Page 1
Contents
Introduction............................. 0-1
Tipper ..................................... 1-1
Dropside ................................. 2-1
Double cab ............................. 3-1
Auxiliary heating systems ....... 4-1
Page 2
0-1 Introduction
Introduction
This manual contains supplementary
information regarding the operation
and use of specific conversions
available for your vehicle. This
manual should be used in conjunction
with the vehicle Owner's Manual.
You must always comply with the
specific laws of the country that you
are travelling through. These laws
may differ from the information in this
manual.
When instructed to consult a
workshop, we recommend that you
consult an Opel Service Partner. All
Opel Service Partners offer first-class
service at reasonable prices.
You will receive quick, reliable and
individual service.
Experienced mechanics, trained by
Opel, work according to specific Opel
instructions.
This manual should always be kept
together with the Owner’s Manual
and Service Booklet in the vehicle:
Ready to hand in the glove
compartment.
Make use of this manual:
Yellow arrows in the illustrations
serve as points of reference or
indicate some action to be
performed.
Black arrows in the illustrations
indicate a reaction or a second
action to be performed.
Directional data, e.g. left or right, or
front or back, in the descriptions
always relates to the direction of
travel.
Page references are indicated
with 3. 3 means “see page”.
9 Warning, Caution
Vehicle passengers should be
informed accordingly.
9 Warning
Text marked 9 Warning provides
information on risk of accident or
injury. Disregard of these
instructions may result in injuries.
Caution
Text marked Caution provides
information on possible damage to
the vehicle. Disregard of these
instructions may lead to vehicle
damage.
Page 3
1-1Tipper
Tipper
Loading
1)
The three-way tipper is designed for
carrying bulk materials that can be
discharged by tipping.
The three-way tipper is not designed
for carrying people or unsuitable/
unsafe materials
.
Ensure the vehicle tailboard and
sideboards are securely closed
before loading.
Load the vehicle evenly,
distributing the load across the
body.
Secure any solid loads with
additional lashing equipment.
Place loads from the minimum
practicable height. Do not drop
loads onto the tipper body.
Do not overload the tipper body.
Ensure the load will not fall out or
endanger other road users.
Do not drive with the body tipped.
Do not drive with the tailboard or
sideboards down.
Do not attempt to tip loads from the
body when body sides or tailboard
are closed.
Loading ................................... 1-1
Tailboard................................. 1-2
Sideboards.............................. 1-3
Lashing points......................... 1-3
Tipper operation...................... 1-4
Isolation switch ....................... 1-4
Safety cable ............................ 1-6
Safety prop ............................. 1-6
Cleaning.................................. 1-7
Owner's checks....................... 1-7
Technical data ........................ 1-8
Maintenance ........................... 1-10
Confirmation of hydraulic fluid
change.................................. 1-11
1)
Observe the national regulations on
securing loads.
Page 4
1-2 Tipper
Tailboard
Opening
To open the tailboard, pull up the
release levers to disengage the locks
and lower the tailboard fully.
To close the tailboard, raise the
tailboard and push firmly into
position. Push down the release
levers ensuring locks engage fully.
Swinging
To release, pull the remote lever
located on the rear left side of the
body. The tailboard is disengaged
and will swing from its upper hinges.
To lock, engage the lower tailboard
hinges and push the remote lever to
lock position. Check the tailboard is
secure
.
Removing
Pull the remote lever located on the
rear left side of the body. The
tailboard is disengaged and will swing
on its upper locks.
With the help of an assistant, support
the tailboard weight and pull up the
release levers. Remove the tailboard
from the tipper body.
9 Warning
Before using the swinging
tailboard, check the release levers
are securely latched on both sides.
9 Warning
Two people are required to carry
out this operation.
Page 5
1-3Tipper
To reinstall: Install the tailboard onto
the upper hinges and push down the
release levers ensuring locks engage
fully.
Insert the tailboard into the lower
hinges and push the remote lever to
lock position.
Check the tailboard is secure.
Sideboards
To open, pull up the release levers to
disengage the locks. Lower the
sideboard fully.
To close, raise the sideboard and
push firmly into position. Push down
the release levers ensuring locks
engage fully.
Lashing points
Secure heavy objects with lashing
straps attached to the lashing points.
