Iveco Massif 2008 User Manual

MASSIF

RANGE BODYBUILDER INSTRUCTIONS

LIGHT RANGE

ISSUE 2008

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

Publication Nr. 603.93.811 - 1
Printed in Italy - 04.08

st

Edition

Produced by:

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

MASSIF

Bodybuilders instructions
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st

edition

Base - April 2008

UPDATE DATA

Section Description Page Revision date

Update data

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Update data

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Foreword

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 working order. Finally, make sure that you operate on 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 included herein and the actual vehicle make-up, contact IVECO prior to carrying
out any work.

Symbols - Warnings

Danger for p ersons

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

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.

General danger

!

It includes the dangers of above described signals.

Environment protection

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

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

Foreword

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Page header and footer interpretation

Vehicle type

Section title

Section number -

page number

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number

Foreword

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Chapter title

Basic edition -

month year

INDEX OF SECTION

Section

General specifications

Operations on the vehicle 2

Fitting superstructures 3

Power Take-offs 4

Specific information and instructions 5

1

Index of section

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Index of section

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MASSIF

Index

GENERAL SPECIFICATIONS

SECTION 1

General specifications

Page

1.1 Aim of bodybuilders instructions 1-3

1.2 IVECO approval for changes and fit tings 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

1-1

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 the Vehicle and Accessibility for Maintenanc e 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

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Index

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MASSIF

Aim ofbodyb uilder si nstructi ons

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 conversion of an original

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

1.2 IVECO approval 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 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 system;

- work carried out on the 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 c o mpliance with the same do not require specific
approval from IVECO. Any modification or fitting not covered by t hese standards shall, on the contrary, be authorized by IVECO
in advance.

Aim of bodybuilders instructions

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1-4

GENERAL SPECIFICATIONS

Liabilities

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1.3 Liabilities

The authorizations issued by IVECO conc ern solely the technical/con c eptual 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 an d 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 th e changes

and th e 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 ou t work or make modifications or fittin gs shall be forwarded to t he 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 the 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.

Liabilities

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MASSIF

IVECO techni cal documents availabl eby 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:

- directives for transformation and equipping of vehicles;

- technical cards;

- chassis cab diagrams;

- chassis diagrams;

- other specifications conc erning 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 n ot 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 th orised by IVECO. They must no t 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 must provide 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 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 accide nts

1.9 Prevention of accidents

Do not 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 these 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.

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1.10 Choice of material to use: Ecology - Recycling

Increasingly greater attention should be paid, at the study and design st age, t o the ch oice of materials to be u sed.

This is especially the case as regards the aspects conn ected with ecology and recycling in the ligh t of domestic and international
regulations that are constan tly being developed in the sector.

In this connection:

- everyonemust be aware of the prohibitions on using harmful or potentially hazardous materials, such as ones containing asbestos,
lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent chrome, 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 c ompatible 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.

- Batteries contain substances that are very hazardous to the environment. When replacing batteries, we advise c ontacting the
service network, which 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).

Prevention of accidents

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Vehicledelivery

GENERAL SPECIFICATIONS

1-7

1.11 Vehicle delivery

Prior to delivering the veh ic le, 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 instru ctions for service and maintenance of the fitting and any additional units to the end custo­mer;

- write the new data down on the special tags;

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

- carry out the checks 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 tha t nails have been replaced with screws, you must check again the closing o f
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 maintenance proc edures
required by the IVECO network are not observed.

Vehicle delivery

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GENERAL SPECIFICATIONS

Vehicl es identi ficati on

1.12 Vehicles identification

The commercial designation of IVECO vehicles is not the same as the type approval (homologation) designation. The tradename

is MASSIF. IVECO

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Vehicles identification

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Dimensionsandmasses

GENERAL SPECIFICATIONS

1-9

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 technical

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 of the frame

As a result of production factors there could be at a ±5% variation in the published weights.

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 th e following:

- weight distribution on the axles;

- width of t he mirrors used;

- rearbumperposition

Greatervalues in compliance with the weights permittedon the axles may be authorized by IVECO aftermodifying such components
as the chassis, bumper, mirrors, etc .

Dimensions and masses

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GENERAL SPECIFICATIONS

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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 t h e following examples below may be used as guidelines.

The technical documentation specific to each model (chassis cab drawing) give t he positions permitted with the vehicle in its standard
form.

