Iveco DAILY 4x4 User manual

DAILY VEHICLE 4X4
RANGE
BODYBUILDER
INSTRUCTIONS
LIGHT RANGE
ISSUE 2007

Publication Edited by:
Technical Application
Strada delle Cascinette, 424/34
10156 Turin - Italy
Publication Nr. 603.93.761 - 1st Edition
Printed in Italy - 05.07
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy
Produced by:

Print 603.93.761 Base - May 2007
Update data
DAILY 4x4
Bodybuilders instructions
Print 603.93.761 - 1st edition
Base - May 2007
UPDATE DATA
Section Description Page Revision date

Base - May 2007 Print 603.93.761
Update data

This publication provides the data, features and instructions for vehicle fitting and modifications.
It is intended for qualified, skill personnel. The body builder 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 case of disagreement between the provisions included herein and the actual vehicle make-up, contact IVECO prior to carrying
out any work.
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
guarantee lapse too.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Symbols - Warnings
!
Foreword
It indicates an additional explanation for a piece of information.NOTE
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Foreword

Page header and footer interpretation
Vehicle type Section title Section number -
page number
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number Chapter title Basic edition -
month year
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Foreword

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Index of section
INDEX OF SECTION
Section
General specifications 1
Chassis modifications 2
Fitting superstructures 3
Power Take-offs 4
Specific information and instructions 5

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Index of section

GENERAL SPECIFICATIONS 1-1 DAILY 4X4
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Index
Index
SECTION 1
General specifications
Page
1.1 Aim of bodybuilders instructions 1-3
1.2 IVECO approval for changes and fittings 1-3
1.3 Liabilities 1-4
1.4 Guarantees 1-4
1.5 Request for approval 1-4
1.6 IVECO technical documents available by means of computer 1-5
1.7 Trademarks and Logos 1-5
1.8 Legal Provisions 1-5
1.9 Prevention of accidents 1-6
1.10 Choice of material to use: Ecology - Recycling 1-6
1.11 Vehicle delivery 1-7
1.12 Vehicles identification 1-8
1.13 Dimensions and masses 1-9
1.13.1 General Specifications 1-9
1.13.2 Determining the Centre of Gravity of the Body and Payload 1-10
1.13.3 Observing the Permitted Weights 1-13
1.14 Instructions for the Correct Functioning of the Parts of the Vehicle and Accessibility for Maintenance 1-14
1.15 Quality System management 1-15
1.16 Vehicle maintenance 1-15
1.17 Conventions 1-16

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Index

GENERAL SPECIFICATIONS 1-3 DAILY 4X4
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Aim of bodybuilders instructions
Aim of b odybuil ders i nstru ctions
1.1 Aim of bodybuilders instructions
The purpose of this publication is to provide data, specifications and instructions for the bodybuilding and conversion of an original
IVECO vehicle to ensure the functionality, safety and reliability of the vehicle and its components.
1.2 IVECO approval for changes and fittings
Changes must be carried out in accordance with the requirements set out in the following guidelines.
The following may be carried out only with IVECO’s approval after submitting a copy of the documentation required for technical
evaluation of the proposed change (drawings, calculations, technical report etc.):
- wheelbase modifications, whereby the value of the newly obtained wheelbase does not fall within the minimum and maximum
values available within the IVECO range for the same vehicle;
- work carried out on the braking system;
- work carried out on the suspension system;
- steering wheel modifications;
- changes to the stabiliser bars and suspensions;
- changes to the cab, cab supports, locking and tipping devices;
- changes to the engine intake and exhaust systems
- engine cooling system modifications;
- power unit and driving component modifications;
- work carried out on front and rear axles;
- fitting decelerator brakes;
- fitting power take-offs;
- changing the tyre dimensions;
- coupling device (hooks, fifth wheels) modifications;
- electric/electronic unit modifications.
The other modifications of fittings covered by the following standards and made in compliance with the same do not require specific
approval from IVECO. Any modification or fitting not covered by these standards shall, on the contrary, be authorized by IVECO
in advance.