Caution
When loading heavy or bulk items,
the lashing point eyes must be flush
with the body floor to avoid causing
any damage.
The maximum force applied to the
lashing point eyes should not
exceed 5000N at 30°.
Page 6
1-4 Tipper
Tipper operation
The tipper body has two locking pins
with each pin having a locator on its
upper edge. The locking pins are
used to obtain any one of the three
tipping positions.
To insert locking pin into pivot, ensure
the handle and locator are facing up.
Rotate the locking pin away from the
upright position to ensure the pin is
secured.
Isolation switch
The system must be activated using
the isolation switch located on the left
side tipper frame behind the cab.
Insert and turn the isolator key in the
switch.
When the tipper is not in use, turn the
isolator key to the off position and
remove it.
9 Warning
The operator must remain at the
control to ensure tipping and
lowering are performed correctly.
Do not allow anyone in or onto the
tipper body whilst operating the
tipper.
Ensure the vehicle is on level
ground and that the tipper body
can be raised to the maximum
height without fouling overhead
obstructions.
Caution
The tipper must not be operated with
locking pins incorrectly installed.
Pins installed diagonally opposite or
in both front pivot positions will result
in damage if tipping is attempted!
Page 7
1-5Tipper
Raising and lowering the tipper
The tipper is operated using the
remote control located on the seat
base.
The remote control enables the user
to supervise the operation of the
tipper from outside the vehicle.
The remote control is magnetic and
can be stored on the seat base when
not in use.
1.With the isolation switch activated,
depress the à switch on the
remote control to raise; or the Ä
switch to lower. The tipper can be
stopped at any time by releasing
the switch.
2. The tipper body will cease moving
automatically when it reaches
maximum height.
An acoustic signal will sound to
indicate when the tipper control is
activated.
Tipping to the rear
Fully insert locking pins into the left
and right-hand rear pivots, ensuring
the handle and locator are facing up.
Rotate the locking pin away from the
upright position to ensure the pin is
secured.
Tipping to the side
To tip to the left side, fully insert
locking pins into the front and rear
left-hand pivots. Ensure the handle
and locator on both locking pins are
facing up. Rotate both locking pins
away from the upright position to
ensure the locking pins are secured.
Page 8
1-6 Tipper
To tip to the right side, fully insert
locking pins into the front and rear
right-hand pivots. Ensure the handle
and locator on both locking pins are
facing up. Rotate both locking pins
away from the upright position to
ensure the locking pins are secured.
Safety cable
The safety cable attached to the
tipper body prevents the tipper body
being raised too far. Should a safety
cable become damaged it must be
replaced immediately. Seek the
assistance of a workshop.
Safety prop
The safety prop is located under the
left-hand side of the tipper body and
is provided only to assist in
supporting the tipper body when
tipped to the rear, for carrying out
visual inspection of the vehicle
components.
Using the safety prop:
1.Prepare the tipper body for tipping
to the rear.
2.Raise the tipper body sufficiently
enough to access the safety prop.
3.Release the safety prop from the
underside of the tipper body and
fold down.
4.Swing the safety prop downwards
to align with support.
5.Carefully guide the safety prop into
the support position then lower the
tipper body.
Page 9
1-7Tipper
Stowing the safety prop:
1.Raise the tipper body sufficiently to
release the safety prop from its
support.
2.Fold the safety prop into the stowed
position and secure in the spring
clip.
3.Lower the tipper body.
Cleaning
Dirt or mud which remains dry on the
body may become abrasive and can
damage paint, seals, locks and
hinges.
Clean the following parts if they
become contaminated with dirt:
Sideboard and tailboard locking
latches and hinges.
Tipper body pivot pins and locating
holes.
After cleaning, check and if
necessary lubricate the components
listed in the owner's checks.
Owner's checks
Check regularly the following items.
Every week:
Lubricate the tailboard and
sideboard locking latches with
high-pressure grease and check for
correct operation.
Lubricate the tailboard and
sideboard hinges with lube oil and
check for correct operation.
Every month:
Visually check the subframe
mountings, the safety cables and
the hydraulic system. If any of the
components appear loose,
defective or leaking, seek the
assistance of a workshop to rectify
the cause of the fault.