Figure 1.1

125490

W

⋅ L

1

=

L

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)

respectively L1 = L −

W

W2 ⋅ L

W

Example of calculation of the load barycentre position

Consider a Massif chassis cab vehicle with a wheelbase of 2768 mm with:

1. GWW= 3050 kg (permitted maximum: 1175 kg on the front and 2150 kg on the rear)

2. KERB WEIGHT = 1,955 kg (1,340 kg on the front axle, 615 kg on the rear)

The permitted maximum load (body + payload) will be W = 3050 - 1860 = 1190 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, o ut of 1190 kg. W

= 1175 - 1020 = 155 kg will affect the front axle, while the remaining W2= 1190 - 155 = 1035

1

kg will affect the rear axle.

Thus, th e following will be obtained:

1

= 155 kg

1. W

2. L = 2768 mm

3. W = 1190 kg

=W1x L / W = 360 mm

L

1

The center of gravit y of the load (Body + payload) must not be more than 360 mm far from the rear axle; o therwise, the front
axle would be overloaded.

Dimensions and masses

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MASSIF

GENERAL SPECIFICATIONS

1-11

In order to determine the payload on the axles, it must be uniformly distributed except when the shape of the loading surface itself
entails a different distribution of the load.

Regarding any equipment, the actual position of the centre of gravity must be u sed.

When building bodies or con tainers, loading and unloading systems must be devised whic h 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.

Figure 1.2

Uniform load distribution Uneven load distribution

Figure 1.3

Uniform load distribution Uneven load distribution

(beware of axle loads and minimum axle ratio)

121792

Dimensions and masses

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1-12

GENERAL SPECIFICATIONS

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Height of centre of gravity

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 definedin compliance with the national or international regulations (e.g. EC Directive regarding braking) or requested
by the Manufactu rer to ensure good handling of th e vehicle (e.g. tran sverse stability of the moving vehic le).

Figure 1.4

Verification with full load:

Wt

Wb

Wc

121858

Wc x Hc + WbxHb

Ht =

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

Wc + Wb

To check the vehicle with its body but no payload, use the above formula but for Wb use only the vehicle unladen weight (The
position for Hc 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 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, sh o uld 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 turnin g, higher dynamic tran s verse 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.

(Wc + Wb) x Ht − Wc x Hc

Hb =

Wb

Dimensions and masses

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MASSIF

GENERAL SPECIFICATIONS

1-13

Using Stabiliser Bars

Supplementary stabilising or anti-roll bars, where available, spring reinforcements or the application of ru bber 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 body type, to
the wheelbase and to the distribution of the transverse forces acting on the suspension both at the front and at the rear of the vehicle.
Modification to the fron t axle may be made where the load is positioned behind the cab (e.g. crane) or where the body is very rigid
(e.g. van conversio n).

1.13.3 Observing the Permitted Weights

All the limits specified on th e IVECO documents must be complied with. It is essential that the maximum weight on the front

axle is not exceeded, under any load condition, so as to ensure the correct steering and braking characteristics regardless of the

road surfac e 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 and superstructu res. A +4% variation on
the rated load (50% of load on the axle) is permissible for each wheel (for example: permissible load on axle 2150 kg; 1032 to 1118
kg allowed for each wheel side); in compliance with load allowed by ty res, without affec t ing braking properties and vehicle driving
stability.

Apart from different specifications for s pecific 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 with loads concentrated on t he 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 h ook and of the rear under-run guard stipulated by the relevant
National an d 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.

Dimensions and masses

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1-14

GENERAL SPECIFICATIONS

Instructionsforthe CorrectFunctioningofthe Partsofthe Vehicleand AccessibilityforMaintenance

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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 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.

- 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 charact eristics 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 according to the instructions provided in the use and maintenance manual.

- In t h e case of parts whic h are supplied loose (e.g. spare wheel, ch o cks) 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.

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

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MASSIF

Quali tySy stem management

GENERAL SPECIFICATIONS

1-15

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 c ompliance with domestic an d 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 correct ive action s.

- 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 c an be obtained from the IVE CO network, for the
aspects affected by the modifications performed.

