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DAILY 4x4 2020
Iveco DAILY 4x4 2020 User Manual
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DAILY
4x4
‒
GUIDELINES
FOR
BODYBUILD
ERS
CHASSIS
INTERVENTIONS
2.13
BODYWOR
K
INTERVE
NTIONS
33
–
Printed
692.68.999
–
3
Ed.
-
Base
08-2
020
228310
Figure
16
1.
Roof
panel
2.
Cutting
limit
area
3.
Side
finishing
of
roof
4.
Door
suppo
rt
ring
5.
Internal
rear
cross
member
6.
Rear
wall
7.
Door
area
rear
finishing
8.
Side
finishing
56
58
Table of Contents
Section 1
9
Table of Contents
9
Scope of the Guidelines
11
Technical Documentation Available Electronically
11
Authorisation
11
Authorisation Request
12
Responsibilities
12
Legislative Requirements
12
MULTI STAGE TYPE APPROVAL - COLLABORATION (Only for Vehicles Registered in the EU, Switzerland and Turkey)
12
Guarantees
13
Quality System Management
14
Accident Prevention
14
Environmental Aspects
14
Vehicle Management on the Part of Bodybuilder
15
Chassis Acceptance
15
Maintenance
15
Delivery of the Vehicle to the End Customer
15
Vehicle Names
16
Type Approval Name
16
Identifications
17
Dimensions and Ground
17
General Information
17
Vehicle Adaptability
17
Rearview Mirrors
18
Determination of the Centre of Gravity of the Superstructure and the Payload
18
Height of Centre of Gravity
19
Adoption of Stabilizer Bars
21
Observance of the Permitted Masses
21
Variations on the Permitted Masses
22
Instructions for Proper Functioning of the Vehicle Parts and Accessibility
22
General Regulation for the Prevention of Fire Risk
23
Conventions
23
Section 2
27
Chassis Modification Standards
29
General Precautions
29
Special Precautions
29
Characteristics of the Material Used in Chassis Modifications
30
Stresses on the Chassis
31
Drills on the Chassis
31
Positioning and Dimensions of the Holes
31
Screws and Nuts
32
Welding
32
Closing Holes by Welding
34
Rust and Paint Protection
34
Original Vehicle Components
34
Added or Modified Parts
36
Precautions
37
Wheelbase Modification
38
General Information
38
Authorisation
38
Impact on Steering
38
Impact on Braking
39
Intervention Procedure
39
Verification of the Chassis Stresses
40
Cross Members
40
Reinforcements on the Chassis
40
Modifications to the Transmissions
41
Rear Overhang Modification
41
General Information
41
Authorisation
42
Shortening
42
Lengthening
42
Installing the Tow Hook
43
General Information
43
Precautions for Installation
44
Tow Hook for Trailers with Central Axle
46
Observations on Payload
48
Increase of Towable Weight
48
Nameplates
48
Assembling an Additional Axle
49
Modifications to the Driveline
49
Work on Suspensions
49
Modifying the Engine Air Intake and Exhaust Systems
50
Intake
50
Engine Exhaust (Only Euro III)
51
Modifying the Engine Cooling System
51
Modifications to the Heating/Conditioning Plant
52
Installing an Additional Heating System
52
Installing an Air Conditioning System
54
Bodywork Interventions
55
General Information
55
Interventions on Chassis Cab Vehicles
56
Protection of the Vehicle Occupants
58
Steering Column Adjustment
59
Changing Tyre Size
59
Requirements
59
Work on the Braking System
60
General Information
60
Brake Pipe
60
Esp (Electronic Stability Control)
62
Derating of the ESP System
64
Variation of GVW
64
Wheelbase Variation
64
Modification or Replacement of Suspensions
64
Modification or Replacement of the Stabilizer Bars
65
Tyre Changes
65
Part Relocation and Anchorage of Additional Units and Equipment
65
Horn
65
Wheel Mount
65
Fuel Tank
65
Installing a Retarder
66
Rear Under-Run Protection (Rup)
66
