Iveco EURO Range User Manual
EURO RANGE
BODYBUILDERS INSTRUCTIONS
EURO RANGE
EDITION 2002
FOLLOW THESE INSTRUCTIONS CAREFULLY IN ORDER TO PRESERVE THE EFFICIENCY AND
RELIABILITY OF ALL VEHICLE COMPONENTS.
OUR PRODUCTS ARE SUBJECT TO CONSTANT DEVELOPMENT; AS A RESULT CERTAIN PARTS
OF THIS PUBLICATION MAY NOT BE FULLY UP TO DATE.
PRODUCED BY
SATIZ S.P.A.
EDITORIA TECNICA
PUBBLICAZIONI TECNICHE C/O IVECO
LUNGO STURA LAZIO 49
10156
TORINO ITALY
PUBLICATION EDITED BY
IVECO ENGINEERING
PUBLICATION NR. 603.42.371 -7THED.
PRINTED IN ITALY - 02.2002
Foreword
For the technical information concerning modification of the vehicle, application of bodies and re-
quests for technical documentation, please contact the relevant IVECO Commercial Sector.
These instructions refer to the vehiclesof the EuroCargo, EuroTech, EuroStar and EuroTrakker ranges
that are currently in production; for vehicles in these ranges that have gone out of production, please
refer to the instructions given in previous editions.
For other current models and ones no longer manufactured by IVECO, refer to the instructions contained in the booklet N
R. 603. 42.141.
Warning
The following symbols are widely used in this manual and the indications to which they refer should
be carefully followed.
Danger to people: failure to fully observe these precautions can involve serious danger
for personal safety.
Warning/Precautions: failure to fully observe these precautions involves the risk of serious damage to the vehicle (with resulting loss of warranty conditions) and/or persons.
Foreword
Contents
SECTION
GENERAL SPECIFICATIONS 1
CHASSIS MODIFICATIONS 2
BUILDING AND MOUNTING THE STRUCTURES 3
POWER TAKE-OFFS 4
SPECIFIC INFORMATION AND INSTRUCTIONS 5
Contents
Alphabetical index to subjects
ABS system, precautions 2-10;2-68;2-75;2-96; 2 -105
ABS system, service operations 2-68
ABS, precautions 2-10; 2-75; 2-96; 2-105
ABS, service operations 2-68
Access to components for maintenance, instructions 1-18
Accident prevention 1-19
Additional alternator, installation 2-75
Additional batteries 2-75
Air conditioning system, installation 2-60; 2-75
Air draw from system 2-69
Alternator, p recautions 2-6; 2-10
Aluminium subframe 3-5
Anti-rust protection 2-7
Antitheft device installation 5-12
Antitheft device, precautions 2-75
Assessment of superstructure centre of gravity and payload 1-9
Authorizations, necessity 2-5; 2-15
Authorizations, request 1-5
Automatic transmissions, precautions 2-75
Ball hooks 2-24
Batteries, precautions 1-21; 2-6; 2-10;2-72
Bolts 2-5; 2-9
Box-body installations 3-19
Brake corrector, installation/adjustment 2-69
Brake piping, precautions 2-6; 2-11; 2-65; 2-67; 2-68
Brake piping, tightening torque 2-65; 2-67
Brakes, precautions / prescriptions 2-6; 2-11; 2-49; 2-65; 2-67; 2-68
Braking system, precautions 2-6; 2-11; 2-49; 2-65; 2-67; 2-68
Braking system, service operations 2-65
C.B., mobile phone, transmitting and receiving systems 2-74
Cab , modification 2-61
CAN line 2-72
Cement mixers, installation 3-28
Alphabetical index to subjects
I
Centre of gravity, transverse stability 1-16
Centre-axle trailer hooks 2-44
Centre-axle trailers 2-28; 5-18
Chassis crossmembers 2-15
Chassis sidemember extension sizes available from IVECO Spare Part Office 5-83
Chassis modifications, general rules 2-5
Chassis reinforcements 2-46
Chassis, specific precautions 2-6
Chassis stress, checks and limits 2-14; 2-46
Chassis weighing 1-9
Chocks, position 2-10
Choice of chassis 1-8
Choice of the material to be used: Ecology — Recycling 1-20