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Liabilities
Liabilities
1.3 Liabilities
The authorizations issued by IVECO concern solely the technical/conceptual feasibility of the modification and/or fitting to be
made on a genuine IVECO vehicle.
The bodybuilder is responsible for the:
- project of the modification or fitting;
- choice and features of the products used;
- workmanship of the modification or fitting;
- compliance of the project and its implementation with all the instructions provided by IVECO;
- compliance of the project and its implementation with all the current regulations in the country where the vehicle is registered;
- the functionality, safety and reliability and in general the effective performance of the vehicle and also the effects that the changes
and the conversion may have on vehicle performance and specifications.
1.4 Guarantees
The bodybuilder/chassis converter who has built the body or who has modified the chassis must guarantee that the work was
undertaken in a professional manner in full compliance with the specifications contained in this manual. IVECO reserves the right
to declare void its own warranties for the vehicles where:
- these specifications have not been adhered to or where unauthorised equipment was installed, or unauthorised modifications
were carried out;
- an unsuitable frame has been used for the required conversion or application;
- the specifications, standards or instructions issued by the Manufacturer for the flawless execution of the operations have not
been heeded;
- original spare parts or components which the Manufacturer has made available for specific interventions were not used;
- read and respect the safety standards and symbols applied before any operation;
- do not use the vehicle for applications other than those for which it is designed.
Maintaining the functionality of vehicle components.
The effective operation of vehicle components, all component safety and running conditions, com-
pliance with national and international regulations (e.g. EC Directives) and also accident prevention
standards must naturally be guaranteed in all permitted conversions and applications.
All our vehicles are covered by a warranty as laid down in the specific documents.
The bodybuilder must arrange to carry out operations at least in an equivalent manner.
1.5 Request for approval
The requests for approval or support to carry out work or make modifications or fittings shall be forwarded to the IVECO marke-
ting offices in charge.
To obtain the approval, the body builder shall provide adequate documents that illustrate the anticipated implementation, utilization
and conditions of use on the vehicle. The drawings shall highlight any item differing from the instructions contained in this manual.
The body builder shall submit the modification and/or fitting to the competent authorities for approval.

GENERAL SPECIFICATIONS 1-5 DAILY 4X4
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IVECO technical documents available by means of computer
IV ECO te chni cal documen ts avail abl e by means of comp uter
1.6 IVECO technical documents available by means of computer
The following technical documents are available on the Internet at www.thbiveco.com:
- directives for transformation and equipping of vehicles;
- technical cards;
- chassis cab diagrams;
- chassis diagrams;
- other specifications concerning the vehicle range.
The body builder shall submit the modification and/or fitting to the competent authorities for approval.
1.7 Trademarks and Logos
Trademarks, nameplates and denominations must not be modified or displaced in relation to the original design. The appearance
of the vehicle must not be changed or modified.
The application of trademarks tied to the transformation or trim levels must be authorised by IVECO. They must not be applied
near to the IVECO tradenames or logos.
IVECO reserves the right to withdraw the tradenames and logos if the fitting or conversion fails to conform with requirements. The
bodybuilder accepts all responsibility for the entire vehicle.
Instruction for added assemblies
Where assemblies are added, the bodybuilder must provide the necessary service and maintenance instructions when the vehicle
is delivered.
1.8 Legal Provisions
On completing the vehicle, the bodybuilder/chassis converter must check the work (modifications, body + equipment etc.) to
ensure that the legal provisions required in the country of registration are observed (e.g. weights, dimensions, braking, noise,
emissions etc.). Information regarding these matters may be obtained from the competent Authorities or the IVECO Area Network.
The vehicles manufactured at our plant (except some versions for Extra-European countries) comply with the EC directives. Conver-
ted vehicles must also comply with these directives. The only permissible exception is granted where local type approval differs from
EC homologation.

