Iveco DAILY M.Y. 2012 User manual

DAILY M.Y. 2012
BODYBUILDERS INSTRUCTIONS
LIGHT RANGE
ISSUE 2011

IVECO S.p.A.
Technical Application
Strada delle Cascinette, 424/34
10156 Torino (TO) - Italy
www.iveco.com
Printed 603.95.241 -1
st ed. 09/2011

Printed 603.95.241 Base - 09/2011
Update data
DAILY
Bodybuilders instructions
Printed 603.95.241 - 1st ed.
Base - 09/2011
UPDATE DATA
Section Paragraph Description Revision date

Base - 09/2011 Printed 603.95.241
Update data

Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
This publication provides the data, features and instructions for vehicle fitting and modifications.
It is intended for qualified, skill personnel. The Bodybuilder is responsible for designing the fitting, its modification and execution, and
will have to ensure compliance with the provisions both of this publication and the law regulations in force.
Prior to carrying out any work, make sure you have the publication of the vehicle model on which you are about to work. Also make
sure that all the accident-prevention equipment such as, for instance, goggles, helmet, gloves, boots, etc. as well as the working, lifting
and handling equipment are available and in good working order. Finally, make sure that you operate on the vehicle in such conditions
as to ensure maximum safety.
The execution of the work by strictly complying with the above provisions, as well as the use of the components shown, ensure that
the work is carried out correctly and safely.
Any change, modification or fitting not covered by this manual and not expressly authorized in written by IVECO will relieve the
latter of any responsibility and make, in particular, the vehicle guarantee null and void.
IVECO is available to provide all and every explanation required to carry out the work and also help you handle the cases not dealt
with in this publication.
After every single intervention, the functioning, efficiency and safety conditions established by IVECO shall be restored. Contact the
IVECO service network for vehicle set-up, if necessary.
IVECO shall not be responsible for any change, modification or fitting concerning the vehicle.
The data and information contained in this publication may not be updated due to the changes made by IVECO, at any time, for
technical or commercial reasons, or to make the vehicles comply with the law regulations in force in the different countries.
In the event of any discrepancy between the contents of this publication and the actual vehicle, please contact the Product Manager
for your market before carrying out any operations.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Symbols - warnings
General danger
It includes the dangers of above described signals.
Danger of serious damage for the vehicle
Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guar-
antee lapse too.
!
Foreword
It indicates an additional explanation for a piece of information.NOTE
Printed 603.95.241 Base - 09/2011
Foreword

Page header and footer interpretation
Vehicle type Section title Section number -
page number
Print
number Chapter title Basic edition -
month year
Base - 09/2011 Printed 603.95.241
Foreword

Index of section
Printed 603.95.241 Base - 09/2011
INDEX OF SECTION
Section
Power Take-offs 4
Special instructions for electronic subsystems 5
Appendix A - Daily PASSENGER TRANSPORT A
Appendix B - Daily CNG and CNG with Recovery Mode B

Index of section
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POWER TAKE-OFFS 4-1 DAILY
Printed 603.95.241 Base - 09/2011
Index
Index
SECTION 4
Power take-offs
Page
4.1 General Specifications 4-3
4.2 Power Take-off from Gearbox 4-5
4.3 Power Take-off from Transfer Box 4-8
4.4 Power Take-off from Drive line 4-8
4.5 Power Take-off from Engine 4-9
4.6 PTO management 4-10
4.6.1 General specifications 4-10
4.6.2 PTO mode 4-13
4.6.2.1 Mechanical Gearbox 4-13
4.6.2.2 Automatic Transmission 4-14
4.6.2.3 Engine speed control for power take-off 4-15
4.6.2.4 Multiple State Switch 4-16