CNG gas-fuelled vehicles, service operations / precautions 5-20
Connection (chassis / subframe), elastic type 3-14
Connection (chassis / subframe), type and features 3-12
Connection (chassis / subframe), with brackets 3-13
Connection (chassis / subframe), with U-bolts 3-15
Connection (chassis / subframe), with shear-resistant plates 3-17
Conversion of a truck into a s emitrailer tractor 3-44
Crane, behind cab 3-49
Crane, installation 3-48
Crane, on rear overhang 3-54
Current draws 2-75; 2-78
Current master switch 2-97
Demountable bodies 3-22
Dimensions and weights 1-9
Distance between holes 2-9
Drilling, closing of existing holes 2-12
Drilling, execution 2-9
Drilling, prohibitions 2-5; 2-9
Drive shafts, modifications 2-17
Earthing, execution and precautions 2-6
ECAS, rear axle air suspension power supply check 5-17
Ecology 1-20
II
Alphabetical index to subjects
EDC, engine speed isochronous check 2-10; 2 -75; 2-105
Electric / electronic on-board systems, interface with Cursor engine version 5-23
Electric / electronic parts, precautions 2-6; 2-10; 2-72; 2-74; 2-75; 2-96
Electric circuits, precautions 2-7; 2-72; 2-96
Electric system, precautions 2-6;2-7; 2-10; 2-72; 2-74; 2-75; 2-96
Electric system, service operations 2-72
Electromagnetic compatibility 2-73; 2-96
Electronic control units, positioning on vehicles 5-6
Electronic control units, precautions 2-6; 2-10; 2-72
Engine air intake system, modifications 2-56
Engine cooling system, modifications 2-58
Engine exhaust, modifications 2-56
Engine speed adjustment 4-27
Engine speed isochronous check (EDC) 2-10; 2-75; 2-105
Fifth wheel mounting 3-33
Fifth wheel supporting structure 3-33; 3-41; 3-42
Fifth wheels, fastening 3-31; 3-33
Forces applied to steering-wheel 2-13
Fuel tank, position 2-102
Gas, electric / electronic arrangements 5-22
Gas, service operations / precautions for gas-fuelled vehicles 5-20
Gas-fuelled vehicles, service operations / precautions 5-20
General specifications 1-5
Grinding, precautions 2-6
Hazard goods transport 2-104
Interchangeable parts, outfits 3-22
Interface with electric / electronic on-board systems with Cursor engine version 5-26
Interface with electric / electronic on-board systems with EuroMover engine version 5-54
Interface with electric / electronic on-board systems with TECTOR engine version 5-67
IVECO approval, necessity 2-5; 2-15
IVECO approval, request 1-5
Alphabetical index to subjects
III
IVECO offices to be contacted 1-5
Legal requirements 1-19
Limits on modifications 1-7
Load permitted variations 2-75; 2-78
Material, chassis 2-10
Minimum load on front axle, limits 1-15
Mudguard flap 2-108
Optimized drive 5-17
Painting 2-7
Plastic brake piping 2-66
Positioning of electronic control units on vehicles 5-6
Power takeoffs from engine 4-16
Power takeoffs from gearbox 4-7
Power takeoffs from torque restorer 4-15
Power takeoffs from transmission 4-15
Power takeoffs 4-5
Quality system management 1-20
Rear axle air suspension load check with ECAS electronic device 5-17
Rear crossmember, lowered position 2-26
Rear crossmember, reinforcements 2-42
Rear mudguards and wheelboxes 2-107
Rear overhang modification 2-22
Recycling 1-20
Repositioning equipment 2-102
Retarder installation 2-75; 2-105
Self-supporting superstructures 3-11
Semitrailer tractors 3-31, 3-32
Side guards 2-108
Side marker lamps, arrangement 2-97
Side member cutting, precautions and procedure 2-6; 2-11; 2-16
Slide-and-dump containers 3-27
Snowplough 3-68
Special / fire-fighting / municipal vehicles 3-68
Speed limiter, precautions 2-75
IV