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Prevention of accidents
Pre vention of acci dents
1.9 Prevention of accidents
Do no allow unauthorised personnel to work on or operate the vehicle.
It is forbidden to use the vehicle if its safety devices have been tampered with or damaged.
The structures and devices fitted to the vehicles must comply with the current regulations concerning
the prevention of accidents and safety regulations in force in the countries where the vehicle is to be
used.
All the precautions dictated by technical awareness must be adopted to prevent malfunction and functional defects.
Compliance with these regulations will be the responsibility of the manufacturers of the structures and devices.
!
Components such as seats, coverings, linings, protective panels etc. may represent a potential fire haz-
ard if they are exposed to an intense heat source.
Arrange for their removal before working with welding equipment and flames.
1.10 Choice of material to use: Ecology - Recycling
Increasingly greater attention should be paid, at the study and design stage, to the choice of materials to be used.
This is especially the case as regards the aspects connected with ecology and recycling in the light of domestic and international
regulations that are constantly being developed in the sector.
In this connection:
- everyone must be aware of the prohibitions on using harmful or potentially hazardous materials, such as ones containing asbestos,
lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent chrome, etc.
- Use materials whose processing produces limited waste and that permit easy recycling after their first use.
- With composite synthetic materials, use components that are compatible with each other, envisaging also their possible utiliz-
ation with the addition of other salvaged components. Affix the markings required in compliance with the current regulations.
- Batteries contain substances that are very hazardous to the environment. When replacing batteries, we advise contacting the
service network, which is suitably equipped for battery disposal in compliance with environmental policies and laws.
In order to comply with EC directive 2000/53 (ELVs), IVECO S.p.A. prohibits fitting parts containing
lead, mercury, cadmium and hexavalent chrome to vehicles (except for the departures referred to in
Attachment II of the above directive).

GENERAL SPECIFICATIONS 1-7 DAILY 4X4
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Vehicle delivery
Vehicle delivery
1.11 Vehicle delivery
Prior to delivering the vehicle, the body builder shall:
- verify that the work has been made correctly;
- perform vehicle and/or equipment set-up;
- check the operation and safety of the vehicle and/or equipment;
- prepare and deliver the necessary instructions for service and maintenance of the fitting and any additional units to the end custo-
mer;
- write the new data down on the special tags;
- confirm that the work carried out complies with the indications provided by the vehicle manufacturer and with the law regula-
tions;
- carry out the checks included in the ”IVECO Pre-Delivery inspection” list (available from the IVECO network) with regard to
the items affected by the work done;
- provide a guarantee for the modifications made;
- in the event that the connections originally provided with screws have been mounted and restored, the same screws shall not
be used. In such an instance, and in the event that nails have been replaced with screws, you must check again the closing of
the connection after travelling approximately 500-1000 km.
- measure the battery voltage. Ensure there is a minimum charge of 12.5 V. If the voltage reading is between 12.1 and 12.49 V,
recharge the battery (slow charge). If the voltage is less than 12.1 V, the battery must be scrapped and replaced with a new one;
- the batteries must be serviced at regular intervals until the vehicle is handed over to the customer to prevent problems of low
charge, short-circuits or corrosion. IVECO reserves the right to terminate the battery warranty if the maintenance procedures
required by the IVECO network are not observed.

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Vehicles identification
Ve hi cles i de nti ficati on
1.12 Vehicles identification
The commercial designation of IVECO vehicles is not the same as the type approval (homologation) designation. Two types
of commercial designation are shown below with the meaning of the codes used:
GVW
(tx10)
Class Engine
rating
(HP:10)
Version Suspension
3 5 S 1 8 W - -
5 5 S 1 8 W - -
Class Rear wheels GVW (t) Version
S single 3.5 - Truck
DCrewcab6+1
Suspension
- mechanic

GENERAL SPECIFICATIONS 1-9 DAILY 4X4
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Dimensions and masses
Dimensions andmasses
1.13 Dimensions and masses
1.13.1 General Specifications
The dimensions and maximum permissible weight on the axles are indicated on the bodybuilder layout drawings, on technical
specification sheets and, in greater details, on the official documentation issued by the Company. The kerb weights refer to vehicles
with standard equipment. Special equipment may involve considerable modification to the weight and its distribution on the axles.
On our vehicles, lights and rear-view mirrors are designed for widths of up to 2350 mm.
Weighing the Chassis
As a result of production factors there could be at a ±5% variation in the published weights for models 35S and a ±3% for models
55S.
It is therefore, advisable to weigh the vehicle in the chassis cab condition before fitting the body and equipment and establish the
weight distribution on the axles.
Body conversions
The body building limits for each model are mainly defined by the following:
- weight distribution on the axles;
- width of the mirrors used;
- position of the rear under run-bar.
Greater values in compliance with the weights permitted on the axles may be authorized by IVECO after modifying such components
as the chassis, under run-bar, mirrors, etc.

