Iveco NEW DAILY User manual

NEW DAILY
BODYBUILDERS INSTRUCTIONS
L I G H T R A N G E
ISSUE 2014

IVECO S.p.A
Technical Application & Homologation
Strada delle Cascinette, 424/34
10156 Torino (TO) - Italy
www.iveco.com
Printed 603.95.789 – 1st ed. 02/2014
Images and text: IVECO S.p.A. 2014
All rights reserved.

NEW DAILY –GUIDELINES FOR TRANSFORMATION AND
GUIDELINES FOR TRANSFORMATION AND VERSIONS
UPDATE DATA
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GUIDELINES FOR TRANSFORMATION AND VERSIONS
UPDATE DATA
Section Description Page Revision date

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NEW DAILY –GUIDELINES FOR TRANSFORMATION AND
GUIDELINES FOR TRANSFORMATION AND VERSIONS
INTRODUCTION
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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 Bodybuilder 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 provided by this manual and not expressly authorised, will res-
ult in exemption of any liability by IVECO and in particular, if the vehicle is covered by a guarantee, the imme-
diate dissolution of the same.
This criterion also applies with regard to single units and components, those described in this manual have
been submitted by IVECO to for deliberations, approvals and inspections and belong to normal production.
The use of any type of unit not recognised (such as PTO, tyres, horns, etc.) relieves IVECO from any liability.
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Data and information contained in this publication may be outdated as a result of changes adopted by IVECO, at any time, for tech-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.

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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
DAILY PEOPLE CARRIER A
DAILY CNG AND CNG
WITH “RECOVERY MODE” B

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SECTION 1
GENERAL
INFORMATION

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NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
Contents
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Contents
1.1 SCOPE OF THE GUIDELINES . . . . . . . . . . . . . 5
1.2 TECHNICAL DOCUMENTATION AVAILABLE
ELECTRONICALLY ....................... 5
1.3 IVECO AUTHORISATION . . . . . . . . . . . . . . . 5
1.4 AUTHORISATION REQUEST . . . . . . . . . . . . . 6
1.5 RESPONSIBILITIES .................... 6
1.6 LEGISLATIVE REQUIREMENTS . . . . . . . . . . . . 6
1.7 MULTI-STAGE APPROVAL - COLLABORATION
(only for EU countries, Switzerland and Turkey) . . . . . 6
1.8 GUARANTEES ...................... 7
1.9 QUALITY SYSTEM MANAGEMENT . . . . . . . . . . 8
1.10 ACCIDENT PREVENTION . . . . . . . . . . . . . . 8
1.11 CHOICE OF MATERIALS TO USE: ECOLOGY
-RECYCLING .......................... 8
1.12 VEHICLE MANAGEMENT ON THE PART OF
BODYBUILDER ......................... 9
Acceptance of chassis . . . . . . . . . . . . . . . . . . . . 9
Maintenance ......................... 9
Delivery of the vehicle to the final customer . . . . . 9
1.13 VEHICLENAMES ................... 10
Type approval name . . . . . . . . . . . . . . . . . . . . 10
1.14 TRADEMARKS AND SYMBOLS . . . . . . . . . . 11
1.15 DIMENSIONS AND GROUND . . . . . . . . . . 11
General information . . . . . . . . . . . . . . . . . . . . 11
Determination of the centre of gravity of the
superstructure and the payload . . . . . . . . . . . . . 11
Respect of the permitted masses . . . . . . . . . . . . 15
1.16 INSTRUCTIONS FOR PROPER
FUNCTIONING OF THE VEHICLE PARTS AND
ACCESSIBILITY ........................ 15
1.17 GENERAL REGULATION FOR THE
PREVENTION OF FIRE RISK . . . . . . . . . . . . . . . . 16
1.18 CONVENTIONS ................... 16

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NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
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NEW DAILY –GENERAL INFORMATION
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 extens-
ive 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
On the website www.ibb.iveco.com the following technical documentation is available:
●Guidelines for transformation and fitting of vehicles;
●technical specifications;
●truck diagrams;
●tractor diagrams;
●chassis diagrams;
●other range-specific data.
Requests to access the site must be made exclusively at www.ibb.iveco.com.
1.3 IVECO AUTHORISATION
Modifications or fittings proved in these Guidelines and carried out in respect of the same do not require a specific authorisation.
On the other hand, IVECO authorisation is required to carry out:
●particular changes to the wheelbase;
●work on the braking system;
●modifications to the steering system:
●modifications to the stabiliser bars and suspensions;
●modifications to the cab, cab mounts, locking and tilting devices;
●modifications to intake, engine exhaust and SCR components;
●applications of retarders;
●power take-off applications;
●variations in tyre measurements;
●modifications to hook organisms (hooks, fifth wheels).

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NEW DAILY –GENERAL INFORMATION
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.
The Bodybuilder will be responsible for obtaining final approval from the competent authority for completed operations.
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 to 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;
●the supply of spare parts for a minimum period of 10 years starting from the last fitting of an order and for all pieces and
components that are installed.
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 APPROVAL - COLLABORATION (only for EU countries, Switzerland and
Turkey)
Attachment XVII of Directive 2007/46/EC concerns Multi-stage 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.

NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
1.8 GUARANTEES
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191319 Figure 1
1. IVECO
2. Dealer
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 guarantee 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 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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NEW DAILY –GENERAL INFORMATION
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 staff to intervene or operate on the vehicle.
It is forbidden to use the vehicle with safety devices that have been tampered with or are damaged.
▶Structures and devices installed on the vehicle must comply with the applicable regulations for
accident prevention, and with safety regulations required in the individual countries where the
vehicles will be 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 builders 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 CHOICE OF MATERIALS TO USE: ECOLOGY - RECYCLING
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.
▶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.

NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
1.12 VEHICLE MANAGEMENT ON THE PART OF BODYBUILDER
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1.12 VEHICLE MANAGEMENT ON THE PART OF BODYBUILDER
Acceptance of chassis
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.
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.
Delivery of the vehicle to the final customer
Before delivering the vehicle, the Body builder must:
●calibrate its production (vehicle and/or equipment) and verify functionality and safety;
●carry out the controls set forth in the Pre-Delivery Inspection (PDI) list available in the IVECO network, for the items being
worked on (obviously the other items of the PDI will be the responsibility of the Dealer, such as the guarantee pamphlet);
●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.
Instructions for additional units
For additional units, the Body builder must provide all necessary maintenance instructions upon vehicle delivery.
All the units that make up the same order must be equipped with components of the same brand, model and quality.

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NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
1.13 VEHICLE NAMES
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1.13 VEHICLE NAMES
The commercial name of IVECO vehicles (for example New DAILY 40-150) does not match the type approval name. A com-
plete example is provided below.
Type approval name
New DAILY 40C15HA SV /P
●New DAILY –Vehicle name
●40 –Gross mass - GVW (no/10 = weight in t)
33 2.8÷3.49 t
35 3.5 t
40 4.2 t
45 4.5 t
50 5.0 t
60 6.0 t
65 6.5 t
70 7.0 t
●C–Rear wheels
S Single rear wheels
C Twin rear wheels
●15 –Engine power (no. x 10 = power in HP)
●H–Engine type
/2.3 F1A Engine (combined with engine power code 15)
N Natural Power Engine (Bi-Fuel - combined with engine power code 14)
G CNG Engine (combined with engine power code 14)
H Euro VI Engine (combined with engine power codes 15 and 17)
●A–Type of transmission
–Manual gearbox
A automatic transmission
A8 Automatic transmission
●SV –Version
–Cab
D Dual cab (6+1)
V Van
SV Semi-windowed
Camper Preparation for camper
CCSCamper Short cowl version for camper
CV Vendor
CC Cowl
CCS Cowl (short)
CA / CAH3 Cut Away / Cut Away con altezza massima del vano carico
●/ P –Rear pneumatic suspensions

NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
1.14 TRADEMARKS AND SYMBOLS
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1.14 TRADEMARKS AND SYMBOLS
Trademarks, symbols and names may not be altered or moved from their original placement, as the originality of the vehicle image
must be protected.
The application of transformation or fitting trademarks must be authorised; their placement should not be in the immediate vicinity
of the IVECO trademark and symbols.
IVECO reserves the right to withdraw trademarks and symbols if the fitting or transformation present features that do not comply
with requirements. the Body builder assumes full responsibility for the entire vehicle.
1.15 DIMENSIONS AND GROUND
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.
Weighing of the chassis
It should be noted that variations are possible on the masses of the order of 5%.
For this reason, before carrying out the fitting, it is a good idea to determine the mass of the vehicle cab and its distribution on the
axles.
Vehicle adaptability
Depending on the vehicle, adaptability limits essentially depend on:
●wheelbase length
●distribution of mass on the axles;
●maximum permitted width
The positioning of clearance lights and rear view mirrors is usually correlated with outline widths of up to 2350 mm.
For larger widths (special body set-ups, refrigerated vans, etc.), reference can be made to the composition of IVECO optionals or
an assessment of the intended solution can be requested.
Determination of the centre of gravity of the superstructure and the payload
Positioning on the longitudinal plane
To determine the position of the centre of gravity of the superstructure and the payload, you can proceed according to the ex-
amples given below.
On the technical documentation for each model (cab version diagram), you can see the positions allowed by the vehicle in the
standard version. The masses and the positioning of the individual components of the vehicle are shown on the chassis and weight
allocation diagram.

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NEW DAILY –GENERAL INFORMATION
GENERAL INFORMATION
1.15 DIMENSIONS AND GROUND
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204643 Figure 2
Example for calculating the position of the centre of gravity of the payload plus superstructure
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 breakdown of the payload on the axes, it should be considered that this is evenly distributed, except in cases in
which the shape of the load surface leads to 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 Body builder should also provide a suitable anchoring systems for the load on the superstructure, so that transport can occur
in maximum security.
204644 Figure 3
Even distribution of load Uneven distribution of load