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Index

POWER TAKE-OFFS 4-3 DAILY
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General Specifications
44444.
Ge ner al Spe ci fi cations
4.1 General Specifications
Different types of power takeoffs (PTO) for motion withdrawal can be mounted to control of the ancillary control units.
According to the type of use and the performances required, the application can be performed as follows:
- the gearbox;
- transmission;
- the front of the engine.
The characteristics and performances are given in the paragraphs which follow and in the relevant documentation which will be
supplied upon request.
For the definition of the power necessary for the apparatus to be controlled, particularly when the values requested are high, the
absorbed power should also be considered during the drive transmission phase (5 to 10% for the mechanical transmissions, belts
and gears, and greater values for the hydraulic controls).
Choose the power take-off transmission ratio to ensure that power uptake occurs within the flexible engine operating range; avoid
low speeds (lower than 1000 rpm) to rule out unevenness and jerkiness in vehicle operation.
The power taken in relation to the number of revolutions of the power take-off at the required torque.
P(CV) =M⋅n⋅i
7023
P(kW) =M⋅n⋅i
9550
P = Useable power
M = Torque permitted for the power take-off (Nm)
n = power take-off rpm.
i = Transmission ratio = PTO output rpm/ engine rpm
Type of use
Applications may be sporadic or continuous.
In sporadic applications, the duration of power take-off operations does not exceed 30 minutes.
In continuous use this is significantly longer; however whenever the use is comparable to that of a stationary engine, it is necessary
to evaluate the opportunity to reduce take off of torque also on the basis of the surrounding conditions (engine cooling, gearbox
etc.).
Take off of torque is possible without problems if the type of use does not result in significant variations of torque in terms of
frequency and amplitude.
Should this not be the case (e.g. hydraulic pumps, compressors), clutches or safety valves may be necessary to avoid overloading.

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General Specifications
PTO transmissions
In respect of the transmission manufacturer’s requirements, particular care must be given to the kinematics (angles, rpm, moment)
from the PTO to the attached device during the design phase and dynamic behaviour during the production phase.
This means that:
- the forces which will be present during maximum power and torque output conditions must be considered when calculating
scaling
- equal shaft-end angles must be realised for good homokinetics (see Figure 4.1); these must be no more than 7”
- solution Z is preferable to W, as the loads on the bearings of the PTO and the driven equipment are lower. In particular, when
it is necessary to realise a transmission line with shafts inclined in the space according to an angle ϕ(as illustrated in Figure 4.2),
it must be remembered that the overall homokinetics can only be ensured if the intermediate shaft is fitted with forks offset by
thesameangleϕandiftheendanglesχ1andχ2areequal.
For transmissions employing multiple sections, the instructions given at point 2.8.2 should be followed.
Solution Z
Solution W
91522
Figure 4.1
0
0
0
0
Figure 4.2
133340

POWER TAKE-OFFS 4-5 DAILY
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Power Take-off from Gearbox
Power Take---offfrom Gearbox
4.2 Power Take-off from Gearbox
Take off from the transmission lay shaft is possible via flanges or couplings positioned in the left part of the casing (see fig. 4.3).
Table 4.1 lists the maximum torques and the output rpm to engine rpm ratios for the various transmission/IVECO optional PTO
combinations.
Any higher take-off torques, for occasional uses, must be individually authorised by IVECO on the basis of the type of use.
The PTO must normally be used with the vehicle parked and must be engaged and disengaged with the clutch disengaged to avoid
excessive stress on the synchronisers.
When, under exceptional circumstances, it is used with the vehicle in movement, no gear changes must be performed.
The same PTOs for manual gearboxes can be used with gearboxes fitted with torque converters.
It must, however, be remembered that for engine rpm of below 60% of the maximum, the converter works hydraulically and in this
stage the PTO rpm is subject to fluctuations depending on power draw, even if the engine rpm is constant.
Figure 4.3
166057
1. Cover for arranging power take-off
After the assembly of the power take-off perform the filling up and check the oil level from the speed
gearbox.
NOTE

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Power Take-off from Gearbox
Transmission PTO data
Post-production installation of a PTO requires reprogramming of the gearbox control unit (if automatic) as well as some work
on the electrical system. As such, it is recommended you read section 4.6 ”PTO management” before proceeding.
The control unit must be reprogrammed by following the instructions found in the relevant IVECO manuals, using the diagnostics
tool available from Dealers and Authorised Workshops and supplying information on the PTO used.
Table 4.1
Gearbox Position
(1)
Output
(1)
Direction of
rotation (2)
Max. torque
Cmax (Nm) (2) PTO ratio
2830.5
2835.6 Left-hand side Rear Clockwise 120 1.00
2840.6
2850.6
6AS400
Left-hand side Rear Clockwise 180 1.04
(1) With respect to forward direction of travel.
(2) When viewing the PTO output from the front.
(3) The maximum torque that can be taken refers to an engine speed of 1,500 r.p.m. output from the PTO For higher speeds, the value for the torque that can
be taken must be reduced proportionally.
IVECO reserves the right not to honour any guarantees on the transmission where the malfunction
can be traced back to the PTO and, in this case, the PTO installed by the Bodybuilder has specifications
and performance different from those indicated in Table 4.1.
Figure 4.4
166656

