IVECO STRALIS AS EURO 4, STRALIS AS EURO 5, STRALIS AT EURO 4, STRALIS AT EURO 5, STRALIS AD EURO 4 Instruction Manual

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STRALIS AS/AT/AD EURO 4/5

BODYBUILDERS INSTRUCTIONS

HEAVY RANGE

EDITION 2008

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

Publication Nr. 603.93.721 - 2 Printed in Italy - 01/08

Edition

Produced by:

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

STRALIS AS/AT/AD EURO 4/5

Bodybuilders instructions

Print 603.93.721 - 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 3-34: paragraph added 3.5.4.3 January 2008

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

4 Power take-off 4-17: Control unit added

Expansion Module (EM) (*)

5 Electronic subsystems 5-4: Cab Module (CM)

integrated in the Body Computer (BC) (*)

5 Electronic subsystems 5-8,5-9: connectors ST14A e ST14B January 2008

5 Electronic subsystems 5-40: note added to paragraph 5.4.8 January 2008

6 Exhaust systems with SCR Chapters 6.6 and 6.7 added.

Full overhaul chapter 6.5

January 2008

(*) Specific parts only for OBD1 Phase 2.

NOTE

The eighth digit of the PIC (Product Identification Code) indicates STEP 2 of the vehicle: 3-4-C-B StralisAS 3-4-C StralisAT/AD

Update data

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Update data

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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 in 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 contact Iveco. On completion ofthe installation e.g. body, crane, wheelbasemodification the vehicle andsystems must be checkedto ensure vehicle

operation and safety is as designed by Iveco and has not been compromised. If a vehicle system needs to beset 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 improvementsand changes in regulations which cover or affectthe 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 thbiveco@iveco.com before starting.

Symbols - Warnings

Danger to people:

failure to fully comply with these precautions can i nvolve 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

number

Foreword

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Chapter title

Basic edition -

month year

INDEX OF SECTION

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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STRALIS AS/AT/AD Euro 4/5

Index

GENERAL SPECIFICATIONS

SECTION 1

General specifications

Page

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

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

TRALIS AS/AT/AD Euro 4/5

Index

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Aim ofbod ybuilde rs instr uctions

GENERAL SPECIFICATIONS

1-3

1.1 Aim of bodybuilders instructions

The purposeof this publication isto provide data,specifications and instructions forthe bodybuilding andconversion of anoriginal

IVECO vehicle to ensure th e function ality, 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 becarried out only with IVECO’sauthorisation after submitting acopy (two forEnglish Market) ofthe 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 minimumand maximum wheelbase available within theIVECOrangeforthesamevehicle;

- 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 intake systems, engine exhaust and SCR components;

- engine cooling 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. Anymodification orfitting not coveredby these standards shall,on the contrary, beauthorized by IVECO in advance

Aim of bodybuilders instructions

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1-4

GENERAL SPECIFICATIONS

Liabilities

TRALIS AS/AT/AD Euro 4/5

1.3 Liabilities

The authorizations issu ed by IVECO concern solely the technical/conceptual feasibility of the modification and/or fitting to be made on a genuine IVECO vehicle. The bodybuilder is responsible for the:

- project of the modification or fitting;

- choice and features of the products used;

- workmanship of the modification or fitting;

- compliance of the project and its implementation with all the instruction s 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 specific ations 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 th e 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 orsupport to carry out work or make modifications or fittingsshall be forwarded to the IVECO marketing offices in charge.

To obtain the approval,t h e body builder shall provide adequate documents that illustrate the anticipated implementation, utilization and c on ditions 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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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 vehicle range.

1.7 Trademarks and Logos

Trademarks, nameplates anddenominations 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 t rademarks tied to the transformation or trim levels must be authorised by IVECO. They must not be applied

near to the IVECO tradenames or logos. IVECO reserves the right to withdraw the tradenames and logos if the fitting or conversion fails to conform with requirements. The

bodybuilder accepts all responsibility for the entire vehicle.

Instruction for added assemblies

Whereassembliesare added,the bodybuilder must providethe necessary service andmaintenance instructionswhen 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 thesematters may be obtained from the competent Authoritiesor the IVECO AreaNetwork.

The vehicles manufacturedat our plant(except some versions forExtra-Europeancountries) complywith the EC directives.Converted vehicles must also comply with these directives.The only permissibleexception 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 accid ents

TRALIS AS/AT/AD Euro 4/5

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

Components such as seats, coverings, linings, protective panels etc. may 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.

1.10 Choice of material to use: Ecology - Recycling

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

This is especially the caseas regards the aspects connected withecology and recycling in the light ofdomestic and international regulations that are constantly being developed in the sector.