Alphabetical index to subjects
Spoiler, fitting 2-61; 2-62
Stabilizer bars, use 1-14
Steering, influence following wheelbase modifications 2-13
Subframe material 3-5
Subframe sections, cement mixers 3-29
Subframe sections, centre-axle trailers 2-30
Subframe sections, crane 3-50; 3-52; 3 -55
Subframe sections, tippers 3 -25; 3 -26; 3-27
Subframe sections, fifth wheels 3-43
Subframe sections, b ox-bodies 3-19
Subframe sections, tail lifts 3-62
Subframe sections, tanks 3-45
Subframe, connection to chassis 3-12
Subframe, , crossmembers 3-10
Subframe, construction 3-5
Subframe, material 3-5
Subframe, profile 3-7
Subframe, stiffening 3-10
Superstructure centre of gravity and positioning payload 1-9; 1-13
Superstructures 3-5
Supplementary axles, installation 2-45
Supplementary heater system 2-59; 2-75
Suspensions, modifications 2-55
Tail lifts, installation 3-58
Tanks, installation 3-44
Tipper installation 3-23
Top-sleeper, assembling 2-62
Towable weight increase 2-25
Towing hook, application 2-24
Towing device installation 2-24
Tractor and semitrailer combination 3-32
Tradenames and logos 1-7
Transmission modifications 2-17
Transmission, drive line modifications 2-17
Transport of indivisible material 3-44
Tyres, replacement 2-64
Under run-bar, modifications 2-106
Alphabetical index to subjects
V
Vans, manufacture 3-23
Vehicle component functions and maintenance 1-6; 1-18
Vehicle delivery 1-21
Vehicle maintenance, accessibility 1-18
Vehicle identification 1-8
Vertical engine exhaust 2-57
Warranty, issue 1-21
Warranty, undertaking 1-6; 2-75
Weight variations 1-15
Weights, compliance with permitted values 1-9; 1-15
Weights, permitted variations 1-15
Welding, execution 2-10
Welding, precautions 2-6; 2-10
Welding, prohibitions 2-5
Wheelbase modification 2-13
Wheelbase, permitted increase 2-13
Winches, installation 3-69
VI
Alphabetical index to subjects
I. GENERAL
SPECIFICATIONS
General specifications
1-1
1-2
General specifications
Index
1. General Specifications
1.1 General Specifications 1-5
1.2 Dimensions and Weights 1-9
1.2.1 General Specifications 1-9
1.2.2 Determining the Centre of Gravity of the Body and Payload 1-9
1.2.3 Observing the Permitted Weights 1-15
1.3 Instructions for the Correct Functioning of the Parts of the Vehicle
and Accessibility for Maintenance 1-18
1.4 Legal Provisions and Prevention of Accidents 1-19
1.5 Choice of material to use:
Ecology - Recycling 1-20
1.6 Quality System management 1-20
1.7 Vehicle delivery 1-21
General specifications
1-3
1-4
General specifications
1.1 General Specifications
Purpose
The purpose of these instructions is to permit modifications and/or fitting genuine IVECO parts while
safeguarding the operation, safet y and reliabilit y of the vehicle and its components.
The modifications and fittings made in compliance with the following instructions, except for the contents of
point 2.1.1, require no specific IVECO approval.
All modifications and fittings not covered in these instructions are to be approved beforehand by IVECO.
IVECO shall not be held liable for any modifications or fittings where approval has not been requested or, if
it has, where approval has been rejected or not given.
Departments to be Contacted and Documentation to be Submitted
Whenever equipment has to be constructed and this is not taken into consideration by the specifications
contained in this manual, the responsible Departments, which can be contacted through the Sales Management
of the Company, will provide the pertinent information. In these cases contact the IVECO Office in your
zone.
