Stabiliser Bars

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

compliance with point 2.7) 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 actin g 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 w ould 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 th e load is positioned behind the cab (e.g. crane) or where the superstructures are very rigid (e.g. van conversion).

Exceeding the Limits

When transportinggoods with an exceptionallyhigh centre of gravity(e.g. machinery, indivisible cargoetc.) from a technical point

of view it is possible to exceed the values indicated in the table provided that the steering system of the vehicle is suitably adapted to this condition (e.g. reduced speed, gradual changes on the steering wheel, etc.).

1.13.3 Observing the Permitted Weights

All limits indicatedin our documentation must be adhered to. The load of the front axle is of particular importance under varying

load co nditions, in order to ensure t he correct steering characteristics on road surfaces of all types. Particular attention must therefore be paid to vehicles with a weight which is concentrated on the rear overhang (e.g. cranes, trailers

with a central axle) and to vehicles with a short wheelbase and a high c entre of gravity (e.g. mixer trucks). When positioning the body and equipment, the loads must be correct ly distributed transversally. For each wheel a variation in the

rated load (1/2 of the axial load) of 4% is permitted (e.g. admitted load on axle: 10,000 kg load admitted on each wheel: 4,800 to 5,200 kg) provided that the tyres permit it, without impairing braking or driving stability.

Apart from different specifications for specific individual vehicles, the following may be taken to be the minimum values for the front axle:

- 20% of the total vehicle weight with uniformly distributed loads

- 25% of the total vehic l e weight for loads that are concentrated on th e rear overhang.

The rear overhang of the body must be built in strict observance of the permitted axle loads, the limitations in length, the positioning of the tow hook and of the underride guard stipulated by the relevant regulat ions and legal requirements.

Variations in the Permissible weight

Special exceptions to t he maximum permissible weight 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 Administrative Authority. A reduction in admissible vehicle load (downrating) may require modifications on some parts, such as the suspension. In these cir-

cumstances, t he nec essary information may be supplied. The request for authorisation must include:

- Vehicle type, wheelbase, identification nu mber, designated use.

- Weight distribution on the axles (e.g. vehicles equipped with crane and body) including positions of the centre of gravity of the payload.

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

Dimensions and weights

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1-14

GENERAL SPECIFICATIONS

Instructionsforthe CorrectFunctioningofthe Partsof theVehicle andAccessibilityforMaintenance

RAKKER Euro 4/5

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

As a ru le, when modifying or installing any ty pe of equipment, nothing must be altered which prevents the correct functioning

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 c abs, adequate space permitting tilting must be assured. In the case of structures whi ch involve the space above the driver’s cab, adequate space for the passage of intake air must be guaranteed (see Figure 1.5).

Figure 1.5

98892

1. Retain adequate room for tilting the driver’s cab - 2. Retain thefreespaceabovethegearbox(fortractorswithsemitrailers consider the movement between tractor and semitrailer) - 3. Cab pivot point - 4. Min. distance to be met

- 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 in flammability and soundproofing characteristics equivalent to those used originally.

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

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TRAKKER Euro 4/5

Quali tyS ystem manageme nt

GENERAL SPECIFICATIONS

1-15

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

- The positioning of the mud-guards and wheel-arches must allow free movement of the rear wheels even when chains are being used. Sufficient space must also be ensured with lifting axles. Some of our models have 3rd axle steering which also steers in the raised position; an d it is necessary to leave space for this function (see point 2.20).

- When the vehicle has been set up, for safety reasons, headlight attitude must be checked and adjusted as necessary. Perform the adjustment according to the instructions provided in the user 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 regulations.

1.15 Quality System management

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

This is a requirement due not only to compliance with domestic and international 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 and organised where t he following are defined an d available:

- organization charts for functions and responsibilities.

- Quality System.

- quality goals.

- technical design documentation.

- process an d cont rol phases with relevant resources.

- product improvement plan, obtained also with corrective ac t ions.