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Dimensions and masses
1.13.2 Determining the Centre of Gravity of the Body and Payload
Positioning on the longitudinal plane
To establish the location of the centre of gravity of the body and payload the following examples below may be used as guidelines.
The technical documentation specific to each model (chassis cab drawing) give the positions permitted with the vehicle in its standard
form. The masses and positioning of the single components of the vehicle are given in the chassis and weight distribution diagram.
respectively L1 =L−W2 ⋅L
W
102452
Figure 1.1
W = Body + payload (kg)
W1 = Body and payload acting on front axle (kg)
W2 = Body and payload acting on rear axle (kg)
L1 = Distance of the centre of gravity from the rear axle centre line (mm)
L = Wheelbase (mm)
L1=W1⋅L
W
Example of calculation of the load barycentre position
Consider a 40C13 vehicle with a wheelbase of 3450 mm with:
1. GWW= 4200 kg (permitted maximum: 1900 kg on the front and 3100 kg on the rear)
2. KERB WEIGHT = 1955 kg (1340 kg on the front axle, 615 kg on the rear)
The permitted maximum load (body + payload) will be W = 4200 - 1955 = 2245 kg. Let us calculate the position of the center
of gravity in which the maximum permitted on the front axle is achieved. Let us assume an uniform distributed load .
In this case, out of 2245 kg. W1= 1900 - 1340 = 560 kg will affect the front axle, while the remaining W2= 2245 - 560 = 1685
kg will affect the rear axle.
Thus, the following will be obtained:
1. W1= 560 kg
2. L = 3450 mm
3. W = 2245 kg
L1=W
1x L / W = 860 mm
The center of gravity of the load (Body + payload) must not be more than 860 mm far from the rear axle; otherwise, the front
axle would be overloaded.

GENERAL SPECIFICATIONS 1-11 DAILY 4X4
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Dimensions and masses
In order to determine the payload on the axles, it must be uniformly distributed except when the shape of the loading surface itself
entails a different distribution of the load.
Regarding any equipment, the actual position of the centre of gravity must be used.
When building bodies or containers, loading and unloading systems must be devised which preclude excessive variations in the
distribution of the load and/or excessive loads on the axles. Relevant instructions should also be given to the operator.
Uniform load distribution Uneven load distribution
Uniform load distribution Uneven load distribution
(beware of axle loads and minimum axle ratio)
102453
Figure 1.2
Figure 1.3

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Dimensions and masses
Height of the centre of gravity
The height of the centre of gravity of the chassis cab is given in the technical documentation specific to each model (chassis
drawing).
For testing the vehicle complete with superstructure, the bodybuilder must check that the height of the centre of gravity of the
equipment including the payload, or of the entire vehicle when fully loaded, falls within the maximum permitted values.
These limits are defined in compliance with the national or international regulations (e.g. as amended by the current EC braking
Directive) or requested by the Manufacturer to ensure good handling of the vehicle (e.g. transverse stability of the moving vehicle).
Figure 1.4
Verification with full load:
102454
Ht =Wc . Hc +Wb . Hb
Wc +Wb Hb =(Wc +Wb) . Ht −Wc . Hc Wb
Wc = Chassis cab vehicle kerb weight
Hc = Height of centre of gravity of chassis cab vehicle (laden condition)
Wb = Body and payload
Hb = Height of centre of gravity of body and payload in relation to ground
Wt = Vehicle weight when fully loaded
Ht = Height of centre of gravity of vehicle with full load
To check the vehicle with its body but no payload, use the above formula but for Ws use only the vehicle unladen weight (The
position for Hv will depend on the load and deflection of the suspension).
The height of the centre of gravity indicated in Table 2.6 represents values which are not to be exceeded for each given equipment
level. These values have been calculated only in terms of the transverse stability of the vehicle and are applicable to a mid wheelbase.
Any other possible restrictive specification, e.g. braking regulation, should be taken into consideration.
The values given in Table 2.6 refer to the body with fixed payload. In versions where the payload tends to move sideways (e.g.
suspended loads, fluid loads etc.) especially when turning, higher dynamic transverse forces is generated which makes the vehicle
less stable. This must be taken into consideration when providing vehicle operating instructions or for possible reduction in the
height of the centre of gravity.