Every 6 months:
Lubricate the tipper body pivots
and the safety prop hinge with high-
pressure grease.
Caution
Do not spray high-pressure water
directly at the hydraulic seals, pump,
reservoir, hydraulic ram ball joints,
or guide clamps.
9 Warning
Do not venture under the tipper
body when raised.
Page 10
1-8 Tipper
Technical data
The technical data is determined in
accordance with European
Community standards. We reserve
the right to make modifications.
Specifications in the vehicle
documents always have priority over
those stated here.
Vehicle identification
The Gross Vehicle Weight and Gross
Train Weight can be found on the
vehicle identification plate, which is
located on the right-hand door pillar.
Page 11
1-9Tipper
Payload (approx. kg)
Dimensions (approx. mm)
Model Wheelbase GVW Kerb weight
1)2)
1)
In accordance with EC directive of base model, including assumed weights of driver (75 kg) and all fluids (tank 90% full).
2)
Depending on optional equipment.
Chassis cab Medium 3500 2276-2438
Crew cab Long 3500 2429-2592
Chassis cab Crew cab
Wheelbase Medium Long
Overall length 5642 5986
Overall height (unladen)
without cab protection
with cab protection 3
maximum height (with conversion)
2182
2552
3500
2182
2552
3500
Turning circle diameter (m) - kerb to kerb
- wall to wall
13.75
14.11
15.20
15.68
Page 12
1-10 Tipper
Maintenance
In addition to the standard
maintenance for your vehicle, the
tipper body requires further checks
and operations to be performed.
Seek the assistance of a workshop.
Hydraulic fluid change
It is necessary to change the
hydraulic fluid annually, or every
1500 tipping operations, whichever
occurs first.
Changing the hydraulic fluid:
1.Ensure the body is fully lowered.
2.Remove filler cap from hydraulic
fluid reservoir.
3.Remove hydraulic fluid from
reservoir using a suitable fluid
extractor.
4.Replace hydraulic fluid ensuring
fluid level is between MIN and
MAX.
5.Replace filler cap and secure.
Bleeding the hydraulic system:
To bleed the hydraulic system, raise
then lower tipper body, then recheck
the fluid level.
Ensure the fluid level is at MIN level
on reservoir when the tipper body is
in its maximum raised position.
Caution
Do not attempt to operate the
system without hydraulic fluid.
Hydraulic fluid
specification
Capacity
HM or HV to
ISO VG32 (-20oC to
+60
o
C)
7 litres
Page 13
1-11Tipper
Confirmation of hydraulic
fluid change
Confirmation of the hydraulic fluid
change must be verified on the
following stamping spaces.
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Page 14
1-12 Tipper
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Date:
Stamp and signature of
Opel Service Partner
Page 15
2-1Dropside
Dropside
Loading1)
The dropside body is not designed for
carrying people or unsuitable/unsafe
materials.
Ensure the vehicle tailboard and
sideboards are securely closed
before loading.
Load the vehicle evenly,
distributing the load across the
body.
Secure any solid loads with
additional lashing equipment.
Place loads from the minimum
practicable height. Do not drop
loads onto the body floor.
Do not overload the dropside body.
Ensure the load will not fall out or
endanger other road users.
Do not drive with the tailboard or
sideboards down.
Sideboards
To open, release both side board
levers by pushing the thumb button
down and pulling the lever out.
Loading ................................... 2-1
Sideboards.............................. 2-1
Tailboard................................. 2-2
Step ........................................ 2-2
Lashing points......................... 2-2
Cleaning.................................. 2-3
Owner's checks....................... 2-3
Technical data ........................ 2-3
1)
Observe the national regulations on
securing loads.
Page 16
2-2 Dropside
Swing the lever up until it contacts the
body and the lock pin becomes
visible. Lower the sideboard carefully.
To close, raise the sideboard and
push firmly against the body. Swing
the lever down into its recess until an
audible click is heard. Check the
sideboard is secure.
Tailboard
To open, release both tailboard
levers and lower the tailboard
carefully.
To close, raise the tailboard and push
firmly against the body. Swing the
lever down into its recess until an
audible click is heard. Check the
tailboard is secure.