- after sales service.

- staff training.

- manufacturer liability documentation.

1.16 Vehicle maintenance

In addition to making the n ecessary checks on the body/structure in keeping with customary working procedures, the bodybuil-

der shall perform the checks specified in the “IVECO pre-delivery inspection” list, which can be obtained from the IVECO n etwork, for the aspects affected by the modifications performed.

Quality System management

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1-16

GENERAL SPECIFICATIONS

Convention

RAKKER Euro 4/5

1.17 Conventions

In these bodybuilders instructions, the wheelbase is taken as the distance between the centreline of the first steering axle and the centreline of the first rear axle (driven or non-driven). This definition differs from th e definition of wheelbase in the CE Directives. The rear overhang is taken as the distance between centreline of the last axle and the rear end of the chassis runner. For dimensions A, B and t of the frame and subframe section please refer to the figure below.

Figure 1.6

91473

Convention

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Index

CHASSIS MODIFICATIONS

SECTION 2

Chassis modifications

2.1 General instructions for chassis modifications 2-5

2.1.1 Specific Precautions 2-5

2.2 Painting and Rust Protection 2-7

2.2.1 Original components 2-7

2.2.2 Added or modified painted parts 2-9

2.2.3 Precautions 2-10

2.2.4 Max indicative height of center of gravity of payload in relation to transverse stability 2-11

2-1

Page

2.3 Drilling the Chassis 2-12

2.3.1 Screws and nuts 2-12

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 2-17

2.4 Modifying the Wheelbase 2-18

2.4.1 General Specifications 2-18

2.4.2 Approval 2-18

2.4.3 Effects on the steering 2-19

2.4.4 Effect on braking 2-19

2.4.5 Recommended procedure 2-20

2.4.6 Chassis Stress Level 2-21

2.4.7 Cross Members 2-21

2.4.8 Changes to transmissions 2-21

2.5 Modifying the Rear Overhang 2-22

2.5.1 General specifications 2-22

2.5.2 Reducing the Overhang 2-22

2.5.3 Increasing the Overhang 2-22

Index

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2-2

CHASSIS MODIFICATIONS

RAKKER Euro 4/5

Page

2.6 Installing a Towing Device 2-24

2.6.1 General Specifications 2-24

2.6.2 Traditional towing hooks 2-25

2.6.3 Towing hook for central axle trailers 2-26

2.6.4 Mid-axled trailer (with rigid drawbar) 2-26

2.6.5 Lowered Rear Cross Member 2-31

2.6.6 Centre axle trailers: towing cross member in lowered and forw ard positions (short hook) 2-33

2.6.7 Reinforcement of Standard Rear Cross Member 2-33

2.6.8 Tow hooks for Centre Axle Trailers 2-34

2.6.9 Remarks about the Payload 2-34

2.6.10 Increasing the Towable weight 2-34

2.7 Installing a Supplementary Axle 2-35

2.7.1 General Specifications 2-35

2.7.2 Chassis Frame Reinforcement 2-35

2.7.3 Installing a Rear Supplementary Axle 2-36

2.7.4 Steering Axles 2-38

2.7.5 Components and Suspension 2-38

2.7.6 Stabilisers 2-38

2.7.7 Connection to the Chassis Frame 2-38

2.7.8 Brake system for additional axle 2-39

2.7.9 Raise Device 2-39

2.7.10 Modifying the suspension 2-40

2.7.11 Changing a Mechanical Suspension into a Pneumatic or Mixed Suspension 2-40

2.8 Modifying the Drive Line 2-41

2.8.1 Permitted lengths 2-41

2.8.2 Determining Driveshaft Positions 2-43

2.9 Modification of the Engine Air Intake and Exhaust Syatem 2-46

2.9.1 Intake 2-46

2.9.2 Vertical Exhaust 2-47

Index

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TRAKKER Euro 4/5

CHASSIS MODIFICATIONS

2-3

Page

2.10 Modification of the Engine Cooling System 2-48

2.11 Installation of a Supplementary Heating System 2-49

2.12 Installation of an Air Conditioning System 2-50

2.13 Cab Modifications 2-51

2.13.1 General Specifications 2-51

2.13.2 Roof Panel Modifications 2-51

2.14 Changing the Size of the Tyres 2-52

2.15 Modifications to the Braking System 2-54

2.15.1 General Specifications 2-54

2.15.2 Brake Pipes 2-54

2.15.3 Electronic braking system control devices 2-59

2.15.4 Taking air from the system 2-59

2.16 Electrical System: Modifications and Drawing-Off Power 2-60

2.17 Repositioning Parts and Mountin g Auxiliary Assemblies and Equipment 2-60

2.18 Carrying hazardous goods ADR 2-62

2.19 Retarder installation 2-64

