SECTION 4 Power take-offs

EUROCARGO M.Y. 2008 POWER TAKE-OFFS 4-1 Index SECTION 4 Power take-offs Page 4.1 General Specifications 4-3 4.2 Power take-off from gearbox 4...
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EUROCARGO M.Y. 2008

POWER TAKE-OFFS

4-1

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 the transfer box

4-8

4.4

Power take-off from transmission

4-8

4.5

Power take-off from engine

4-9

4.5.1

Taking torque from engine front side

4-9

4.5.2

Power take off from the rear of the engine

4-11

4.6

PTO management

4-13

4.6.1

General specifications

4-13

4.6.2

PTO Mode 0 (run mode)

4-14

4.6.3

PTO modes 1, 2, 3 configurable

4-14

4.6.4

Intermediate speed rate governor

4-18

4.6.5

Standard configurations

4-19

4.6.6

Specific indications: correlation between PTO configuration and power take-offs installed

4-20

4.6.7

Power take-off depending on the clutch

4-20

4.6.8

Second speed limiter

4.23

4.7

Electrical system

4-24

4.8

Pneumatic system

4-24

4.9

Isochronous control of engine rate

4-24

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POWER TAKE-OFFS

4-3

44444.

General Specifications

4.1

General Specifications

Different types of power takeoffs can be used dependine on the type of use and the performances required, the PTO can be fitted to: - the gearbox. -

driveline.

-

the front of the engine.

-

the rear 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). The choice of transmission ratio for the power take-off should be made so that the absorption of power occurs in a flexible engine operating range. Low r.p.m. (below 1000 r .p.m.) must be avoided to prevent irregular running. The power taken in relation to the number of revolutions of the power take-off at the required torque. M ⋅ n M ⋅ n P(kW) = P(CV) = 9550 7023 P = Useable power M = Torque permitted for the power take-off n = power take-off r.p.m.

Type of use A distinction must be made between occasional and continuous uses. In occasional uses, the duration of torque transfers is not longer than 30’. Continuous uses are those that contemplate long transfer durations; however, if the use is comparable to that of a stationary engine, one should consider the opportunity of reducing the values of the torque to be transferred, depending also on the conditions of use (motor cooling, gearbox, etc.). The scheduled take-off values are also applicable for uses which do not involve large variations of torque either in frequency or magnitude. To avoid overloading, in some cases (e.g. hydraulic pumps, compressors) it may be necessary to include the application of devices like clutches or safety valves. PTO transmissions To respect the instructions of the transmission manufacturer, particular care will be taken in the design stage with the mechanism (angles, n° of revs, moment) from the power take-off to the using appliance and with the dynamic behaviour in the realisation stage. This means that: - the dimensions should take into consideration the forces which might occur under maximum power and torque conditions -

to obtain good homokinetic results angles must be made with the same value at the ends of the shafts (see Figure 4.1) and the max value can be 7”

-

the Z solution will be preferable to W, as smaller loads are exerted on the bearings of the power take-off and of the unit to be controlled. In particular, when it is necessary to create a transmission line with the sections inclined in space at an angle ϕ (as shown for example in figure 4.2), it must be remembered that the homokinetic result of the whole can be guaranteed only if the intermediate section is equipped with forks offset at the same angle ϕ and if the condition of equality is respected between the end angles χ1 and χ2. For transmissions employing multiple sections, the instructions given at point 2.8.2 should be followed.

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Figure 4.1

0 0

Solution Z

0 0 Solution W 91522

Figure 4.2

133340

Electrical system The VCM and EM electrical/electronic system makes available innovative methods and processes for control of power take-offs that can significantly improve safety and reliability. Activation takes place by connecting the power take-off control switch to connector ST40B. This connector is fitted as standard if the customer has chosen a power take-off as standard. If a later power take-off is installed, please observe the instructions given in Chapter 4.6.

Pneumatic system See description in Paragraph 2.15.4.

