Iveco DAILY 4x4 2020 User manual

LIGHT RANGE
BODYBUILDERS
INSTRUCTIONS
ISSUE 08-2020
4 x 4

IVECO S.p.A
“TECH PE T&H - BODY BUILDER SUPPORT”
Lungo Stura Lazio, 49
10156 Torino (TO) - Italy
www.iveco.com
Printed 692.68.999 – 3rd Ed. 08/2020
Images and text: IVECO S.p.A. 2020
All rights reserved.

–Printed 692.68.999 –3 Ed. - Base 08-2020
UPDATE DATA
Section Chapter Description Revision date

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INTRODUCTION
This publication provides information, features and instructions for transformation and fitting of the vehicle; considering the type of
content, it is meant for qualities and specialised staff.
The Body builder is manager of the project and its execution, and must assure compliance with what is set forth in this publication
and in the laws in forth.
Any modification, transformation or fitting not described in this manual and not expressly authorized will re-
lieve IVECO of any liability and the warranty, if present, will immediately be null and void.
The same applies to individual assemblies and components; those described in this manual have been deliber-
ated, approved and tested by IVECO and are part of normal production. The adoption of any type of unit that
is not approved (e.g. PTO, tyres, horns, etc.) shall relieve IVECO of any responsibility.
IVECO is available to provide information on the implementation of the interventions and to provide instructions for any cases and
situations not covered in this publication.
Before performing any operation, it is necessary to:
●verify that you have the manuals for the vehicle model on which you are about to work;
●ensure that all the safety devices (goggles, helmet, gloves, shoes, etc.), as well as the equipment used for work, lifting and trans-
port, is available and working;
●ensure that the vehicle is placed in safe conditions.
At the end of the operation, the operational, efficiency and safety conditions set by IVECO must be restored. Contact the Service
network for vehicle calibration if necessary.
Data and information contained in this publication may be outdated as a result of changes adopted by IVECO, at any time, for tech-
nical or commercial reasons or due to the need to adapt the vehicle to new legal requirements.
In the event of discordance between the information herein and the actual vehicle, please contact the Product Manager operating
on the market before performing any interventions.
SYMBOLS - WARNINGS
Danger for persons
Failure to comply with these prescriptions can result in the risk of serious injury.
Risk of serious damage to the vehicle
Partial or complete non observance of these prescriptions can lead to serious damages to the vehicle and can sometimes result in the
guarantee being voided.
General danger
Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order that vehicle use is as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.

INDEX OF SECTIONS
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GENERAL
INFORMATION 1
CHASSIS
INTERVENTIONS 2
APPLICATIONS OF
SUPERSTRUCTURES 3
POWER
TAKE-OFFS 4
ELECTRONIC
SUB-SYSTEMS 5
ADBLUE AND
SCRT SYSTEM 6
EXPANSION
MODULE 7
Hi-MATIC
AUTOMATIC GEARBOX C

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SECTION 1
GENERAL
INFORMATION

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
Contents
3
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Contents
1.1 SCOPE OF THE GUIDELINES . . . . . . . . . . . . . 5
1.2 TECHNICAL DOCUMENTATION AVAILABLE
ELECTRONICALLY ....................... 5
1.3 AUTHORISATION .................... 5
1.4 AUTHORISATION REQUEST . . . . . . . . . . . . . 6
1.5 RESPONSIBILITIES .................... 6
1.6 LEGISLATIVE REQUIREMENTS . . . . . . . . . . . . 6
1.7 MULTI STAGE TYPE APPROVAL -
COLLABORATION (only for vehicles registered in the
EU, Switzerland and Turkey) . . . . . . . . . . . . . . . . . . 6
1.8 GUARANTEES ...................... 7
1.9 QUALITY SYSTEM MANAGEMENT . . . . . . . . . . 8
1.10 ACCIDENT PREVENTION . . . . . . . . . . . . . . 8
1.11 ENVIRONMENTAL ASPECTS . . . . . . . . . . . . 8
1.12 VEHICLE MANAGEMENT ON THE PART OF
BODYBUILDER ......................... 9
1.12.1 Chassis acceptance . . . . . . . . . . . . . . . . 9
1.12.2 Maintenance .................... 9
1.12.3 Delivery of the vehicle to the end
customer ........................... 9
1.13 VEHICLENAMES ................... 10
Type approval name . . . . . . . . . . . . . . . . . . . . 10
1.14 IDENTIFICATIONS . . . . . . . . . . . . . . . . . . 11
1.15 DIMENSIONS AND GROUND . . . . . . . . . . 11
1.15.1 General information . . . . . . . . . . . . . . 11
1.15.2 Vehicle adaptability . . . . . . . . . . . . . . . 11
1.15.3 Rearview mirrors . . . . . . . . . . . . . . . . 12
1.15.4 Determination of the centre of gravity of
the superstructure and the payload . . . . . . . . . . 12
1.15.5 Height of centre of gravity . . . . . . . . . . 13
1.15.6 Adoption of stabilizer bars . . . . . . . . . . 15
1.15.7 Observance of the permitted masses . . . . 15
1.15.8 Variations on the permitted masses . . . . . 16
1.16 INSTRUCTIONS FOR PROPER
FUNCTIONING OF THE VEHICLE PARTS AND
ACCESSIBILITY ........................ 16
1.17 GENERAL REGULATION FOR THE
PREVENTION OF FIRE RISK . . . . . . . . . . . . . . . . 17
1.18 CONVENTIONS ................... 17