In this connection:

- everyonemust be aware ofthe prohibitionson using harmful orpotentially hazardous materials,such as onescontaining asbestos, lead, halogen additives, fluoroc a rbons, cadmium, mercury, hexavalent chrome, etc.

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

- With composite synthetic materials, use components that are compatible with each other, envisaging also their possible utilization with t he 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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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 deliverthe necessary instructions for service and maintenance of the fitting and any additionalunits to the end customer;

- write the new data down on the special tags;

- confirm that the work carried out complies with the indications provided by the vehicle manufacturer and with all legal requirements;

- 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 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 connection after travelling approximately 500-1000 km, to ensure it is to the correct torque.

- 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.

Vehicle delivery

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GENERAL SPECIFICATIONS

Vehicl es ide ntificati on

TRALIS AS/AT/AD Euro 4/5

1.12 Vehicles identification

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

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

Cab

Range

CAB VERSIONS

TRACTOR

AS 260 /PSS24

AS 440 /PS54XT

EXTERNAL NAMEPLATE ON VEHICLE

CAB RANGE

AS = Active Space AT = Active Time AD = Active Day

SUSPENSION

/TN = 6x2P, mechanics with third fixed axle to twinned wheels /P = 4x2, 6x4, 6x2P, air suspension at rear. 6x2P with single wheels fixed third axle /PT = Only for 6x2P, air suspension at rear with twin wheels fixed third axle /PS = Only for 6x2P, air suspension at rear with single wheels third axle, controlled steering /FP = 4x2, 6x4, 6x2P, full air /FS = Only for 6x2P full air with single wheels third axle, controlled steering

Model Power Version Suspension

PTT-Cab versions

(n˚/10 → hung in ton)

PTC-Tractors

(with semitrailers)

(n˚/10 → hung in ton)

STRALIS Engine power

(n˚ x10→ HP)

VERSION

T=Tractor X = 6x2C Y = 6x2P (Z= 6x4)

X Y Z

MISSION

GV = Bulky Goods

transport CM = Mobile Boxes LT = Low Tractor RR = Rough Roads HM = Heavy Mission D = Delivery CT = With Transporter HR = Hub Reduction

/TN /P /PT /PS /FP

/FS

Vehicles identification

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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 issued 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 our vehicles is designed for w idths 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 vehicle with its c ab before fitting the body and equipment and establishing their distribution o n th e axles.

1.13.2 Determining the Centre of Gravity of the Body and Payload

Positioning on longitudinal plane

To establishthe location of the centreof gravity of the body and payloadthe following examples belowmay be used asguidelines.

The technical documentation specific to each model (chassis cabdrawing) give the positions permitted with thevehicle in itsstandard 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

TRALIS AS/AT/AD Euro 4/5

Figure 1.1 Vehicles with 2 axles; vehicles with 3 axles with an equal load on the two

rear axles

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

= Share of payload on front axle

= Shareof payload on rear axle (ortandem)

Figure 1.2

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

= Distance of centre of gravity from

centre-line of rear axle (or tandem centre-line)

L = Actual wheelbase

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.

L1=

respectively L1=L-

W1⋅ L

W2⋅ L

Example to verify compliance of admitted weight on the axles

W = Payload + body

= Share of payload on front axle

= Share of payload on rear axles

= Share of payload on first rear axle

= Share of payload on second rear axle

= Distance of centre of gravity relative

calculated centreline L = Calculated wheelbase (ideal) L

= Calculated centreline (ideal)

A = Distance between rear axles

=Wx

3=W2

WxL

W2xL

(L - L1)

(A - L2)

Attention: On vehicles with three or more axles, with a variable mass distribution ratio o n the two re a r a xles depending on the lo a d , t he ”i d e a l” values of wheelbase and centreline between the axles will have to be calc ula ted 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 todetermine the co r r e ct positioning of the cent r e of gravi t y of the equipment and payload on the basis of the actual load (see point 5.4 in section 5).

Dimensions and weights

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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 unloading systems for the transported goods must be devised which preclude ex-

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

The bodybuilder willalso need to installsu itable payload securing systemson the body sothat transport can be madewith the utmost

safety.

Figure 1.3

Uniform distribution of the load Non-uniform distribution of the load due to the

Uniform distribution of the load Non-uniform distribution of th e load (beware of load on axles

lack of rear overhang

and minimum ratio)

Dimensions and weights

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GENERAL SPECIFICATIONS

TRALIS AS/AT/AD 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 when fully loaded, falls within the maximum permitted values. These limits are defined in compliance with the national or international regulations (e.g. as amended by the current EC braking

Directive) or requested by the Manufacturer to ensure good handling of the vehicle (e.g. transverse stability of the moving vehicle). In order toc omply with the current ECDirective, IVECO providesinformation forthe 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:

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).