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POWER TAKE-OFFS

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Power Take---off from Gearbox

4.2

Power take-off from gearbox

Depending on the type of gearbox power can be taken from the layshaft through the flange or spline located on the rear, side or lower part of the gearbox. The technical characteristics necessary are given in the documentation supplied upon request for the various gearboxes. The types of power take-off and the torque values obtained with the ratio between the number of output revolutions and engine r.p.m. are shown in Table 4.1. The values refer to the conditions indicated in the table. Higher values for occasional use must be agreed upon as each occasion arises depending on the type of use. Check the vehicle to ascertain whether it is possible to fit a power take-off suitable to its size. The power take-off applied to the gearbox must only be used when the vehicle is stationary and must be engaged and disengaged when the clutch is disengaged to avoid excessive stress on the synchronisers during gear change. For special situations when the power take-off is used and the vehicle is moving the gear must not be changed. For gearboxes equipped with a torque converter, the same power take- offs used for normal gearboxes are, as a rule, used. It should be carefully noted that, when the engine r.p.m. is below 60% of the max. value the converter will be in the phase of hydraulic r.p.m.; in this phase, depending on the absorbed power, the r.p.m. of the power take-off is subject to oscillation despite the fact that the engine r.p.m. is constant.

Direct Application of Pumps When the application of pumps of other equipment (e.g. for tippers or cranes) is carried out directly from the power take-off, without the use of intermediate shafts and after checking that the size of the pump permits margins of safety with chassis and engine unit (cross member, transmission shaft etc.), the static and dynamic torques exerted by the mass of the pump and by the power take-off should be checked for compatibility with the resistance of the walls of the gearbox. By way of an example, the moment due to the additional masses must not have values of over 3% approx. of the maximum engine torque. In cases where the gearbox is applied in a single unit with the engine, the value of the additional masses must be verified with regard to the inertial effects in order to avoid the induction of resonance conditions in the engine unit within the field of operational engine r.p.m.

!

When fitting power take-offs the torque values shown in Table 4.1 must not be exceeded. Transmission oil temperature must not exceed 120ºC 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.

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Data of power take-off from gearbox The following table gives the types of PTO tested by IVECO. Application of a PTO after production of the vehicle will mean that it is necessary to reprogram the BC (Body Controller), as well as requiring various modifications to the electrical and pneumatic systems. For this reason, before applying a PTO you should make sure you read the paragraph carefully. The electronic control units must be reprogrammed following the instructions given in the IVECO manuals, only via the EASY Stations (available from Dealers and the IVECO Authorized Workshops), providing the information related to the PTO used. Table 4.1 - PTO tested by IVECO on gearbox Gearbox

Direction of rotation

Type PTO

Version

Installation position

Transmission ratios

Torque (Nm)

Clockwise

NS42/2C

pump

Side

Slow

0.93

270

Anticlockwise

NL/4C

pump

Rear

Slow

0.73

430

Anticlockwise

88Z1

pump

Rear

Slow

0.962

430

Clockwise

NLC/1C (1)

pump

Rear

Slow

0.57

600

ZF 6S800

Anticlockwise

NH/4C

pump

Rear

Slow

0.67

350

ZF 6AS800

Anticlockwise

88Z1

pump

Rear

Slow

0.962

450

ZF 6S 6S1000 000

Anticlockwise

NH/4C

pump

Rear

Slow

0.67

350

ZF 6AS1000

Anticlockwise

88Z1

pump

Rear

Slow

0.962

450

ZF 6S1000 + PTO (2)

Anticlockwise

NL/10

flange

Rear

Fast

1.70

320

Anticlockwise

NL/10

flange

Rear

Fast

1.19

480

Clockwise

NH/4C

pump

Rear

Slow

0.79

330

ZF 9S-75 9S 75 TD

Anticlockwise

N75/10C

pump

Rear

Slow

0.92

410

Anticlockwise

NH/1C

pump

Rear

Slow

0.62

600

Clockwise

NH/4C

pump

Rear

Fast

1.08

350

Anticlockwise

N75/10C

pump

Rear

Fast

1.27

410

Anticlockwise

NH/1C

pump

Rear

Slow

0.85

500

Clockwise

NH/4C

pump

Rear

Fast

1.24

350

Anticlockwise

N109/10

pump

Rear

Fast

1.45

530

Anticlockwise

NH/1C

pump

Rear

Slow

0.97

990

ALLISON S1000

Anticlockwise

06A2

pump

Side

Slow

0.82

400

ALLISON S2500

Anticlockwise

06A2

pump

Side

Slow

0.82

400

ALLISON S3000

Anticlockwise

17A1

pump

Side

Slow

0.93

600

ZF SS-42 ZF 6S700 ZF6AS700

ZF 9S 9S-75 75 TO O

ZF 9S 9S-1110 0

When any PTO is ordered, the option 2463 (Cruise Control) and the opt. 4572 (Expansion Module) must always be provided. (1) PTO NL/1C is only available on models ML60E - ML120EL. (2) available on 4x4 models.