When contacting these bodies two copies of the following documentation must be submitted:
a) Drawing of the vehicle including dimensions of the body or of the modified components or of the new
equipment.
b) A break down of the weights, with indications regarding the centre of gravity where necessary.
c) Description of the auxiliary frame, dimensions, fastenings to the chassis of the vehicle.
d) Distribution of the forces and moments acting on the vehicle as a result of the equipment (cranes, cement
mixers, hoists, concrete pumps etc.).
Reference must be made on the drawings themselves to all the points which differ from these specifications.
Furthermore, the use of the vehicle and the conditions under which it is to be used must be briefly described.
IVECO Technical Documentation Available on Computer
The specific IVECO - THB web site contains technical documentation on the product concerning:
- Instructions for bodybuilders;
- Technical descriptions;
- Bodybuilder drawings
- Chassis, transmission, p.t.o. diagrams;
- Type-approval data.
Access information can be requested directly from the above-mentioned IVECO office.
This same office will be able to provide you with CD-ROMs with the collection of chassis cab diagrams for the
various product ranges in CAD - IGS and/or DXF format.
General specifications
1-5
Authorization and Liabilities
The authorizations issued by IVECO concern solely the technical 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;
- operation, safety, reliability and generally the good handling of the vehicle as well as the
effects the modifications and fitting may have on the performance and specifications of the
vehicle.
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.
- The chassis was used in a way which is not suitable for the equipment or for the intended purpose of the
vehicle.
- The specifications, standards or instructions issued by the Manufacturer for the flawless execution of the
operations have not be heeded.
- Original spare parts or components which the Manufacturer has made available for specific interventions
were not used.
Maintaining Proper Operation of Parts and Vehicle
It is clearly understood that for all authorised modification and applications, the proper
functioning of the various parts of the vehicle, the safety of operation and use of the various
elements of the vehicle, in compliance with the national and international regulations (EEC
Standards) and to the norms pertaining to the prevention of accidents must be guaranteed.
1-6
General specifications
Limits on Modifications
To ensure driving safety and good vehicle operation, the following assemblies in general must not be
modified:
-Axles
- Steering system
- Brakes
- Suspension (springs, brackets, anchor bar)
- Chassis
- Power unit
- Coupling devices (hooks, fifth wheels)
- Cab supports, locking and tilting devices
- Electrical system.
Modifications to the above assemblies, where included in these directives, may only be carried out after
approval has been received from IVECO.
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.
Instructions for Additional Units
The bodybuilder shall, upon delivering the vehicle, supply the necessary service and maintenance
instructions for additional installed units.
General specifications
1-7
Choosing the Chassis
The correct choice of chassis, in the appropriate version, is very important if the o utcome of the
modification is to be successful.
Before proceeding with the modifications, ensure that the vehicle supplied corresponds to the one requested
by checking information given on the order, and in the technical documentation provided by the Manufacturer.
