Iveco DAILY 4x4 Body Builder Instructions

DAILY MCA2014 4x4 ‒ BODYBUILDER INSTRUCTIONS
CHASSIS INTERVENTIONS
Contents
3
– Printed 603.95.994 – 1 Ed. - Base 05/2015
Contents
2.1 GENERAL CHASSIS MODIFICATION
STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preventive measures . . . . . . . . . . . . . . . . . . . . 5
Characteristics of the material used in chassis
modifications . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stresses on the chassis . . . . . . . . . . . . . . . . . . . 7
2.2 DRILLS ON THE CHASSIS . . . . . . . . . . . . . . . 7
Hole position and size . . . . . . . . . . . . . . . . . . . 7
Screws and nuts . . . . . . . . . . . . . . . . . . . . . . . 8
Sealing holes by welding . . . . . . . . . . . . . . . . . . 8
2.3 RUST AND PAINT PROTECTION . . . . . . . . . . 9
Original vehicle parts . . . . . . . . . . . . . . . . . . . . 9
Added or modified parts . . . . . . . . . . . . . . . . . 11
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 WHEELBASE MODIFICATION . . . . . . . . . . . 12
2.5 REAR OVERHANG MODIFICATION . . . . . . . 12
2.6 INSTALLING THE TOW HOOK . . . . . . . . . . 13
General information . . . . . . . . . . . . . . . . . . . . 13
Precautions for Installation . . . . . . . . . . . . . . . 13
Drawbar couplings for centre axle trailers . . . . . . 15
2.7 ASSEMBLING AN ADDITIONAL AXLE . . . . . . 17
2.8 GEARBOX MODIFICATION . . . . . . . . . . . . 17
2.9 WORK ON SUSPENSIONS . . . . . . . . . . . . . 18
2.10 MODIFYING THE ENGINE AIR INTAKE AND
EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . 19
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine exhaust . . . . . . . . . . . . . . . . . . . . . . . 19
2.11 MODIFYING THE ENGINE COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.12 MODIFICATIONS TO THE
HEATING/CONDITIONING PLANT . . . . . . . . . . . 20
Installing an additional heating system . . . . . . . . . 20
Installing an air conditioning system . . . . . . . . . . 23
2.13 BODYWORK INTERVENTIONS . . . . . . . . . 23
General information . . . . . . . . . . . . . . . . . . . . 23
Operations . . . . . . . . . . . . . . . . . . . . . . . . . 24
Protection of occupants . . . . . . . . . . . . . . . . . 26
2.14 CHANGING TYRE SIZE . . . . . . . . . . . . . . . 27
Prescriptions . . . . . . . . . . . . . . . . . . . . . . . . 27
2.15 WORK ON THE BRAKING SYSTEM . . . . . . 28
General information . . . . . . . . . . . . . . . . . . . . 28
Brake pipes . . . . . . . . . . . . . . . . . . . . . . . . . 28
ESP (Electronic Stability Program) . . . . . . . . . . . 30
ESP SYSTEM Derating . . . . . . . . . . . . . . . . . . 32
2.16 ELECTRICAL SYSTEM: CURRENT
INTERVENTIONS AND DRAWS . . . . . . . . . . . . . 33
2.17 PART RELOCATION AND ANCHORAGE OF
ADDITIONAL UNITS AND EQUIPMENT . . . . . . . . 33
2.18 TRANSPORT OF HAZARDOUS MATERIALS
(ADR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.19 INSTALLING A RETARDER . . . . . . . . . . . . 34
2.20 REAR UNDER-RUN PROTECTION
(RUP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.21 REAR MUD GUARDS AND WHEEL
ARCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.22 RAIN FLAP . . . . . . . . . . . . . . . . . . . . . . . 35
2.23 SIDE PROTECTIONS . . . . . . . . . . . . . . . . 35

Iveco DAILY 4x4 Specifications

General

Brand	Iveco
Model	DAILY 4x4
Category	Scooter
Language	English