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POWER TAKE-OFFS

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Figure 4.3 - Position and PTO output

Direction of travel Rear assembly Side assembly

Direction of travel

Front output

Direction of travel

Rear output

91542

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Power take---off from the transfer box

4.3

Power take-off from the transfer box

For four-wheel drive vehicles (4x4), it is possible to apply power take-offs to the torque distributor. The application r.p.m. can be selected according to the required function by engaging the most appropriate gear. Use is only with the vehicle stationary (transfer box in neutral). The prescriptions on correct use are given in the vehicle’s Use and Maintenance booklet. There follow the possible measurements: Table 4.2 Power take-off Type of transfer box

TC 850

4.4

PTO

Max. capacity (Nm)

Output type

Only types tested by IVECO

500

ext. diameter flange 90 mm 4 holes diameter 8.1 mm

Power take-off from transmission

Authorisation to fit a power take-off on the transmission downstream of the gearbox will be issued after examination of the full documentation, which must be presented to IVECO. The various power and torque values will be evaluated as each occasion arises on the basis of the conditions of use. In general the following should be noted: - the drive take-off may be operated only when the vehicle is stationary. - the power take-off r.p.m. is tied to the gear selected. - the power take-off must be located immediately downstream of the gearbox. For vehicles with the transmission in two or more sec tions, the power take-off may also be applied at the site of the flexible support included between the first and second sections (respect the indications given in point 2.8.8). - the angles of the transmission on the horizontal plane and vertical plane must be kept as close as possible to the original values. - masses and rigidity added to the transmission must not provoke a loss of balance or abnormal vibrations or damage to the organs of the drive transmission (from engine to axle) either during vehicle movement or during operation with the motor running - the power take-off must be anchored to the chassis with its own suspension.

!

As the transmission is is an important organ for the safety of the vehicle, modification to it must only be carried out by specialist companies approved by the supplier of the transmission.

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POWER TAKE-OFFS

4-9

Power take---off from engine

4.5

Power take-off from engine

In general the use of these power take-offs is planned for apparatus requiring a continuous power supply.

4.5.1

Taking torque from engine front side

The drive take-off from the front part of the crankshaft is obtained, for limited power values to be drawn off (e.g. conditioning group commands) by the drive belt transmission, the use of cardan shafts is normally reserved for take-offs of a greater m agnitude (e.g. municipal use). These uses, when not specifically planned, require complicated interventions to the front part of the vehicle, e.g. modifications to the radiator, cab, bumpers etc. Part icular attention must therefore be paid: - to the system composed of additional masses and relative rigidity which must be flexibly disengaged from the crankshaft with regard to the torsional and flexional effects; -

to the additional mass values and relative moments of inertia and to the distance from the centre of gravity of the masses from the centreline of the first main bearing which must be contained as much as possible;

-

to avoiding a reduction in the radiator cooling capacity;

-

to restoring the rigidity and resistance characteristics of the modified elements (cross member, bumper etc.);

-

to avoid exceeding, during extended use, temperatures of the engine cooling fluid of over 100 °C and engine oil temperature (measured on the main duct of the pressure switch area) of 120 °C. A margin of approx. 10% should however be left. In other cases include supplementary heat exchangers.

Table 4.3 shows the values to be referred to for the take-off. On the front of the engine a pulley is positioned with 2 races from which it is possible to draw power. The position of the take-off and the size of the pulley are given in the following figure. Figure 4.4

Engine front side

Pulley for take-off

91605

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Figure 4.5

91606

Table 4.3 - PTO on the front of the engine Maximum bending moment (Nm) (2)

Engine code

nmax

E14, E16, E18

F4AE3481

2700

400

0.015

100

E22, E25, E28, E30

F4AE3681

2700

400

0.015

100

Engine

Tector

Maximum moment of inertia (kgm2) (1)

Max torque that can be taken off (Nm)

(1) Maximum moment of inertia of the rigidly added masses. (2) Maximum bending moment at due to the radial forces in relation to the axis of the first main support. Depending on the angular position that the added resulting radial forces form with the axis of the cylinders (zero is in the top dead centre position and clockwise rotation), the maximum bending moment can be multiplied by the factor contained in the table. Multiplier factor 1 2 3 4 3 2

Angular position 225-15 15-60 60-105 105-165 165-210 210-225

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4.5.2

POWER TAKE-OFFS

4-11

Power take off from the rear of the engine

4.5.2.1 Multipower power take-off on flywheel side On models 150E ÷ 190EL with powers of 280 to 300 BHP, the IVECO Multipower, designed to take off higher torques than those of other PTOs power take-off can be installed on request. This unit is fitted on the rear part of the engine (Figure 4.3) and takes drive from the flywheel. It is independent of the vehicle clutch drive and suitable for use with the vehicle running and/or at a standstill (e.g. municipal applications, concrete mixers, etc.). Some precautions: - the PTO must be engaged only with the engine at a standstill (a safety device prevents engagement with the engine running in any case); - the unit may be disengaged with the engine running but only if power is not currently being taken off; - the engine must be started when no torque is being taken from the PTO.