2.20 Modifications to the Rear Underrun 2-65

2.21 Rear Mudguards and Wheel Boxes 2-66

2.22 Mudflaps 2-67

2.23 Side Guards 2.68

2.24 Chocks 2-70

Index

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CHASSIS MODIFICATIONS

RAKKER Euro 4/5

Index

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TRAKKER Euro 4/5

22222.

General i nstructi ons for chassi sm odificati ons

CHASSIS MODIFICATIONS

2-5

2.1 General instructions for chassis modifications

Changes must be performed according to criteria contained in related paragraphs below.

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 3.4);

- Where rivet ed connections exist and can be modified as explained below, these can be replaced by flanged-head screws and nuts of min. class 8.8 or by hex screws of the next greater diameter and self loc kin g nut s. Screws greater than M14 must not be used (max. diameter of hole 15 mm) unless otherwise specified.

- In cases where the original joints were detached and rejoined with bolts it is forbidden to reuse the same bolts. In this 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

Figure 2.1

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

2.15.2 and 5.5).

91444

General instructions for chassis modifications

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CHASSIS MODIFICATIONS

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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 h as to be tow start ed make certain that the batteries are c onnected. S hould it be necessary to c harge t he 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.

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, the paint on th e chassis side and on the terminal side creat-

ing 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 th e 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 started motor depending on the driving position) points for the earth connect ion s for control switches (e.g. sensor or low absorption devices).

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

Specifications and standards for correct installation of wires in electrical systems

Power cables (+ direct) must be fed on their own into corrugated piping (of appropriate diameter) and not together with other smaller cables (signal and negative cables); th ey must be spaced a minimum distance of 100 mm apart (reference value = 150 mm) from high heat sources (engine turbine, exhaust manifold,...) and a distance of at least 50 mm must be maintained from chemical agent containers (batteries, etc.).

The same prescription is applicable with regard t o th e proximity to moving parts. The passage of cables th rough openings and over sharp edges of sheet metal must be protected by means of cable glands (in addition

to the flexible conduit covering). The flexible conduit must protect the cable entirely and it must be joined (with shrink wraps or by taping) to the rubber caps on

the terminals. In addition, the clamps securing the flexible conduit (cut longitudinally) must not deform it; this precaution prevents the risk of cables c oming out of the conduit or coming into contact with the cut edge of the conduit.

All connection clamps (+) for the above cables and their terminals must be protected by sealed rubber in areas exposed to atmospheric agents with the possible risk of standing water.

Fixing of the cable lugs to the terminals (including negative terminals) must be assured in such a way as to prevent them working loose, applying tightening torque wherever possible and arranging the lugs in a star configuration in the case of multiple connections (to be avoided if possible).

The route of the cables in question must be defined as far as possible with dedicated brackets and ties that are close enough together to avoid loose sections and provide the possibility (and obligation) to reconstruct the same installation in the event of repairs or the installation of additional equipment.

In the case of connection between the chassis-tilting cab, the position of the cable harness must be checked with the cab in its driving position and when tipped, in order to identify any points of interference or pulling, which must be corrected.

General instructions for chassis modifications

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