Hyundai Body Builder 2015 User manual

Body Builder Manual V1.0, February 2015
Body Builder Manual
Part II - Specific Book LCV

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONSMAINTENANCE AND DAMAGE PREVENTIONWORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMSAPPENDIX
2 Body Builder Manual Part II, Specific Book LCV V1.0, February 2015

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
V1.0, February 2015 Body Builder Manual Part II, Specific Book LCV 3
Ammendment Index
Body Builder Manual - Part II Specific Book LCV (Light commercial vehicles)
Chapter Subject Page No.

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
4 Body Builder Manual Part II, Specific Book LCV V1.0, February 2015
Content
1 INTRODUCTION.......................................................................................7
1.1 Scope of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Content structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Convention of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.3.1 Copyright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2 PRELIMINARY STUDIES AND CONSIDERATIONS ...............................11
2.1 Recommendations for planning work . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.2 Range of vehicles supplied by HYUNDAI . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.3 Technical limit values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.3.1 General considerations - Legislation to consider . . . . . . . . . . . . . .21
2.3.2 Vehicle main dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
2.3.3 Weight distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2.3.4 Centre of Gravity (CoG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.3.5 Wheelbase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.3.6 Vehicle overhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.3.7 Wheel dimensions and clearances . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.3.8 Wheel clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
2.3.9 Noise insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.3.10 Turning diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2.3.11 Body and chassis clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3 MAINTENANCE AND DAMAGE PREVENTION .....................................45
4 WORK ON BASIC VEHICLE ...................................................................46
4.1 Prevention and recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.1.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.1.2 Drilling work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
4.1.3 Bolted connection work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.1.4 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
4.1.5 Corrosion protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.2 Chassis frame modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.2.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.2.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
4.2.3 Main sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
4.2.4 Attachment of groups or additional equipment . . . . . . . . . . . . . . .60
4.2.5 Overhang modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.2.6 Wheelbase modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.3 Bodyshell modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
4.3.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
4.3.2 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
4.3.3 Roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
4.3.4 Side walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
4.3.5 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
4.3.6 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
4.3.7 Wheel wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
4.3.8 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
4.3.9 Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
4.4 Suspension modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
4.5 Interior modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
4.5.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
4.5.2 Noise insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
4.5.3 Safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
4.5.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
V1.0, February 2015 Body Builder Manual Part II, Specific Book LCV 5
4.5.5 Additional seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
4.6 Propeller shaft modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
4.7 Coupling device adaptations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
4.8 Brake system modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
4.9 Engine system modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
4.10 Exhaust and intake system modifications . . . . . . . . . . . . . . . . . . . . . . . .110
4.10.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
4.10.2 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
4.10.3 SCR technology and AdBlue product. . . . . . . . . . . . . . . . . . . . . . .114
4.10.4 Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
4.11 Fuel system modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
4.11.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
4.11.2 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
4.11.3 Alternative systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.11.4 Considerations and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .121
4.12 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
4.12.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
4.12.2 Underride guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
4.12.3 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.12.4 Mud guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.12.5 Wind deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
4.12.6 Undercover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
4.12.7 Additional air conditioning systems. . . . . . . . . . . . . . . . . . . . . . . .135
4.12.8 Equipment installed on roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
4.12.9 Interior installations for load fixations . . . . . . . . . . . . . . . . . . . . . 137
4.12.10 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
4.12.11Other additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
4.13 Steering system modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
4.14 Axle and wheel modifications .........................................................................139
4.15 Electrical and electronic system modifications . . . . . . . . . . . . . . . . . . . .141
5 MOUNTING AND CONSTRUCTION OF BODIES ................................. 143
5.1 Machinery Directive and CE marking. . . . . . . . . . . . . . . . . . . . . . . . . . . .144
5.1.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
5.1.2 Machinery directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.1.3 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
5.2 Subframe features and design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
5.2.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
5.2.2 Subframe permissible material . . . . . . . . . . . . . . . . . . . . . . . . . . .147
5.2.3 Subframe: permissible sections . . . . . . . . . . . . . . . . . . . . . . . . . . .148
5.2.4 Subframe design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .150
5.2.5 Subframe on roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
5.3 Subframe attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.3.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
5.3.2 Flexible connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
5.3.3 Rigid connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
5.3.4 Combining flexible and rigid connections . . . . . . . . . . . . . . . . . . .159
5.3.5 Self-supporting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.3.6 Particular points to be considered. . . . . . . . . . . . . . . . . . . . . . . . .161
5.4 Study of different types of bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.4.1 General considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
5.4.2 Platform bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
5.4.3 Van bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.4.4 Tipper bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
5.4.5 Tankers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
5.4.6 Refrigerated vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.4.7 Tractor for semi-trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
6 Body Builder Manual Part II, Specific Book LCV V1.0, February 2015
5.4.8 Motor caravans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
5.4.9 Loading cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
5.4.10 Tail lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
5.4.11 Special service vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
5.4.12 Aerial platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
5.4.13 Tilt platforms (roadside assistance). . . . . . . . . . . . . . . . . . . . . . . .194
5.4.14 People carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
5.4.15 Low chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
5.4.16 Consideration on integrated bodies. . . . . . . . . . . . . . . . . . . . . . . .197
5.4.17 Other type of bodies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
6 POWER TAKE-OFF.............................................................................200
6.1 PTO general considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
6.2 Study of different types of PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
7 ELECTRIC AND ELECTRONIC SYSTEMS............................................212
7.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
7.2 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
7.2.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
7.2.2 Wire features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
7.2.3 Fuse features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
7.2.4 Wiring process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
7.2.5 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
7.3 Additional electricity consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
7.3.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
7.3.2 Possibilities of connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
7.3.3 Connection types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
7.3.4 Earth wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
7.3.5 Fuse protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
7.4 Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
7.4.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
7.4.2 Extra batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
7.4.3 Maintenance of batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
7.5 Lighting guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
7.5.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
7.5.2 CE Directives for lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
7.5.3 Lighting system installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
7.6 Communication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
7.7 Electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
7.7.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
7.7.2 CAN-bus technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
7.7.3 Electronic control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
7.7.4 Automatic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
A APPENDIX...........................................................................................259
A.1 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
A.2 Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
A.2.1 General concepts and formulas . . . . . . . . . . . . . . . . . . . . . . . . . . .261
A.2.2 Calculating the axle load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
A.2.3 Calculating the Centre of Gravity (CoG) . . . . . . . . . . . . . . . . . . . .266
A.2.4 Coupling device calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
A.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
A.3.1 Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
A.3.2 Light loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274
A.3.3 Recommended lubricants and capacities. . . . . . . . . . . . . . . . . . . .275
A.3.4 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
A.3.5 PTO information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
V1.0, February 2015 Body Builder Manual Part II, Specific Book LCV 7
1 INTRODUCTION
This chapter provides the following information:
- Scope of this manual
- Content structure
- Convention of symbols
-Copyright