!

To guarantee correct engagement, the static a moment of connected units must not exceed 35 Nm. According to the version of the connected units, it may be necessary to consider a clutch engageable by load (weight) in the transmission.

For the PTO Multipower outfit (ccp 2395) it is necessary in combination with: the Expansion Module (CCP 4572), Cruise Control (CCP 2463), 90A alternator (ccp 6315) and the 360 cc air compressor (CCP 6319). The main technical specifications are given in Table 4.4.

Figure 4.6

126402

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Table 4.4 Output rpm/engine rpm ratio Max. torque available Output flange Control Direction of rotation Installation on engines Weight Oil capacity

1.29 900 Nm ISO 7646-120 X 8 X 10 pneumatic as engine Tector 6 -cylinder 280 CV and 300 CV 70 kg 2 litres

If turned on during transfers, you must be well aware that depending on the gearing ratio of the power take-off (see Table 4.4), connected pumps may reach high rotating speeds (e.g.: an engine speed of 1800 rpm corresponds to a pump speed of 2400 rpm). Accordingly, to be able to manage an FMO (Fast Moving Object) with this type of power take-off, it is necessary to activate different methods of operation of the vehicle’s control unit (see paragraph 4.6).

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PTO management

4.6

!

PTO management

Operations which do not comply with the instructions specified by IVECO or made by non qualified personnel can cause severe damage to on-board systems, effect driving safety and good operation of the vehicle and cause considerable damage which is not covered by warranty.

The control units present in Figure 4.7 are located on the right side of the dashboard (lower place) facing the passenger seat. Figure 4.7

130574

1. ABS - 2. VCM - 3. ECAS - 4. EM - 5. Central locking The EM control unit (if present) performs the task of managing the PTO.

4.6.1

General specifications

PTO activation requires two conditions to be met: 1.

mechanical engagement of the power take-off;

2. calling up a PTO mode to associate with the power take-off. See further on for the definition of the PTO mode. The actions 1) and 2) can be executed with two separate controls, in succession 1) - 2), or with a single control by using, as explained further on, the PTO switches on the central peninsula in the cab. Generally, the PTO can be engaged by electric control (activation of a solenoid valve).

!

It is recommended to use the available signals on the Bodybuilder connectors (for instance parking brake activated, vehicle stationary signal, signal indicating reverse not engaged) in order to ensure correct management of the PTO and avoid possible damage to the vehicle kinematics. These signals must be taken exclusively from the Bodybuilder connectors.

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EUROCARGO M.Y. 2008

PTO Mode 0 (run mode)

In normal driving mode, the vehicle allows a top speed of 25 km/h. Below this, when the resume key (CC controls) on the steering wheel interface is pressed, an intermediate speed of 900 rpm is activated. It is possible to set a new intermediate rpm stored by the driver by a long press of more than 5 s on the resume key; in this case, it is not necessary to have a reprogramming carried out by IVECO Service. (IMPORTANT: above 25 km/h, the speed regulator is activated automatically) The maximum and minimum rpm levels achievable using the SET+ and SET- keys (CC controls) respectively are the same for all modes (PTO 0 mode and PTO 1, 2, 3 modes) and are configurable by means of EASY only for PTO modes 1, 2 and 3. The settings shown in table 4.5 cannot be amended for PTO 0 mode (drive mode). Table 4.5 Button

Function

Resume/OFF

Activation/deactivation of the intermediate rpm speed. The engine rpm for activation is fixed in the plant at 900 rpm and can be altered by the driver.

SET+/SET-

Increase/reduction of intermediate speed rate activated

Accelerator pedal

Activated

Max rpm limit that can be reached with SET+ button or accelerator pedal

NLL(1) ÷ maximum speed permitted by the engine

Torque delivered

Maximum specific engine torque.