Vehicles Identification
Two examples concerning the identification of the Euro Range of vehicles are given below together with
the meaning of the relevant initials:
Cab Range Model Power Version
CHASSIS
CAB VEHICLES
TRACTOR
EXTERNAL NAMEPLATE ON VEHICLE
LD190 /FPE25
MP 400 /PE83XT
ML
MH
MP
LD
FF
M
CC
CAB RANGE
ML = Medium light
MH= Medium Heavy
MP = Multipurpose
LD = Long distance
FF = Fire fighting
M = Military
CC = Chassis cowl
GVW-Vehicles with cab
GVC - Tractors for
semitrailers (:10 in ton)
EURO Engine power
190 E 25
Configuration
C
D
H
K
T
R
V
X
(x 10 in HP)
VERSION
C=Combi
D = Double cab
H = Heavy duty
HM = Heavy mission
K = Kipper
T = Tractor for semitrailers
R = Drawbar
V=Van
X = 6x2COnlytractors
Y = 6x2PRoad
Z = 6x4
W = All wheel drive
Y
Z
W
Gearbox
Suspension
/TN
/P
/PT
/PS
/FP
/FT
/FS
/E
1-8
SUSPENSION
/TN = Only for 6 x 2P vehicles, mechanical rear suspension with fixed 3rd axle (twin wheels)
/P = 4x2, 6x4, 6x2P vehicles, rear air suspension. 6x2P with fi xed 3rd axle, single wheels
/PT = Only for 6x2P rear air suspension with fixed 3rd axle, controlled steering
/PS = Only for 6x2P, rear air suspension with fixed 3rd axle (twin wheels)
/FP = 4x2, 6x4, 6x2P, 6x2C, full air suspension
/FT = Only 6x2P, full air suspension with fixed 3rd axle (twin wheels)
/FS = Only 6x2P full air suspension with 3rd single wheel axle, controlled steering
/E = Rubber rear suspension (6x4, U.K. market)
General specifications
1.2 Dimensions and weights
1.2.1 General Specifications
The dimensions and maximum permissible mass on the axles are indicated on drawings, on technical
specifications 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 mass and its distribution on the axles.
Lights and rear-view mirrors positioning on our vehicles is designed for widths of 2,500 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 mass of approx. 5%.
It is, therefore, advisable to determine the mass of the vehicle with its cab before fitting the body and equipment
and establishing their distribution on the axles.
1.2.2 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 masses and positioning of the single components of the vehicle are given
in the chassis and weight distribution diagram.
General specifications
1-9
Figure 1.1
Vehicles with 2 axles; vehicles with 3 axles with an
equal load on the two rear axles
Rear wheel axle or
tandem centre line
Example to determine the position of the centre of gravity of the payload plus body
W = Payload + body
= Share of payload on front axle
W
1
= Share of payload on rear axle (or tandem)
W
2
= Distance of centre of gravity from centre-line
L
1
of rear axle (or tandem centre-line)
L = Actual wheelbase
Figure 1.2
W1xL
=
L
1
W
respectively L
1
=L-
W2xL
W
Vehicles with 3 or more axles with a constant mass
distribution ratio on the two rear axles. For these
vehicles the ”ideal” values of the wheelbase and
centreline between the axles, resulting from mass
distribution, is determined by the Manufacturer.
Example to verify compliance of admitted masses on the axles
W = Payload + body
= Share of payload on front axle
W
1
= Share of payload on rear axles
W
2
= Share of payload on first rear axle
W
3
= Share of payloa d on second rear axle
W
4
= Distance of centre of gravity relative
L
1
calculated centreline
L = Calculated wheelbase (ideal)
= Calculated centreline (ideal)
L
2
A = Distance between rear axles
1-10
W
1
W
2
W
3=W2
W
4
WxL
=
=Wx
W2xL
=
x
L
A
1
(L - L1)
L
(A - L2)
A
2
Attention:
On vehicles with three or more axles, with
a variable mass distribution ratio on the two
rear axles depending on the load, the ”ideal”
values of wheelbase and centreline between
the axles will have to be calculated on the basis of the information given in the chassis cab
diagram, or in the specific documentation
specially prepared by IVECO. In this way, for
special versions (e.g. cranes on rear overhang) it will be possible to determine the correct positioning of the centre of gravity of the
equipment and payload on the basis of the actual load (see point 5.4 in section 5).
General specifications
Figure 1.3
4 axle vehicles with the same loading on both the
front and rear axles
Front axle
centreline
Example to determine the position of the centre of gravity of the payload plus body
W = Payload + body
= Share of payload on front axles
W
1
= Share of payload on rear axles (tandem)
W
2
= Distance of centre of gravity from centreline
L
1
of rear bogie
L = Actual wheelbase
respectively L
1
L
1
=L-
=
Rear axle (tandem)
centre line
W1xL
W
W2xL
W
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 considered.
When building bodies or containers, loading and unloading systems for the transported 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 bodybuilder will also need to install suitable payload securing systems on the body so that transport can
be made with the utmost safety.