INTRODUCTION PRELIMINAR STUDIES AND CONSIDERATIONS MAINTENANCE AND DAMAGE PREVENTION WORK ON BASIC VEHICLE
MOUNTING AND CONSTRUCTION POWER TAKE-OFF ELECTRIC AND ELECTRONIC SYSTEMS APPENDIX
8 Body Builder Manual Part II, Specific Book LCV V1.0, February 2015
1.1 Scope of this manual
The purpose of this manual is to provide the Body Builders with technical informa-
tion and indications necessary for proper assembly between the superstructure and
the various chassis from Hyundai Motor Company (subsequently referred as HMC).
This manual has been specifically created for Light Commercial Vehicles (LCV).
It also refers to different binding regulations, recommendations for maintenance
and conservation as well as for the prevention of damage during construction work.
All this is in order to ensure the safety and good service of the vehicle and its com-
ponents after any modifications and alterations have been made.
This manual is specifically targeted for professionals, assuming they have the basic
knowledge needed to understand and manage this manual. Likewise, HMC recom-
mends having the construction work carried out by qualified personnel, in order to
avoid potential hazards or accidents and get the best result in the realisation of the
projects undertaken.
As for possible data discrepancies in this manual or between different versions of
additional manuals to it, the last upgrade always applies.
If any error or mistake is found, or you have any questions about the installation of
bodies on the HMC chassis, please contact with HMC freely.
See General Book, chapter 2.4 "Contact possibilities".
Detailed information in this book can be altered without notice beforehand accord-
ing to engineering revision. In this case the additional information should be revised.
HMC is continually striving to improve the technology for making the perfect vehi-
cle. HMC hopes that this book will help you and appreciates the habitual use of their
vehicles.