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.1 SCOPE OF THE GUIDELINES
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GENERAL INFORMATION
1.1 SCOPE OF THE GUIDELINES
The scope of this publication is to provide information, features and instructions for fitting and transformation of the original
IVECO vehicle in order to ensure its functionality, safety and reliability.
These Guidelines also aim to indicate to bodybuilders:
●the quality level to be obtained;
●obligations regarding the safety of operations;
●obligations regarding the objective responsibility of the product.
It should be noted that the collaboration with IVECO is based on the assumption that the bodybuilder uses the maximum of their
technical and organisational skills and that operations are technically and perfectly complete.
As outlined below, the topic is extensive and we can only provide the rules and minimum precautions that can
allow development of the technical initiative.
Faults or defects caused by total or partial failure to comply with these Guidelines are not covered by the guarantee on the chassis
or relative mechanical units.
1.2 TECHNICAL DOCUMENTATION AVAILABLE ELECTRONICALLY
The following technical documentation is available from http://ibb.iveco.com/en/SitePages/Home.aspx:
●Directives for transformation and fitting of vehicles;
●technical specifications;
●truck diagrams;
●tractor diagrams;
●chassis diagrams;
●other range-specific data.
1.3 AUTHORISATION
Modifications or versions indicated in these Guidelines and carried out in full compliance of the instructions provided, do not re-
quire any specific authorisation.
If this is not the case, IVECO authorisation is required to carry out:
●particular changes to the wheelbase;
●work on the braking system;
●Modifications to the steering system, as a mechanical element and as power steering (also electric):
●modifications to the stabilizer bars and suspensions;
●modifications to the cab, cab mounts, locking and tilting devices;
●replacing the engine or the "driveline" with electric motor or hybrid systems;
●modifications to intake, engine exhaust and SCR components;
●power take-off applications;
●tyre size variations;
●modifications to the coupling parts (hooks, articulations);
●any modification not included in these Guidelines.

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.4 AUTHORISATION REQUEST
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1.4 AUTHORISATION REQUEST
Authorisation requests, when necessary, must be sent to the responsible IVECO Departments on the market.
The Bodybuilder must provide vehicle data (cab, wheelbase, overhang, chassis No.) and adequate documentation (drawings, cal-
culations, technical report, etc.) showing the realisation, use and operating conditions of the vehicle. The drawings should evidence
everything that differs from these instructions.
Upon completion of the interventions the bodybuilder shall be responsible for attainment of definitive approval from the compet-
ent authority.
1.5 RESPONSIBILITIES
The authorisations issued by IVECO are exclusively related to the technical/conceptual feasibility of the modification and/or fitting.
The bodybuilder is therefore responsible for:
●the design;
●the choice of materials;
●the implementation;
●the compliance of the design and implementation of any specific indications provided by IVECO and the laws in force in the
countries where the vehicle is destined;
●effects on functionality, safety, reliability and, in general, good behaviour of the vehicle;
●components that are installed and/or those already present on the vehicle if they are to be modified and / or replaced;
●supply of replacement parts for a period of at least 10 years from the last fitting of an order.
1.6 LEGISLATIVE REQUIREMENTS
The bodybuilder must verify that the final product is compliant, without exception, to all applicable legal requirements, on the muni-
cipal/autonomous/national level of each State in which it is registered and/or will circulate (Highway code, Official Regulations, etc.)
and on the international level (European Union Directives, ONU/Geneva ECE Regulations, etc.). It is also necessary to comply with
all requirements for accident prevention, instructions for assistance, the environment, etc.
The regulations on accident prevention or the legal indications cited in these Guidelines may be considered
the most important, but are not meant in any way to replace or eliminate the obligation and responsibility of
the bodybuilder to stay properly informed.
For this reason, IVECO shall not be held liable for any consequences due to errors caused by insufficient knowledge or incorrect
interpretation of the legal provisions in force.
1.7 MULTI STAGE TYPE APPROVAL - COLLABORATION (only for vehicles registered in the
EU, Switzerland and Turkey)
Annex XVII of Directive 2007/46/EC concerns Multi-stage Type Approval.
This procedure requires that each manufacturer is responsible for the approval and compliance of the production of systems, com-
ponents and "separate technical units" produced by the same or applied to the vehicle.
The manufacturer of the vehicle is defined as first-stage manufacturer, while the bodybuilder is defined as Second-stage manufacturer
or that of the next stage.

DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.8 GUARANTEES
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191319 Figure 1
1. IVECO
2. Authorised workshop upon Dealer order
3. Bodybuilder
4. Customer
Based on this Directive, IVECO (main vehicle manufacturer) and a bodybuilder intending to launch the multi-stage approval process
must sign a specific Collaboration Contract, called Technical Agreement, which sets out the content and reciprocal obligations in
detail.
Consequently:
1. IVECO has the responsibility of providing, in the agreed form, the approval documents (EC/ECE approvals) and the technical
information necessary for the proper implementation of the fitting and/or transformation (manuals, drawings, specifications);
2. the bodybuilder has the following responsibilities:
■the design and implementation of modifications to the basic vehicle received from IVECO,
■reattainment of approvals of systems already approved in a previous stage when, due to changes on the basic vehicle the
approvals need to be updated,
■compliance with national/international laws and in particular the laws of the destination country, for all changes made,
■presentation of the changes made to a technical service, for evaluation,
■appropriate documentation of the changes made, in order to give objective evidence of compliance to the aforemen-
tioned provisions of law (e.g. approval documents/test reports).
Before signing the Technical Agreement IVECO reserves the right to visit the bodybuilder, in order to verify qualifications to carry
out the fittings and/or processing for which the above collaboration is requested.
The contents of the Technical Agreement can be evaluated in detail upon request to the Manager for relations with the bodybuilder
for the single Market.
1.8 GUARANTEES
The guarantee that the work has been performed to standard must be given by the bodybuilder who made the superstructure or
modifications to the chassis, in full compliance with the instructions in these Guidelines.
IVECO reserves the right to void the warranty on the vehicle, if:
●unauthorised fittings or transformations have been carried out;
●a chassis not suitable for the fitting or intended use has been used;
●the standards, specifications and instructions, provided by IVECO for proper execution of the work, have not been respected;
●original spare parts or equivalent, or components made available by IVECO for specific operations have not been used;
●safety regulations have not been respected;
●the vehicle is used for purposes other than those for which it was designed.

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.9 QUALITY SYSTEM MANAGEMENT
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1.9 QUALITY SYSTEM MANAGEMENT
IVECO has always promoted the training and development of a Quality System for Bodybuilders.
This requirement is not only due to regulations on product liability, but also to the increasingly higher quality level demands, new
organizational forms in various sectors and the search for more advanced levels of efficiency.
IVECO therefore considers it appropriate for Bodybuilders to be equipped with:
●organizational charts for roles and responsibilities;
●quality objectives and indicators;
●design technical documentation;
●process documentation, including controls;
●plan for product improvement, also obtained through corrective actions;
●post-sales assistance;
●training and qualification of staff.
The availability of ISO 9001 certification, even though not required, is considered very important by IVECO.
1.10 ACCIDENT PREVENTION
Do not allow unauthorised personnel to intervene or operate on the vehicle.
▶It is forbidden to use the vehicle with safety devices that have been tampered with or are dam-
aged.
▶Structures and devices installed on the vehicles must comply with the applicable regulations for
accident prevention, and with safety regulations required in the individual countries where the
vehicles are used.
All precautions dictated by technical knowledge must be taken to avoid damage and functional defects.
Compliance with these requirements must be overseen by the manufacturer of the structures and devices.
▶Seats, coatings, gaskets, protective panels, etc., may pose a fire hazard when exposed to an in-
tense heat source. Remove them before working with welding and with flames.
1.11 ENVIRONMENTAL ASPECTS
In the study and design phase, the choice of materials to be used by be made carefully, even from the ecological and recycling point
of view.
To this regard, please note that:
●it is forbidden to use materials that are harmful to health, or at least which may pose a risk, such as those containing asbestos,
lead, halogen additives, fluorocarbons, cadmium, mercury, hexavalent chromium, etc.;
●it is advisable to use materials whose processing produces limited waste quantities and allows easy recycling after first use;
●in synthetic materials of the composite type, it is advisable to use components that are compatible with each other, allowing
use with the possible addition of other recovery components. Prepare the required markings in accordance with the regula-
tions in force;
●the batteries contain substances that are very dangerous for the environment. To replace the batteries it is possible to go to
the Service Network, equipped for disposal in accordance with the nature and the law.

DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.12 VEHICLE MANAGEMENT ON THE PART OF BODYBUILDER
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▶To comply with Directive 2000/53 EC (ELVs), IVECO prohibits the in-vehicle installation of com-
ponents that contain lead, mercury, cadmium and hexavalent chromium; exceptions are made
in cases allowed by Annex II of the above Directive.
1.12 VEHICLE MANAGEMENT ON THE PART OF BODYBUILDER
1.12.1 Chassis acceptance
The bodybuilder receiving a chassis/vehicle from IVECO or from a Dealer must perform a preliminary check, notifying of any miss-
ing accessories or damage attributable to the transporter.
1.12.2 Maintenance
To preserve the chassis/vehicle in its full efficiency, even while parking in the warehouse, maintenance operations may be necessary
within a predetermined time.
The expenses for carrying out these operations are borne by the owner of the vehicle in that moment (Bodybuilder, Dealer or
Customer).
▶In case of long periods of vehicle inactivity, it is advisable to disconnect the negative pole of the
battery to maintain optimal charging status.
1.12.3 Delivery of the vehicle to the end customer
Before delivering the vehicle, the bodybuilder must:
●calibrate its production (vehicle and/or equipment) and verify functionality and safety;
●for items which will be subjected to the intervention, carry out the controls set out in the Pre Delivery Inspection (PDI) list,
available in the IVECO network;
●measure battery voltage with a digital multimeter (2 digit decimal), keeping in mind that:
1. optimal value is equal to 12.5 V,
2. between 12.1 V and 12.49 V the battery should be put under a slow charge,
3. with values less than 12.1 V the battery should be replaced.
Note The batteries must be maintained at regular intervals (refer to IVECO Std 20-1812 and/or IVECO Std 20-1804) until delivery of
the vehicle to the Customer/Dealer to avoid problems of insufficient charging, short circuit or corrosion. IVECO reserves the right to
nullify the guarantee on the battery if the prescribed maintenance procedures are not respected.
●carry out a functional road test (in case of vehicle transformation). Any defects or problems should be notified to the IVECO
Assistance Service to verify conditions for inclusion in the PDI costs;
●prepare and deliver to the final Customer the necessary instructions for service and maintenance of the fitting and any added
units;
●report new data on special labels;
●provide confirmation that the operations carried out comply with the indications of the vehicle Manufacturer and legal re-
quirements;
●draw up a guarantee covering the changes made.

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.13 VEHICLE NAMES
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1.13 VEHICLE NAMES
The commercial name of vehicles (DAILY 4x4) does not match that of the type-approval, a complete example of which is
provided below.
Type approval name
DAILY 70C18HA8 CC W
●DAILY ‒Vehicle name
●70 ‒Gross mass - GVW (no/10 = weight in t)
35 3.5 t
55 5.5 t
70 7.0 t
●C‒Rear wheels
S Single rear wheels
C Twin rear wheels
●18 ‒Engine power (no. x 10 = power in HP)
15 146 HP
18 180 HP
●H‒Engine type
H Euro VI Engine (combined with engine power code 18)
E3 Euro III Engine (combined with engine power code 15)
●A8 ‒Type of transmission
–Manual gearbox
A8 Automatic gearbox
●CC ‒Version
–Chassis-cab version
D Dual cab (6+1)
V Van
SV Semi-windowed
CC Cowl
CCS Stripped chassis cowl
CA Cut Away
●W‒4x4

DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.14 IDENTIFICATIONS
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1.14 IDENTIFICATIONS
Logos, identification trade names and nameplates must not be modified, displaced or removed since the original design appearance
of the vehicle must be safeguarded.
The application of trademarks relating to the transformation or outfitting must be authorised. They must not be applied near to the
IVECO trade names or logos.
In the event of cowl vehicles, the positioning of the IVECO logo on the engine bonnet must be done only after final paint spraying
and must respect the measurements indicated qualitatively in the following figure.
222674 Figure 2
1. Front view
2. Side view
a. Bonnet lower edge
For the actual measurements and for the realization of a possible template, please consult the design 5801620982.
IVECO reserves the right to withdraw its trade names and logos if the above requirements are not met.
1.15 DIMENSIONS AND GROUND
1.15.1 General information
The dimensions and masses of vehicles allowed on the axles are shown in the drawings, the technical descriptions and, more gener-
ally, on the documents on the official IVECO website. Defects refer to vehicles in their standard versions; the use of special equip-
ment may lead to changes on the masses and their distribution on the axles.
1.15.2 Vehicle adaptability
The body length limits mainly depend on:
●wheelbase length
●distribution of mass on the axles
●maximum permitted width