Figure 1.4
Uniform distribution of the load Non-uniform distribution of the load due to the
Uniform distribution of the load Non-uniform distribution of the load (beware of
lack of a rear overhang
load on axles and of minimum ratio)
1-12
General specifications
HeightoftheCentreofGravity
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. EC Directive 71/320
as amended by the current braking directive regarding breaking) or requested by the Manufacturer to ensure
good handling of the vehicle (e.g. transverse stability of the moving vehicle).
In order to comply with the current EC Directive, IVECO provides information for the various models
(wheelbase and 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 1.5
Verification with full load:
(Wv . Hv) + (Ws . Hs)
Ht =
Wv = Chassis cab vehicle tare weight
Hv = Height of centre of gravity of chassis cab vehicle (laden condition)
Ws = Payload plus superstructure tare
Hs = Height of centre of gravity of body and payload in relation to ground
Wt = Vehicle mass when fully loaded
Ht = Height of centre of gravity of vehicle with full load
Wv + Ws
[(Wv + Ws) . Ht] − (Wv . Hv)
Hs =
Ws
To check the vehicle with its body but no payload, use above formula but for Ws use only the body tare weight
(The position for Hv will depend on the load and deflection of the suspension).
General specifications
1-13
The height of the centre of gravity indicated in table 1.1 represents values which are not to be exceeded for
each given equipment level. These values have been calculated 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 1.1 refer to the superstructure with fixed payload. In versions where the payload tends
to move on side (e.g. suspended loads, fluid loads etc.) especially when turning, higher dynamic stress 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.
Using Stabiliser Bars
Supplementary stabilising or anti-roll bars, where available, spring reinforcements or the application of
rubber components (incompliance 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
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).
Exceeding the Limits
When transporting goods with an exceptionally high centre of gravity (e.g. machinery, indivisible cargo etc.)
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, running path gradual variations,
etc.).
Modifications may only be carried out after approval has been received from IVECO.
1-14
General specifications
1.2.3 Observing the Permitted Weights
All limits indicated in our documentation must be adhered to. The mass of the front axle is of particular
importance under varying load conditions, in order to ensure the 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, tail-lifts, centre axle trailers) and to vehicles with a short wheelbase and a high centre of gravity
(e.g. silo vehicles, cement mixers).
When positioning the body and equipment, the loads must be correctly 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.
For vehicles with an added rear lift axle it must be remembered that, with the axle in the raised position, the
effective wheelbase is reduced, whereas the rear overhang is increased. It is therefore advisable that the centre
of gravity of the body and payload is located in front of the centre line of the driving axle. In addition to this
it is not advisable to equip a vehicle which has its load concentrated at the rear, with a lifting device. 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 mass with uniformly distributed loads
- 25% of the total vehicle mass for loads that are concentrated on the 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 laws and
regulations.
Variations in the Permissible Mass
Special exceptions to the maximum permissible mass 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 admissable vehicle load (downrating) may require interventions on some parts, such as the
suspension. In these circumstances, the necessary indications may be supplied.
The request for authorisation must include:
- Vehicle type, wheelbase, identification number, designated use.
- Tare 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.