Conditions for cutting out the intermediate speed rate

-

operation of the brake or clutch pedal CC activation Off operation of the engine brake operation of the Intarder PTO mode 0 cut-out speed not ”NEUTRAL for automatic gearboxes”

(1) NLL N° revs at minimum.

4.6.3

PTO modes 1, 2, 3 configurable

Through the IVECO service it is possible to programme three different and independent PTO mappings on the electronic control units. Obviously the engine can work with only one PTO mode at a time. The following priority order solves this problem: - PTO mode 3: high priority - PTO mode 2: medium priority - PTO mode 1: low priority - PTO mode 0: drive mode

!

These priorities must be considered already in the programming phase. Incorrect operation may arise if this prioritisation is not respected and PTO wiring and programming may then need to be modified or the VCM and/or EM control unit reconfigured.

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The following table shows the parameters that, as a whole, form a PTO mode. The parameters can only be programmed using a EASY diagnosis station, available at IVECO Service stations. Table 4.6 Parameter

Possible values

Maximum No. of revs that can be reached with SET+, NSET_max (9)

NLL ÷ Nmax (2)

Maximum rpm achievable by means of the accelerator pedal

Nmax_acc

Engine revs increase with SET+ button

250 rpm for each second of pressing the button

Engine revs decrease with SET- button

As above

Torque limitations (3)

See Table

Runaway speed regulator gradient

”High Idle” vertical by default

Use of the CC buttons (Resume/OFF/SET+/SET-)

Enabled / disabled

Storing of intermediate speed rate

Fixed (EASY) / free (driver) (8)

’TIP function, for SET+/SET- buttons (4)

Enabled / disabled

Exclusion of PTO mode using brake or clutch (for each mode separately) (5)

Enabled / disabled

Accelerator pedal

Enabled / disabled

Call-up intermediate speed rate stored with Resume on enabling PTO mode (7)

Enabled / disabled

Minimum No. of revs that can be reached with SET-, NSET_min (9)

> 500 rpm

Exclusion of PTO mode using parking brake (6)

Enabled / disabled

Maximum speed of the vehicle, above which PTO mode is disabled (intermediate r.p.m. rate VZDR_max)

between 2 km/h and 95 km/h (programmable)

Possible power take-off rate range (1)

NLL ÷ Maximum achievable rpm (2)

Abbreviations: NLL No. revs at minimum Nmax Max. no. revs Nres No. intermediate revs stored, is called up by pressing RESUME or enabling a PTO mode NSET_max Maximum No. of revs that can be reached with SET+ button, identical for all PTO modes NSET_min Minimum No. of revs that can be reached with SET- button Nmax_acc Maximum rpm achievable by means of the accelerator pedal

(1) the speed to which we refer is that of the crankshaft and not that of the PTO. The corresponding number of revs of the power take-off must be calculated by means of the power take-off reduction ratio. (2) For setting the intermediate speed rate, the following rules apply: - you must never go below the value of NLL - you must never exceeded the value of Nmax - in general we will have NLL ≤ NSET_min ≤ Nres and Nres ≤ NSET_max ≤ Nmax. If this last inequality is not verified, the engine revs number is limited to the value Nmax. (3) See paragraph 4.6.3.1. (4) The TIP function (quick pressure on the rocker key) allows you to gradually vary the intermediate rpm regulator or the speed regulator by a short press (V0 km/h the speed control is activated. The change for the intermediate speed rate regulator is equal to 20 rpm for each TIP or 1 km/h for each TIP with the speed regulator. If the SET+ and SET- buttons are pressed any longer (>1s), the intermediate speed rate or the requested speed is modified continuously. The actual number of revs or true speed at the time of releasing the SET+ and SET - buttons is saved as the new required value. The TIP function with SET+ and SET- can be turned off. This configuration is valid for all the PTO modes (drive mode 0, PTO mode 1, 2 and 3). Turning off the TIP function triggers the functional limitation on the speed regulator, therefore this change should only be used after a thorough examination.

NOTE

This function is for regulating the hydraulic units.