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V1.0, February 2015 Body Builder Manual Part II, Specific Book LCV 9
1.2 Content structure
This manual is divided into three books, GENERAL, SPECIFIC and DRAWINGS, trying
to facilitate and to improve handling and understanding.
This distribution seeks to follow the logical process in the carrying out of construc-
tion work, from general aspects to others more technical or specific.
For the correct application of the rules and recommendations of this manual, the
three books into which it is divided should be considered.
The content structure is organised as follows:
Table 1-1 Content of the Body Builder Manual
GENERAL BOOK
LATEST UPDATES
TAB LE OF CO NTENTS
1INTRODUCTION
2GENERAL INFORMATION
3PRELIMINAR STUDIES AND CONSIDERATIONS
4MAINTENANCE AND DAMAGE PREVENTION
INDEX
SPECIFIC BOOK (LCV)
LATEST UPDATES
TAB LE OF CO NTENTS
1INTRODUCTION
2PRELIMINAR STUDIES AND CONSIDERATIONS
3MAINTENANCE AND DAMAGE PREVENTION
4WORK ON BASIC VEHICLE
5MOUNTING AND CONSTRUCTION OF BODIES
6POWER TAKE-OFF
7ELECTRICAL AND ELECTRONIC SYSTEMS
APPENDIX
INDEX
DRAWINGS
LATEST UPDATES
TAB LE OF CO NTENTS
1INTRODUCTION
2DRAWINGS

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10 Body Builder Manual Part II, Specific Book LCV V1.0, February 2015
1.3 Convention of symbols
There are various WARNINGS, ENVIRONMENT, CAUTIONS and NOTICES symbols in
this manual. These were prepared to enhance your personal safety.
You should carefully read and follow all procedures and recommendations provided
in these advice notes.
References for additional information are indicated with: See chapter 1.2.3.
Notice that the index in pdf format, as well as bookmarks and the references for
additional information are linked to help you find the required information easily.
1.3.1 Copyright
The rights in the designs, pictures, logos, photographs and other contents of this
manual (including, but not limited to, hardcopy, online, CD, DVD editions) are owned
by or licensed to Hyundai Motor Company (HMC). They are protected by copyright,
trademarks and other intellectual property rights as acknowledged by the applicable
law. You may not copy, reproduce, modify, distribute, republish, display, post or
transmit any part of this manual without the written permission of HMC except as
otherwise permitted by the applicable law.
WARNING
A WARNING indicates a situation in which harm, serious bodily injury or death
could result if the warning is ignored.
ENVIRONMENT
An ENVIROMENT indicates a situation in which HMC provides information to pre-
vent damages to the environment.
CAUTION
A CAUTION indicates a situation in which damage to your vehicle could result if
the caution is ignored.
NOTICE
A NOTICE indicates interesting or helpful information is being provided.

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2 PRELIMINARY STUDIES AND CONSIDERATIONS
This chapter provides the following information:
- Recommendation for planning work
- Range of vehicles supplied by HYUNDAI
- Technical limit values