General specifications
1-15
Table 1.1
gypy(
MP260
Maximum heights in relation to the centre
1)
of gravity
of the payload and cornering stability
MODELS BASIC EQUIPMENT
ML 60; 60P x x 2450
ML 60K x x 2400
ML 65; 75; 80; 65P; 75P; 80P x x 2300
ML 65K; 75K x x 2250
ML 65H x x 2400
ML 80K x x 2350
ML 85H x x 2400
ML 95W x x 2750
ML 100; 100P x x 2200
ML 100K x x 2250
ML 100W x x 2470
ML 120; 120P x x 2400
ML 110EL ; /P x x 2200
ML 120K x x 2550
ML 120H x x 2550
ML 130 x x 2300
ML 130P; 130FP x x 2400
ML 130K; 150K x x 2500
ML 135W x x 2750
ML 140W x x 2500
ML 150 x x 2350
ML 150P; 150FP x x 2400
ML 150H x x 2600
ML 170; ML 180 x x 2550 ; 2400
ML 170P; ML 180; /P x x 2650 ; 2500
ML 170K x x 2600
ML 260KE x - - 2650
MP 180; 180P x x 2650
MP 180FP x x 2590
MH / MP 190 x x 2720
MH / MP 190P x x 2750
MP 190FP x x 2700
MP 190H x x 2720
MP 190W x x 2800
MP 240; 240TN; MH 260; TN x x - 2740
MP 240P; PS; MH 260P; PS x x x 2720
MP 240FP; FS x x x 2690
MP 240PT; MH 260PT x x x 2830
MP 240FT x x x 2850
MP 260
with anti-roll bars
Front Rear
1212
x - - 2650
x SW - 2650
Max. height (approx.) of centre
of gravity of payload (includ.
body or equipment) in relation
to the ground (mm)
1-16
General specifications
Table 1.1 (continued)
gypy(
Maximum heights in relation to the centre
1)
of gravity
of the payload and cornering stability
MODELS BASIC EQUIPMENT
with anti-roll bars
Front Rear
1212
MP 260P x x x 2720
MP 260FP x x x 2680
MP 260H x x - 2780
MP 260W x x - 2890
MP 330H x x - 2600
MP 330W x x - 2620
MP 380H x x - 2510
MP 380W x x - 2520
MP 340H x - x - 2290
MP 410H/HB x - x - 2510
Max. height (approx.) of centre
of gravity of payload (includ.
body or equipment) in relation
to the ground (mm)
Note:
1) = values referred to the transversal stability of the vehicle comply with further possible restrictions imposed b y the
regulations in force (e.g. braking system).
x = with standard anti-roll bar
- = without anti-roll bar
SW = anti-roll bar on request
General specifications
1-17
1.3 Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance
As a rule, when modifying or installing any type of equipment, nothing must be altered which prevents the
correct functioning of assemblies and parts of the vehicle under all operational conditions.
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 assured. 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 (see fig1.6).
Figure 1.6
1 Retain adequate room for tilting the driver’s cab
2 Retain the free space above the gearbox (for tractors with semitrailers consider the movement between tractor and semitrailer)
3 Cab rotational centre
4 Observe the minimum distance required by the specific documentation
- 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.
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General specifications
- Adequate ventilation of the brakes and battery case (especially in the case of vans) 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; and it is necessary to leave space for this function
(see point 2.20).
- When vehicle body building has been completed the adjustment of the headlights must be checked for safety
and re-adjusted where necessary. In these circumstances it may be necessary to adjust the screw on the
headlights or to check the adjustment range of theadjusting device when the vehicle is laden. The adjustment
must be carried out in compliance with the instructions given in the Owner’s Manual in which the new values,
if any, will be included.
- 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.
1.4 Legal Provisions and Prevention of Accidents
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 at our plant (except some versions for extra-European countries) comply with the
EEC directives. Converted vehicles must also comply with these directives. The only permissible exception is
granted where local type approval differs from EEC homologation.
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 the manufacturers of the structures and devices.
Warning
Components such as seats, upholstery, seals, protective panels etc, may constitute a potential fire risk if
exposed to sources of intense heat.
Remove these components before undertaking welding or flame-cutting work.
General specifications
1-19
1.5 Choice of material to use: Ecology - Recycling
Increasingly greater attention should be p aid, at the study and design stage, to the choice of materials to
be used. T his is especially the case as regards the aspects connected with ecology and recycling in the light
of domestic and international regulations that are constantly being developed in the sector.
In this connection:
- Everyone must be aware of the prohibitions on using harmful or potentially hazardous materials, such as
ones containing asbestos, lead, halogen additives, fluorocarbons, 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 the current regulations.
1.6 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 expedient 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.
1-20
General specifications
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