POWER TAKE-OFFS 4-7 DAILY
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Power Take-off from Gearbox
Direct Application of Pumps
In the case that pumps or other equipment are directly connected to the PTO, that is without intermediate shafts, you should
first check that the there is a safety margin between the chassis and power unit, and then that the static and dynamic torques exerted
by the mass of the pump and the PTO are compatible with the resistance of the gearbox casing walls.
Moreover, the inertial effects of any added masses must be verified so as not to induce resonance conditions in the power unit inside
theoperationalrangeofenginespeeds.
For torque drawing, keep values defined in Table 4.1.
Transmission oil temperature must not exceed 110 °C during prolonged use. Coolant temperature
must not exceed 100 °C.
Not all types of power take-off available on the market are suitable for continuous use. When in use the
specifications (working periods, pauses etc.) specific to the power take-off in question should be respected.
!
PTOs supplied by IVECO have a flange for direct attachment of pumps with UNI 4-hole connectors.
The output consists of a 21 ISO 14 splined shaft (Figure 4.4).

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Power Take-off from Transfer Box
Power Take---off fromT ransfer Box
4.3 Power Take-off from Transfer Box
Not present on Daily 4x2.NOTE
4.4 Power Take-off from Drive line
Authorisation of the installation of a PTO on the transmission after the gearbox will be given after examination of the complete
documentation which must be presented to IVECO.
The power and torque values are defined each time on the basis of the usage conditions.
As a general rule, bear in mind that:
- the PTO may only operate with the vehicle stationary;
- the power take-off r.p.m. is dependent on the gear selected;
- the installation must be performed immediately after the gearbox; for vehicles with transmissions of two or more shaft sections
the PTO may also be installed in correspondence with the oscillating mount between the first and second section (follow
indications in point 2.9.2);
- the original transmission angles in the horizontal and vertical planes must be maintained as closely as possible;
- anything added to the transmission must not cause abnormal vibrations or instability or otherwise damaging effects on the drive
transmission components (from the engine to axle) either during driving or use of the PTO;
- the PTO must be attached to the chassiswithitsownsuspensionsystem.
The transmission is a component that is important to vehicle driving safety. Any operations on the
transmission must be carried out only by highly specialised companies that have been approved by the
supplier.
!
Any operation carried out on the propeller shaft without obtaining previous authorisation from IVECO
will cause the vehicle warranty to immediately become null and void.
!

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Power Take-off from Engine
Power Take---offfrom Engine
4.5 Power Take-off from Engine
The use of these PTOs is intended for equipment requiring continuous power and with low torque values (e.g. driving AC
systems).
Power is taken from the front part of the engine via belt drive.
The data listed in Table 4.2 refer to take off with a specific pulley designed according to Figure 4.5.
Table 4.2 - Power take-off from the front of the engine
Engine Engine code (1) nmax
(rpm) (2)
Max. take-off values
Max. no-load
speed (r.p.m.)
Max. torque
that can be
taken (Nm)
Max. inertia
moment (kgm2)
Max. bending
moment (Nm) (3)
F1A Euro 5 Series
.11 F1AE3481A*A 3900 4600 35 0,005 42
.13 F1AE3481B*A 3600 4600 35 0,005 42
.15 F1AE3481C*A 3600 4600 35 0,005 42
F1C Euro 5 Series
.15 F1CE3481J*B 3500 4200 35 0,005 42
.17 F1CE3481K*B 3500 4200 35 0,005 42
.21 F1CE3481D*B 3500 4200 35 0,005 42
F1C EEV Series
.15 F1CE34818*C 3500 4200 35 0,005 42
.17 F1CE3481C*C 3500 4200 35 0,005 42
.14 F1CE0441A*B (CNG) 3500 4200 35 0,005 42
(1) Verify engine code on engine plate
(2) Maximum revs corresponding to the maximum rating
(3) With respect to the base front edge
Figure 4.5
BASE UNIT FRONT EDGE
102475
F1A - F1C engine