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2.1 Recommendations for planning work
For proper work planning, the most appropriate body and chassis combination
should be determined. Only through close cooperation between the Body Builder,
client and HMC, will optimum results be achieved.
The most important factor will consist in the study of all documentation provided by
each of the parties and a detailed analysis of the requirements that the vehicle must
comply with, once the changes have been made in it.
In this way, we will proceed to the selection of the most appropriate chassis and
equipment in respect of:
- Activity for which the vehicle is intended.
- Characteristics of the roads in which the vehicle will circulate normally.
- Observance of the laws and legal guidelines in Europe and in each country.
- Technical limits values to respect, such as centre of gravity, wheelbase...
See chapter 2.3 "Technical limit values".
- Characteristics of vehicle components, such as engine type, PTO, gearbox, etc.
- Possible additional equipment that can be supplied from the factory with the
original vehicle, and its various settings and features.
- Provide sufficient space to ensure the functioning and operational safety of
the additional equipment.
- Appropriate selection of materials to be used.
- Main dimensions of the vehicle after modification
- Maximum gross weight and height according to laws of each country.
The vehicles supplied by HMC comply with European CE Directives and national
standards in each country. See chapter 5.1 "Machinery Directive and CE mark-
ing".
After the work has been carried out on the vehicle, the Body Builder must ensure
that the finished product continues to meet the standards. There are different var-
iants of vehicles supplied by HMC; an original vehicle with the features and dimen-
sions that can be adapted in the best way to achieve the final result should be
chosen. See chapter 2.2 "Range of vehicles supplied by HYUNDAI"
WARNING
Never exceed the carrying capacity of the vehicle. This can produce damage or
malfunction in some vehicle systems. In this case, the driver could lose control of
the vehicle and cause an accident.
WARNING
Changes must not be made to the steering or in the brake system. Incorrect
manipulation of these systems could cause vehicle malfunction. In this case, the
driver could lose the control of the vehicle and cause an accident.

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A place should likewise be provided for the proper storage of the vehicle during the
work and after it has been completed, as well as for appropriate maintenance.
See General Book, chapter 4 "Maintenance and damage prevention".
NOTICE
Before beginning construction work, it is recommended that the vehicle provided
should be verified, to check whether it satisfies requirements.
NOTICE
The vehicle identification data and the main features of the vehicle can be found
on the vehicle identification plates and features.
See Vehicle identification and feature plates, chapter 2.2 "Range of vehicles
supplied by Hyundai"
NOTICE
The complete vehicle technical documentation can be provided on request.
Contact the relevant department in each case.
See General Book, chapter 2.4 "Contact Possibilities"

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2.2 Range of vehicles supplied by HYUNDAI
HMC provides a wide range of vehicles with different specifications and technical
characteristics. These different variants are intended to provide the best support
possible to the finished vehicle, thereby achieving the best strength properties,
comfort, cargo handling, etc.
This specific manual deals with the range of Light Commercial Vehicles.
Vehicle designation system
In order to easily identify the different variants of vehicles supplied by HMC, the
meanings of the codes and rules used for this purpose are detailed below.
HMC has created a system which is divided into three main groups:
Table 1-2 Main groups of vehicle designation
In order to clarify this system, its operation is explained by means of an example:
Designation system explanation:
Table 1-3 Example of vehicle designation
NOTICE
The complete technical documentation for the vehicle can be provided on request.
Contact the relevant department in each case.
See General Book, chapter 2.4 "Contact Possibilities.
VEHICLE IDENTIFICATION Commercial name of the vehicle.
TECHNICAL DATA
SPECIFICATION
Technical data features of each variant.
This will always be preceded by vehicle designation.
SPECIAL FEATURES Specification of the features that certain special
products have due, for example, to special
equipment. (Chassis low, reinforced chassis, spoilers
etc.)
H350.1S 35 L1H2-A13-ST
VEHICLE IDENTIFICATION TECHNICAL DATA SPECIFICATION SPECIAL
H350.1S 35 L1H2-A13 - ST
HYUNDAI
SERIES
TYPE OF
VEHICLE
REAR
AXLE
CONFIG
GVW WHEEL-
BASE
ROOF
MODEL
ENGINE
MODEL
POWER SPECIAL
FEATU-
RES
H350 1 S 35 L1 H2 A13 - ST
"TABLE A" "TABLE B" "TABLE C" "TABLE D" "TABLE E" "TABLE F" "TABLE G" "TABLE H" "TABLE I"

