Opel Automobile, Double cab, Dropside Chassis cab, Dropside Crew cab Owner's Manual

Contents

Introduction............................. 0-1

Tipper ..................................... 1-1

Dropside ................................. 2-1

Double cab ............................. 3-1

Auxiliary heating systems ....... 4-1

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.

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.

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.

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°.

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!

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.

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.

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.