Transport of Hazardous Materials (Adr)
66
Mudflaps
67
Rear Mud Guards and Wheel Arches
67
Rearview Mirrors
68
Side Protections
68
Section 3
73
Construction of the Subframe
75
Material
75
Dimension of Sections
75
Aluminium Subframe
76
Elements Making up the Subframe
77
Longitudinal Sections
77
Cross Member
79
Stiffening of the Subframe
79
Self-Supporting Superstructures with Subframe Functions
81
Connection between Chassis and Subframe
81
Connection with Brackets
81
Connections with Greater Flexibility
82
Container Application
83
Dimensions and Centres of Gravity
83
Fixed Bodies
83
Creation of Van Versions
84
Tipping Bodies
85
Tractor for Semi-Trailer
86
Transport of Inseparable Materials
86
Installation of Tanks and Loose Material Containers
87
Installation with a Subframe
87
Installation Without a Subframe
88
Installing a Crane
89
Crane Behind the Cab
90
Crane on the Rear Overhang
91
Removable Cranes
92
Installation of Tail Lifts
92
Front Installation of Snow Plough Attachments
95
Tipper Bodies (Breakdown Recovery)
95
Vehicles for Council, Fire Prevention and Special Uses
95
Application of a Winch
96
Bull Bar Application
96
Special Outfits
97
Cowl Chassis Versions
97
Motor Homes
97
Aerial Work Platforms
97
Section 4
101
General Information
103
Type of Use
103
PTO Transmissions
104
Power Take-Off from Transfer Box
105
Power Take-Off on the Gearbox
105
Power Take-Off from Drive Line
106
Power Take-Off from Engine
106
Pto Management
106
Adjust the Engine Speed for Drive Take-Off
106
After-Sales Installation of PTO
107
Section 5
111
Electronic System
113
Location of Control Units
113
Bodybuilder Connectors
114
Connector 72105A, Black, 32-Pin, Dwg
115
Electronic Control Units
124
Precautions
124
Disconnecting the Electronic Control Units
125
Repositioning the Electronic Control Units
125
Electrical System
125
General Information
125
Precautionary Measures When Working on the System
126
Precautionary Measures When Working on the Chassis
127
Engine Start-Up
127
Ground Points
127
Electromagnetic Compatibility
134
Receiver-Transmission Systems
136
General Instructions
136
Amateur Equipment for CB (27 Mhz) and 2 M Band (144 Mhz)
137
Bluetooth Pre-Installation
138
GPS Receiver and Satellite Navigation Units
140
Radio Installation
140
Toll Collect
140
Additional Equipment
141
Current Draws
142
Current Draw from the CBA2 Control Unit in the Engine Compartment
142
Fuses
143
Passage of Cables from Cab Interior to Cab Exterior
145
Additional Circuits
145
Miscellaneous
145
Interventions for Modifying Wheelbase and Overhang
147
Pre-Installation for Trailer
147
Installation of Lateral Side Lights (Side Marker Lamps)
150
Reverse Gear Signal
152
Antitheft System
153
Daily 4X4 - Guidelines for Bodybuilders
157
General Information
159
The Nitrogen Oxide Catalytic Reduction Principle
159
Main Components of the SCRT System
159
Instructions
160
Adblue Tank
160
Adblue Refuelling Filler
161
Moving Adblue System Components
161
General Information
167
Wiring Diagram
167
20-Way EM Connector, Black (61071B)
168
12-Way EM Connector, Black (72075B)
170
9-Way EM Connector, Yellow
171
Additional Functions
172
General Information
177
Layout
177
Requirements
178
Gearbox Release Lever
178
Bowden Cable
178
Propeller Shaft
179
Rear Cross Member
179
Cooling
180
Additional Devices
180
Warning Indicators
180
Gearbox Oil Temperature
180
4
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Iveco DAILY 4x4 2020 Specifications
General
Brand
Iveco
Model
DAILY 4x4 2020
Category
Trucks
Language
English
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