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The following tables refer to the meaning of each of the acronyms and different
vehicle configurations which are possible:
Table 1-4 A - Acronyms vehicle series
Table 1-5 B - Acronyms type of vehicle
Table 1-6 C- Acronyms rear axle configuration
Table 1-7 D - Acronyms max. gross vehicle weight
Technical Data specification
Table 1-8 B - Acronyms wheelbase length
TABLE A HYUNDAI TRUCK SERIES
Acronym Description
H350 Describes vehicles series
TABLE B TYPE OF VEHICLE
Acronym Description
1Panel van
2Passenger van
3Chassis cab
TABLE C REAR AXLE CONFIGURATION
Acronym Description
SSingle
DTwin
TABLE D MAX. GROSS VEHICLE WEIGHT
Acronym Description
35 3.5 tons
40 4.0 tons
41 4.1 tons
46 4.6 tons
50 5.0 tons
TABLE E WHEELBASE
Acronym Description
L1 3435 mm
L2 3670 mm
L3 4330 mm

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Table 1-9 C- Acronyms roof model
Table 1-10 A - Acronyms engine model
Table 1-11 B - Acronyms engine power output
Table 1-12 A - Acronyms special features
TABLE F ROOF MODEL
Acronym Description
H1 Standard roof
H2 High roof
TABLE G ENGINE MODEL
Acronym Description
AA-engine
TABLE H ENGINE POWER OUTPUT
Acronym Description
13 130 HP
15 150 HP
17 170 HP
TABLE I SPECIAL FEATURES
Acronym Description
ST Describes special features

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Range of vehicles
The following table shows the range and features of the vehicles to which this man-
ual refers.
Table 1-13 SPBTC22_012 Range of vehicles supplied by HMC
PANEL VAN
Standard roof H1 High roof H2
5M 3.5 t
H350. 1S 35 L1H1-A13/15/17 H350. 1S 35 L1H2-A13/15/17
6M
3.5 t
4.0 t
4.1 t
H350. 1S 35 L2H1-A13/15/17 H350. 1S 35 L2H2-A13/15/17
H350. 1S 41 L2H2-A17
7M
3.5 t
4.6 t
5.0 t
- -
H350. 1S 35 L3H2-A13/15/17
H350. 1S 41 L2H2-A17

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Table 1-14 SPBTC22_012 Range of vehicles supplied by HMC
*) Rear wheel twin is possible for 4.6 ton; 1 - Front door; 2 - FR & Mid door
PASSENGER VAN CHASSIS CAB
Standard roof H2 Standard roof H1
5M 3.5 t - -
H350. 3S 35 L1H1-A13/15/17
6M
3.5 t
4.0 t
4.1 t
H350. 2S 40 L2H2-A17 * H350. 3S 35 L2H1-A13/15/17
7M
3.5 t
4.6 t
5.0 t
H350. 2D 46 L3H2-A17 *) H350. 3S 35 L3H1-A13/15/17
H350. 3D 50 L3H1-A17

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Vehicle identification and features plates
The Vehicle Identification Number (VIN) allows the identification of the vehicle, pro-
tecting it from theft, manipulation and falsification.
In Hyundai vehicles, this number is punched on the engine compartment bulkhead,
near the lower edge of the windshield. This plate must be incorporated by law in all
motor vehicles.
The standard in Europe is regulated by the Standard ISO 3779 "Road vehicles - Ve-
hicle Identification Number (VIN)".
Fig. 2-15 VIN location
The VIN is also on a plate attached to the top of the dashboard. The number on the
plate can easily be seen through the windshield from outside.
Fig. 2-16 VIN location on the dashboard

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In addition to this identification plate, the vehicles incorporate a certification label
plate on which relevant technical specifications of the vehicle are written, such as
the model, the maximum authorised weight, which is attached on the driver´s (or
front passenger´s) side centre pillar. It also normally gives the vehicle identification
number (VIN).
Fig. 2-17 Technical characteristics plate
Special equipment
In addition to the standard equipment, vehicles supplied by HMC may include option-
al equipment (always on prior request), with the intention of adapting the vehicle as
well as possible to the final task.
The fact that the installation of this special equipment will increase the weight of
the vehicle should be taken into account. For this reason, it is recommended that
the vehicle should be weighed before starting construction work, in order to know
the actual weight.
1Driver seat 3Technical characteristics plate
2B-pillar
NOTICE
None of these plates should be modified or installed elsewhere.
NOTICE
To obtain more information about special equipment supplied, contact HMC.
See General Book, chapter 2.4 "Contact Possibilities".