The height of the centre of gravity indicated in Tabella 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 , shou ld be taken into consideration.

The values given in Tabella 2.6 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 int o consideration when providing vehicle operating instructions or for possible reduction in the height of the centre of gravity.

Dimensions and weights

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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 act in 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 would give th e 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 transportinggoods with anexceptionally highcentre of gravity(e.g. machinery,indivisiblecargo etc.) froma 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 limitsindicated in our documentation must be adhered to. The load of the front axle is of particular importance undervarying load conditions, in order to ensure the correct steering characteristics on road surfaces of all types.

Particular attention must th erefore be paid to vehicles with a weigh t 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 th e 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 advisableto equipa 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 weight with uniformly distributed loads

- 25% of the total vehicle weight 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 regulations and legal requirements.

Variations in the Permissible weight

Special exceptions to the maximum permissible weight may be granted for particular applications for which, however, precise limitations regarding th e 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, the necessary information may be supplied. The request for authorisation must include:

- Vehicle type, wheelbase, identification number, designated use.

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

payload.

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

Dimensions and weights

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GENERAL SPECIFICATIONS

Instructionsforthe CorrectFunctioningofthe Partsof the Vehicle andAccessibilityforMaintenance

TRALIS AS/AT/AD Euro 4/5

1.14 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 fu n ctioning

of assemblies and parts of the vehicle under all operational conditions. For example:

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

- For tilting cabs, adequate space permitting tilting must be 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 1.5).

Figure 1.5

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 u sin g material with inflammability and sou ndproofing c haracteristics equivalent to those used originally.

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

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GENERAL SPECIFICATIONS

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

1-15

- 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 3

axle steering which also steers in

the raised position; and 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 c ase 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 trainin g for bodybuilders.

This is arequirement duen ot only to compliance with domestic andinternation al regulations on productliability, but alsothe 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 organ ised where the following are defined and available:

- organization charts for functions and responsibilities.

- Quality System.

- quality goals.

- technical design documentation.

- process and control phases with relevant resources.

- product improvement plan, obtained also with corrective actions.

- after sales service.

- staff training.

- manufacturer liability documentation.

1.16 Vehicle maintenance

In addition t o making the necessary checks on the body/structure in keeping with customary working procedures, the bodybuil-

der shall perform the checks specified in th e “IVECO pre-delivery inspection” list, whic h can be obtained from the IVECO network, for the aspects affected by the modifications performed.

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

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1-16

GENERAL SPECIFICATIONS

Convention

TRALIS AS/AT/AD 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 ornon-driven). This definition differs fromthe definition of wheelbase inthe CE Directives. The rear overhang is taken as the distance between centreline of the lastaxle and the rear end ofthe chassisrunner. For dimensions A, B and t of the frame and subframe section please refer to the figure below.

Figure 1.6

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Convention

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Index

CHASSIS MODIFICATIONS

SECTION 2

Chassis modifications

2.1 General instruct ions 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

2.3 Drilling t he Chassis 2-12

2-1

Page

2.3.1 Screws and nuts 2-12

2.3.2 Characteristics of the material to be u sed 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 Authorisation 2-18