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PTO management
PT O manage men t
4.6 PTO management
4.6.1 General specifications
The vehicle may be equipped with the following alternative original equipment options:
a) only PTO (opt. 6364/6365);
b) PTO (opt. 6364/6365) and Expansion Module (opt. 8657);
c) only Expansion Module (opt. 8657);
where the Expansion Module is an electronic interface designed to manage certain types of conversion (additional lights, alarms,
after-market PTOs, etc).
See the specifications in IVECO Guideline no. 603.95.231 of 12/2010 for description of the characteristics and methods of use.
In case (a) where only the PTO is present, a control panel is installed on the instrument cluster (Figure 4.6, page 4-11), which consists
of:
•PTO section, which provides management of the engagement and disengagement of the power take-off using a pushbutton
(1) with a warning light (2) signalling the situation in progress;
•VALVE section, for managing the operation of a dump body (if present) and interaction with the hydraulic distributor fitted
on the lifting system. For vehicles without a tipping body, the VALVE section is not operational.
For operation of the tipping body, see instructions on page 4-11.
In case (b), in addition to the panel for the PTO, a special button (6, Figure 4.6, page 4-11) for operation of the Expansion Module
is located in the centre of the dashboard.
In case (c) the Bodybuilder is left free to decide where to position the PTO controls.

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PTO management
Figure 4.6
147477
PTO CONTROL PANEL EXPANSION MODULE ACTIVATION BUTTON
Operating tipper box (if present)
Button (3) controls tipping body lifting: this action will be simultaneous and will be cancelled when the button is released.
A continuous LED light (5) indicates that lifting of the tipper truck is in progress.
Button (4) controls tipping body lowering: this action will be simultaneous and will be cancelled when the button is released.
See any additional functions and safety features in the manufacturer’s handbooks.
After-market PTO installation
After-market installation of the PTO is possible on vehicles with or without Expansion Modules.
Installation of the PTO is possible only where this is provided for on the vehicle.
a) For vehicles without an Expansion Module it is necessary to order the components for installation of the PTO, the cable for
connection to the engine compartment cable connector (1) (connector on anti-theft bracket), the enabler relay to install on
SCM1/B in the engine compartment (tab 5.14 pag. 5-46, relay T55) and the PTO control panel (fig 4.6) to connect to the
dashboard cable.
Figure 4.7
166053
PTO connector on engine compartment cable

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PTO management
b) For vehicles with an Expansion Module it is necessary to order the components for installation of the PTO, the cable for
connection of this to the engine compartment cable connector (1-fig. 4.7), the two relays (1-fig. 4.8) to install in the Expansion
Module (fig 4.8) and the PTO activation/deactivation request button (6-fig 4.6).
Figure 4.8
166054
Relay and fuse module for PTO with Expansion Module
Table 4.3
SCM1/C Power Protection Presence Capacity Type EURO5
4x2
EUROV
4x2 BIFUEL
SOPT
F79 30 Expansion Module relay T61 (30-87) for PTO X 15 A0 X X X
F80 30 Expansion Module relay T62 (30-87) for PTO X 15 A0 X X X
F86 AVAILABLE A0
F88 AVAILABLE A0
F89 AVAILABLE A0
F90 AVAILABLE A0
SCM1/C Power Protection Presence Capacity Type EURO5
4x2
EUROV
4x2 BIFUEL
SOPT
T61 Expansion Module X 20 X X X
T62 Expansion Module X 20 X X X
- With the PTO installed, the Engine Control Unit can be configured by IVECO service in order to
set the engine operating conditions with PTO engaged.
- If you wish to install a PTO after market, you must check whether the vehicle is fitted with Cruise
Control.
- The Expansion Module does not manage the tipper body. If a PTO is to be installed after market
for this use, the kit with PTO control panel must be purchased (kit for vehicles without Expansion
Module).
NOTE