Step
To lower the step with the tailboard
down, lift the step plate up in the
mounting bracket and swing it down.
To stow the step, swing the step plate
up into the vertical position and slide
it down into the mounting bracket.
Lashing points
Secure heavy objects with lashing
straps attached to the lashing points.
Caution
When loading heavy or bulk items,
the lashing point eyes must be flush
with the body floor to avoid causing
any damage.
The maximum force applied to the
lashing point eyes should not
exceed 5000N at 30°.
Page 17
2-3Dropside
Cleaning
Dirt or mud which remains dry on the
body may become abrasive and can
damage paint, seals, locks and
hinges.
Clean the following parts if they
become contaminated with dirt:
Sideboard and tailboard locking
latches and hinges.
After cleaning, check and lubricate
the latches and hinges as necessary.
Owner's checks
It is essential that the owner regularly
checks the following items.
Every week:
Check the tailboard and sideboard
hinges for correct operation.
Every month:
Visually check the subframe
mountings. If any fixings appear
loose or are missing, seek the
assistance of a workshop to rectify
the cause of the fault.
Technical data
The technical data is determined in
accordance with European
Community standards. We reserve
the right to make modifications.
Specifications in the vehicle
documents always have priority over
those stated here.
Vehicle identification
The Gross Vehicle Weight and Gross
Train Weight can be found on the
vehicle identification plate, which is
located on the right-hand door pillar.
Page 18
2-4 Dropside
Payload (approx. kg)
Dimensions (approx. mm)
Model Wheelbase GVW Kerb weight
1)2)
1)
In accordance with EC directive of base model, including assumed weights of driver (75 kg) and all fluids (tank 90% full).
2)
Depending on optional equipment.
Chassis cab Medium 3500 1861-2012
Long 3500 1909-2074
Crew cab Long 3500 2044-2201
Chassis cab Crew cab
Wheelbase Medium Long Long
Overall length 5680 6130 5995
Overall height (unladen)
without cab protection
with cab protection 3
2200
2290
2200
2290
2195
2285
Turning circle diameter (m) - kerb to kerb
- wall to wall
13.75
14.11
15.20
15.68
15.20
15.68
Page 19
3-1Double cab
Double cab
Introduction
The double cab uses an additional
rear bench seat to provide increased
seating for up to six people.The rear
loadspace area is separated from the
passenger compartment by a
partition wall.
Additional loadspace under the rear
seat provides increased storage in
the load compartment.
Introduction ............................. 3-1
Technical data ........................ 3-3
Page 20
3-2 Double cab
Child restraint systems 3
The table shows permissible locations for installing a child restraint system. Refer to Owner’s Manual for further information.
Rear seats
X = Seat position not suitable for children of this mass group.
Group, weight and age class Facing
direction
Rear bench seat
Outer Centre
0: up to 10 kg or approx. 10 months
Rearward XX
0+: up to 13 kg or approx. 2 years
I: 9 to 18 kg or approx. 8 months - 4 years Forward XX
II: 15 to 25 kg or approx. 3 - 7 years
Forward XX
III: 22 to 36 kg or approx. 6 - 12 years
Page 21
3-3Double cab
Technical data
The technical data is determined in
accordance with European
Community standards. We reserve
the right to make modifications.
Specifications in the vehicle
documents always have priority over
those stated here.
Vehicle identification
The Gross Vehicle Weight and Gross
Train Weight can be found on the
vehicle identification plate, which is
located on the right-hand door pillar.
Page 22
3-4 Double cab
Payload (approx. kg)
Loadspace dimensions (approx. mm)
Model Wheelbase GVW Kerb weight
1)2)
1)
In accordance with EC directive of base model, including assumed weights of driver (75 kg) and all fluids (tank 90% full).
2)
Depending on optional equipment.
Double cab Medium 3500
3500
2004 - 2019
2012 - 2026
3)
3)
Easytronic transmission.
Long 3500
3500
2047 - 2061
2055 - 2069
3)
Wheelbase Medium Long
Maximum length at load floor 2730 3230
Maximum length behind rear seats 2160 2660
Maximum width 1764 1764
Maximum height 1912
2146
1)
1)
High roof version.