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DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.15 DIMENSIONS AND GROUND
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1.15.3 Rearview mirrors
Depending on the width of the version, the rear visibility angles imposed by the Regulations can be respected choosing the most
appropriate of the three rear-view mirrors with two arms of varying widths available in the catalogue (opt. 8644, 78318).
1.15.4 Determination of the centre of gravity of the superstructure and the payload
To determine the position of the centre of gravity of the superstructure and of the payload, proceed according to the following
examples.
The specific technical documentation for each model (chassis cab version diagram) illustrates the positions allowed with the
standard version vehicle. The masses and the positioning of the individual components of the vehicle are shown on the chassis and
weight allocation diagram.
261809 Figure 3
W = Payload plus superstructure
W1 = Measurement of payload on front axle
W2 = Measurement of payload on rear axle
L1 = Distance of centre of gravity from centre line of rear axle
L = Actual wheelbase
For the purposes of payload distribution on the axles, it is assumed that this is evenly distributed, except in cases in which the shape
of the load surface results in a different load distribution.
For equipment, the centre of gravity is obvious considered for its actual position.
In the realisation of the superstructure or containers, automatic loading and unloading of the goods transported must be provided
to avoid excessive variations of the distribution and/or excessive loads on the axles, providing information for users if necessary.
The bodybuilder should also provide a suitable anchoring systems for the load on the superstructure, so that transport can occur in
maximum security.

DAILY 4x4 ‒GUIDELINES FOR BODYBUILDERS
GENERAL INFORMATION
1.15 DIMENSIONS AND GROUND
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261810 Figure 4
Even distribution of load Uneven distribution of load
261811 Figure 5
Even distribution of load Uneven distribution of load (attention to loads on axles
and minimum ratio)
1.15.5 Height of centre of gravity
For the chassis cab version and no-load vehicle, the value of the height of the centre of gravity is shown on the specific technical
documentation for each model (chassis cab version diagram).
For the vehicle complete with super structure and full load, this height must comply with the maximum values allowed by national
or international standards, in particular, Directives ECE 13 on longitudinal stability and ECE 111 on lateral stability while driving.
The following cases should be distinguished:
a) fixed loads,
b) mobile loads,
c) loads that result in increased aerodynamic actions.

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GENERAL INFORMATION
1.15 DIMENSIONS AND GROUND
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a) Fixed loads
261812 Figure 6
Control at full load
Hw = Vehicle centre of gravity height (loaded)
Hs = Height of payload centre of gravity from the ground
Ht = Complete full-load vehicle centre of gravity height
Ww = Vehicle tare weight
Ws = Payload
Wt = Complete vehicle ground at full load
For any inspections with the vehicle set up without payload you can proceed similarly, assuming Ws is only the tare weight of the
superstructure (considering for Hv a value appropriate for the load and between the no-load chassis cab version trim and the full-
load trim).
The following table lists the maximum indicative heights of the overall centre of mass of the outfitting (payload + dump body
and/or equipment) with reference to the crossways stability of the vehicle.
Table 1.1
Tyres 225/75 R16
twin wheels
265/70 R19.5
single wheel 255/100 R16
T.G.W. [kg] 7000 7000 5500
Max. mass on front axle [kg] 2700 2700 2450
Max. mass on rear axle [kg] 5000 5000 3700
Height of centre of mass of outfitting [mm] 1620 1670 1710
Height of centre of mass of vehicle complete with load [mm] 1480 1510 1500
b) Mobile loads
In the versions where the load can be moved laterally while cornering (e.g.: suspended loads, liquid transport, animal transport,
etc..) high lateral dynamic forces may be generated which may jeopardise the stability of the vehicle.
With reference to the indications of the regulation ECE 111, special attention should therefore be paid to:
●in defining the height of the fitted vehicle's centre of gravity and at full load;
●in assessing the dynamic forces and the lateral displacement of the centre of gravity;
●in considering (for liquids) the density;
●in prescribing the adoption of adequate precautions for driving.
Any cases where evaluation is difficult should be submitted to IVECO for approval.