Quality System management

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1-16

GENERAL SPECIFICATIONS

Convention s

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1.17 Conventions

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

Figure 1.5

wheelbase area side member section rear overhang area side member section

121794

121795

Conventions

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Index

OPERATIONS ON THE VEHICLE

SECTION 2

Operations on the vehicle

2.1 General instructions 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 2-10

2.2.4 Exceeding the Limits 2-11

2.3 Drilling the Chassis 2-12

2.3.1 Screws and nuts 2-12

2-1

Page

2.3.2 Characteristics of the material to be used when modifying the chassis 2-12

2.3.3 Stresses on the chassis 2-13

2.3.4 Welding the Chassis 2-13

2.3.5 Closing of existing holes 2-14

2.4 Modifying the Wheelbase 2-15

2.4.1 General Specifications 2-15

2.4.2 Authorisation 2-15

2.4.3 Consequences for steering 2-15

2.4.4 Effect on Braking 2-15

2.5 Modifying the Rear Overhang 2-15

2.5.1 Authorisation 2-15

2.6 Installing a Towing Device 2-16

2.6.1 General Specifications 2-16

2.6.2 Traditional towing hooks 2-17

2.6.3 Kinds of hook 2-18

2.6.4 Lowered Rear Cross Member 2-19

2.7 Installing a Supplementary Axle 2-20

2.8 Modifying the Drive Line 2-20

2.9 Modifications of the E n gin e Air Intake and Exhaust Systems 2-21

Index

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OPERATIONS ON THE VEHICLE

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Page

2.9.1 Intake 2-21

2.9.2 Engine exhaust 2-21

2.10 Modification of the Engine Cooling System 2-22

2.11 Work on the Suspension 2-23

2.11.1 General Specifications 2-23

2.12 Heating/Air conditioning sy stem modifications 2-24

2.12.1 Installation of a Supplementary Heating System 2-24

2.12.2 Installing an Air-Conditioning Sy stem 2-25

2.13 Cab Modifications 2-26

2.13.1 General Specifications 2-26

2.13.2 Roof Panel Modifications 2-26

2.13.3 Van and combi bodywork modifications 2-27

2.13.4 Crew Cabs 2-28

2.13.5 Occupant protection 2-28

2.14 Changing the Size of the Tyres 2-29

2.15 Modifications to the Braking System 2-30

2.15.1 General remarks 2-30

2.15.2 Brake pipes 2-30

2.15.3 Fitting pipes on the vehicle 2-31

2.15.4 Instruction s for adjusting the braking load proportioning valve 2-34

2.16 Electrical System: Modifications and Drawing-Off Power 2-37

2.16.1 Earth points 2-39

2.16.2 Electromagnetic compatibility 2-46

2.16.3 Additional equipment 2-53

2.16.4 Current drawing 2-56

2.16.5 Additional Circuits 2-64

2.16.6 Operations to adjust overh ang 2-65

2.16.7 Provision for trailer 2-65

2.16.8 Side Marker Lights 2-66

2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment 2-67

Index

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OPERATIONS ON THE VEHICLE

2-3

Page

2.18 Retarder Installation 2-68

2.19 Modifications to the Rear Underrun 2-68

2.20 Rear mudguards and wheel boxes 2-68

2.21 Mudflaps 2-68

2.22 Side Guards 2-69

2.23 Chocks 2-69

Index

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2-4

OPERATIONS ON THE VEHICLE

M

ASSIF

Index

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MASSIF

2222.2

General i nstruction sfor chas sis modifi cations

OPERATIONS ON THE VEHICLE

2-5

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 e 2.5);

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

- If the original bolted connections have been fitted and renewed, it is forbidden to reuse the same bolts. In this case, the tightness
of the connection must be rechecked after about 500-1000 km.

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

General instructions for chassis modifications

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OPERATIONS ON THE VEHICLE

M

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Regarding the electrical equipment remember to:

a) Take precautions concerning the alternator and t he electric al/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 wi th 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, the paint on the chassis side and on the terminal side
creating a resting plane free from indentations or ridges.

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

- Connect the earth cables with in 5 minutes from the application of the paint.

For signal level earth connections (e.g. s ensors or devices with low power uptake), avoid using IVECO m3, m4, m5 (battery earth
connection), and is m6 standard points under all circumstances (see point 2.16.1).

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).

c) Electric wiring

For further informatio n regarding the braking and electronic system, refer to point 2.15 and 2.16.

General instructions for chassis modifications

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