1912
2146
1)
Page 23
4-1Auxiliary heating systems
Auxiliary heating
systems
Coolant heater
The Webasto engine-independent,
fuel-powered coolant heater, located
under the vehicle, provides rapid
heating of the engine coolant to
enable heating of the vehicle interior
without running the engine. It will also
help the engine to reach operational
temperature more quickly.
The heater can be programmed to
start at a specific time or switched on
for immediate use.
The heater is controlled with a control
unit on the instrument panel or with a
radio remote control 3.
Before switching the heater on or
programming heating operation, turn
the temperature switch on the heating
and ventilation system to the red
zone and set fan to position 2.
When the heater unit is on, fuel
consumption increases. Switch off
the unit whenever it is not required.
The heater will cease to operate if the
vehicle fuel level drops too low.
The heater unit stops automatically
after a maximum 1 hour of
continuous use. The fuel supply to
the heater is cut-off.
To ensure efficient performance, the
heater must be operated briefly once
a month.
If the heater does not start when
switched on, switch it off and back on
again. If it still does not start, seek the
assistance of a workshop.
Refer to the supplied instructions for
the heater unit for further information.
Coolant heater ........................ 4-1
Air heater ................................ 4-3
Remote control unit 3 ............. 4-6
9 Warning
Do not operate the heater in an
enclosed space and ensure it is
switched off when refuelling!
The additional exhaust pipe on
the side of the vehicle becomes
very hot during use of the heater.
Page 24
4-2 Auxiliary heating systems
Manual control unit
The heater control unit is located on
the instrument panel.
The heater unit can be switched on
for immediate use (one-off mode) and
the timer function 3 (programmed
mode) set using the four buttons on
the control unit.
The control unit can be used to
programme up to 3 preset departure
times 3 during 24 hours.
Switching heater on for
immediate use
Press the heating button to switch the
heater on: the flame symbol and the
heating duration appears in the
display. Heating duration disappears
after a brief delay.
With heater unit switched on, press
the back or next button to change
heating duration for this use of the
heater only. The value can be set
from 10 to 60 minutes.
Switching heater off
Press the heating button again to
switch heating off: the flame symbol
extinguishes.
Programming departure times
Press the set button until the preset
time for memory location 1 appears in
the display.
The flame symbol and 1 flashes.
Change the preset time using the
back or next button and/or press set.
The flame symbol and 2 flashes.
Change the time and/or press set.
The flame symbol and 3 flashes.
Change the time and/or press set.
The preset departure times are
stored and the display disappears.
Programming heating duration
Press and hold the set button and
press the back or next button.
The time and the clock symbol are
displayed.
Release the set button.
1 Back button
Adjusts values.
Switches on time display.
2 Display
Display of settings and status.
3 Next button
Adjusts values.
Switches on time display.
4 Set button
Switches on presetting mode.
Confirms inputs.
5 Heating button
Switches heater on/off.
Page 25
4-3Auxiliary heating systems
Press and hold the set button again
and press the back or next button.
Then release the set button.
The heating duration is displayed
and the flame symbol flashes.
Change heating duration using the
back or next button. The value can be
set from 10 to 60 minutes. Press set
to confirm.
The preset heating duration for
programmed mode is stored and the
display disappears.
Activating departure times
Departure times must be activated
individually. Only one departure time
can be activated at a time.
Press the set button until the desired
departure time and memory location
is displayed. After a brief delay, the
memory location to be activated
flashes in the display along with the
flame symbol, until the heater starts.
Deleting departure times
While the next preset memory
location to be activated is flashing in
the display along with the flame
symbol, press the set button.
The flame symbol and 1, 2 or 3
extinguishes.
Resetting
If the power supply is interrupted or
the battery voltage is too low, the
current time and all programmed
departure times are lost: The unit will
need to be reset.
To reset time: With heater off, press
and hold the set button, press the
back or next button, then release set.
Time of day is displayed and the
clock symbol flashes.
Set the time using the back or next
button and press set. The time is
stored and the display disappears.
Air heater
The Webasto engine-independent
auxiliary air heater, located under the
vehicle, provides additional heating
for the rear passenger compartment
during driving and while the vehicle is
parked.
The heater can be programmed to
start at a specific time or switched on
for immediate use.