2.4.3 Effects on the steering 2-18

2.4.4 Effects on braking 2-19

2.4.5 Recommended procedure 2-19

2.4.6 Chassis Stress Level 2-20

2.4.7 Cross Members 2-20

2.4.8 Changes to transmissions 2-20

2.5 Modifying the Rear Overhang 2-21

2.5.1 General Specifications 2-21

2.5.2 Reducing the Overhang 2-21

2.5.3 Increasing the Overhang 2-21

2.6 Installing a Towing Device 2-23

Index

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CHASSIS MODIFICATIONS

TRALIS AS/AT/AD Euro 4/5

Page

2.6.1 General Specifications 2-23

2.6.2 Traditional towing hooks 2-24

2.6.3 Towhook for mid-axled trailers 2-25

2.6.4 Lowered Rear Cross Member 2-27

2.6.4.1 Centre axle trailers: towing cross member in lowered and forward positions (sh o rt coupling) 2-35

2.6.4.2 Reinforcement of Standard Rear Cross Member 2-35

2.6.4.3 Tow hooks for Centre Axle Trailers 2-37

2.6.4.4 Remarks about the Payload 2-37

2.6.4.5 Increasing the Towable weight 2-38

2.7 Installing a Supplementary Axle 2-38

2.7.1 General Specifications 2-38

2.7.2 Chassis Frame Reinforcement 2-38

2.7.3 Installing a Rear Supplementary Axle 2-40

2.7.4 Steering Axles 2-41

2.7.5 Components and Suspension 2-41

2.7.6 Stabilisers 2-41

2.7.7 Connection to the Chassis Frame 2-41

2.7.8 Braking system for additional axle 2-42

2.7.9 Raise Device 2-42

2.7.10 Modifying the suspension 2-45

2.8 Modifying the Drive Line 2-43

2.8.1 Permitted lengths 2-44

2.8.2 Determining Driveshaft Positions 2-46

2.9 Modifications of t he Engine Air Intake and Exhaust Syatem 2-49

2.9.1 Intake 2-49

2.9.2 Engine exhaust 2-49

2.10 Modification of the Engine Cooling System 2-50

2.11 Installation of a Supplementary Heating System 2-51

2.12 Installing an Air-Conditioning System 2-52

Index

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CHASSIS MODIFICATIONS

2-3

Page

2.13 Cab Modifications 2-53

2.13.1 General Specifications 2-53

2.13.2 Roof Panel Modifications 2-53

2.14 Changing the Size of the Tyres 2-54

2.15 Modifications to the Braking System 2-56

2.15.1 General Specifications 2-56

2.15.2 Brake Pipes 2-56

2.15.3 Electronic braking system control devices 2-61

2.15.4 Taking air from the system 2-61

2.16 Electrical System: Modifications and Drawing-Off Power 2-62

2.17 Repositioning Parts and Mounting Auxiliary Assemblies and Equipment 2-62

2.18 Transporting hazardous goods ADR 2-65

2.19 Retarder installation 2-67

2.20 Modifications to the Rear Underrun 2-68

2.21 Rear Mudguards and Wheel Boxes 2-69

2.22 Mudflaps 2-70

2.23 Side Guards 2.71

2.24 Chocks 2-73

Index

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2-4

CHASSIS MODIFICATIONS

TRALIS AS/AT/AD Euro 4/5

Index

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2222.2

General i nstructi ons for chassis modi fications

CHASSIS MODIFICATIONS

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, 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 riveted 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 locking nuts. 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 c hecked after the vehicle has been driven approximately 500 ÷ 1.000 kms.

2.1.1 Specific Precautions

Figure 2.1

During welding, drilling, grinding and cutting operations near brake system pipes, and electrical cables, adopt the appropriate precautions for their protection. Remove them altogether if necessary (observe the requirements set out under points 2.15.2 and 5.5).

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General instructions for chassis modifications

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CHASSIS MODIFICATIONS

TRALIS AS/AT/AD Euro 4/5

Take precautions concerning the alternator and the electrical/electronic components

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

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 andon 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. galvanizin g paint IVECO Part

number 459622 by PPG).

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

Do not use the IVECO standardised M1 (battery earth connection) M2, M8 (earth connection for started motor depending on the driving position) points for the earth connections for control switches (e.g. sensor or low absorption devices).

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

Electric wiring

Stralis vehicles are equipped with an innovative electronic system called MUX. Before performing any operation on the electrical system, read section 5 “Special instructions for electronic subsystems”.

For further information regar ding the braking and electronic system, refer to point 2.15 and 5.5. List of technical guidelines and standards for correct installation of electrical cables in vehicle electron ic systems Power cables (+ direct type) must be fed on their own into corrugated piping (of appropriate diameter) and not together with other

smaller cables (signal and negative cables); they must be spaced a minimum distance of 100 mm apart (reference value = 150 mm) from high heat sources (engine turbine, exhaust manifold, etc., ...). and a distance of at least 50 mm must be maintained from chemical agent containers (batteries, etc.).

This rule also applies to the area around moving parts. Cables that run through perforated or angled panels must be protected by screw-on adaptors for cables (in addition to the corru-

gated pipe). The corrugated pipe must wrap fully around the entire cable and must be secured with a heat-shrink sleeve or using adhesive tape

to the plastic terminal caps. Collars securing the corrugated pipe cut along their length must not deform the pipe, otherwise the cables could be laid bare or come into contact with the sharp corners of the corrugated pipe.

All connection terminals (+) of the above cables and also their terminals must be covered with plastic caps waterproof version, at all points exposed to atmospheric ingress or where water builds up.

The fastening of the terminal on the clamps (including the earth clamps) must be protected against accidental loosening. For this reason, it is necessary to apply an appropriate tightening torque if possible. In the case of multiple terminal connections, these must be in a star configuration (but this connection method should be avoided if possible).

The relevant cable route must be supported by fastenings and collars spaced close together to prevent hanging cables. After repair, outfitting or conversion work, restore the wiring harness to its original condition.

When connecting the frame andthe tipper cab, check the wiring with the cab raised and tipped to detect and correct any abrasions or tautness of the cables.

General instructions for chassis modifications

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