The heater is controlled with a control
unit on the instrument panel or with a
radio remote control 3.
When the heater unit is on, fuel
consumption increases. Switch off
the unit whenever it is not required.
The heater will cease to operate if the
vehicle fuel level drops too low.
The heater unit stops automatically
after a maximum 2 hours of
continuous use.
To ensure efficient performance, the
heater must be operated briefly once
a month.
Page 26
4-4 Auxiliary heating systems
If the heater does not start when
switched on, switch it off and back on
again. If it still does not start, seek the
assistance of a workshop.
Refer to the supplied instructions for
the heater unit for further information.
Manual control unit
Heater settings and adjustment are
made using the control unit located
on the instrument panel.
The heater unit can be switched on
for immediate use (one-off mode) and
the timer function 3 (programmed
mode) set using the buttons on the
control unit.
The control unit can be used to
programme up to 3 preset departure
times 3, either during one day or over
one week.
The temperature of the rear
passenger compartment can be
adjusted to the desired value using
the rotary knob.
Switching heater on for
immediate use
Press the heating button to switch the
heater on: the button illuminates and
the heating symbol Y appears in the
display.
With heater unit switched on and the
ignition off, press the back or next
button to change heating duration for
this use of the heater only. The value
can be set from 10 to 120 minutes.
9 Warning
Do not operate the heater in an
enclosed space and ensure it is
switched off when refuelling!
The additional exhaust pipe on
the side of the vehicle becomes
very hot during use of the heater.
1 Display
Display of settings and status.
2 Temperature knob
Changes temperature.
3 Next button
Selects display options and
adjusts values.
4 Back button
Selects display options and
adjusts values.
5 Heating button
Switches heating on/off.
6 Program button
Switches on presetting mode.
7 Clock button
Switches on clock mode.
Page 27
4-5Auxiliary heating systems
Switching heater off
Press the heating button again to
switch heating off: the light in the
button and the heating symbol Y
extinguishes.
Programming departure times
Press the program button.
Preset memory location 1, 2 or 3
flashes.
Select desired program memory
location by repeatedly pressing the
program button, and set departure
time using the back or next button.
Weekday flashes.
Set the weekday using the back or
next button. When flashing ceases,
the time and weekday are set.
Repeat procedure to programme the
other preset memory locations.
Programming heating duration
With heater unit switched off, press
and hold the back button for approx.
3 seconds.
Heating duration flashes.
Change heating duration for
programmed mode using the back or
next button. The value can be set
from 10 to 120 minutes.
Activating departure times
Departure times must be activated
individually. Only one departure time
can be activated at a time.
Press the program button until the
desired memory location flashes.
When flashing ceases, the memory
location to be activated appears in
the display.
Deleting departure times
Press the program button.
Preset memory location 1, 2 or 3
flashes.
Select desired program memory
location by pressing the program
button and erase departure time by
repeatedly pressing the program
button until the time is displayed
instead of the memory location.
Resetting
If the power supply is interrupted or
the battery voltage is too low, the
current weekday and time and all
programmed departure times are
lost: The unit will need to be reset.
To reset weekday and time: Press
and hold the clock button for approx.
2 seconds.
Time of day flashes.
Set the time using the back or next
button.
Weekday flashes.
Set the weekday using the back or
next button.
When flashing ceases, the time and
weekday are set.
Page 28
4-6 Auxiliary heating systems
Air vents
Two adjustable air vents are located
on the lower part of the sidewall cover
in the rear passenger compartment.
Remote control unit 3
The heater can be started and
stopped using the remote control unit.
The remote control has a maximum
range of 600 metres. The range will
reduce due to environmental
conditions.
Press ON to switch the heater on; the
LED on the remote control flashes
until the heater is switched off or the
programmed heating duration
elapses. Press OFF to switch the
heater off again; LED extinguishes.
Refer to the supplied instructions for
the heater and the remote control unit
for further information.
Battery replacement
Replace the batteries (MN21 or
equivalent) when the range of the
remote starts to become reduced.
Open the rear cover and replace
batteries. Ensure the new batteries
are installed correctly, with the
positive (+) sides facing the positive
terminals. Replace cover.
Dispose of old batteries in
accordance with environmental
regulations.
Loading...