Increase/decrease in the speed with SET+/SETWith a longer press (>1s) on the SET+/SET- keys and with the TIP function deactivated (the TIP function is automatically deactivated by a long press on the SET+/SET- keys), the requested intermediate speed regulator value is altered and thus also the speed (engine rpm increase/decrease per second). The required time for this change can be calculated with the following formula: Required time [s] = Difference in number of revs [rpm/s] / increase in revs per second [rpm/s/s] Example: the intermediate number of revs must be taken from 800 rpm to 1800 rpm with the SET+ button. The difference in the number of revs is equal to 1000 rpm, therefore: - with a speed of 250 rpm/s, the time interval is 1000/250 = 4s Accelerator pedal on/off In the normal drive mode (PTO mode 0) the accelerator pedal is always activated. In PTO modes 1, 2 or 3, the throttle pedal can be turned off. In this case the PTO setting of the engine ignores the accelerator pedal. If however the accelerator pedal remains on, it is possible to increase the number of revs of the engine with this pedal up to the maximum number of revs Nmax valid at that moment.

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4.6.5

POWER TAKE-OFFS

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Standard configurations

The following table gives the adjustments made in the factory. Table 4.7 PTO mode

Enabled using 21 pin connector Max engine torque Maximum N° of revs that can be reached with SET+, NSET_max Minimum N° of revs that can be reached with SET-, NSET_min Runaway speed regulator gradient

Mode 0

Mode 1

Mode 2

Mode 3

No activation is needed

Pin 18 and 17 connected

Pin 19 and 17 connected

Pin 20 and 17 connected

Maximum engine torque

Maximum engine torque

Maximum engine torque

Maximum engine torque

maximum speed according to the maximum no. of turns of the engine minimum speed according to the default NLL no. of turns of the engine Dependent on nominal curve

0 rpm/Nm

0 rpm/Nm

0 rpm/Nm

On

On

On

Off

Accelerator pedal Use of the CC buttons (Resume/OFF/SET+/SET-)

On

On

On

Off

N° revs stored, Nres

900 rpm

900 rpm

1100 rpm

1300 rpm

Maximum speed of the vehicle, above which PTO mode is disabled, VZDR_max

25 km/h

35 km/h

35 km/h

35 km/h

Exclusion of PTO mode using brake or clutch

On

Off

Off

On

Call-up intermediate speed regime stored on enabling PTO mode

On

Off

Off

Off

Exclusion of PTO mode (using parking brake)

On

On

On

On

PTO mode cut-out by means of engine brake

On

On

On

On

The increase or decrease in the engine revs with the SET+/SET- button is 250 rpm.

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Specific indications: correlation between PTO configuration and power take-offs installed

No direct connection exists between the PTO mode (that can be activated by means of the 20-way coupling) and the power take-offs physically installed on the vehicle. A Bodybuilder is therefore free to determine the necessary connections. This setting offers the possibility to use the power take-off(s) with different PTO configurations. If the work cycle requires the installed power take-off to operate under different conditions, for example, up to 3 PTO modes may be used. Activation of the corresponding PTO modes must be commanded by EM or, if this is not present, by connection of the relevant connector (21-way above). Similarly, it is possible to configure a PTO mode without a physically-installed power take-off or with more than one physically-installed power take-off.

4.6.7

Power take-off depending on the clutch

The power take-offs fitted on the gearbox can only be engaged with the clutch fully pressed. The PTO modes can be activated independently of this. With Allison transmission With an Allison transmission, engagement of the installed power take-off is coordinated by the transmission control unit and the Expansion Module and occurs in the following stages: - request to engage the power take-off (the gearbox control unit verifies the internal conditions to perform the operation safely: engine speed 120 [°C]

Allison transmission PTO

PREDEFINED CONFIGURATION Allison automatic transmission option: 8292 (PTO included) The following conditions may be modified by IVECO Service. Table 5.22 - Conditions of activation Engine status

ON (500 < rpm < 900)

Gearbox status

neutral

Vehicle status

stationary or reduced speed (0 < v < 2 [km/h])

Coolant temperature

< 120 [°C]

Table 5.23 - Conditions of deactivation Engine status

OFF

Vehicle speed

> 20 [km/h]

Coolant temperature

> 120 [°C]

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Electrical system: modifications and drawing---off power

5.8

Electrical system: modifications and drawing-off power

5.8.1

General Information

The vehicles are fitted for operation with a 24V electric system for normal use, the chassis frame stands for ground (it acts as a current return conductor between the components situated on it and the source of energy, batteries/alternator), it is connected to the negative pole of the batteries and components, if there is not an isolated return for this. The installation of auxiliary equipment or circuits added by the Bodybuilder must take account of the following indications. Depending on the complexity of the work, there must be suitable documentation (e.g. wiring diagram) to be included together with that of the vehicle. Using the same colours/codes for the cables and connections as those used on the original vehicle makes the installation more correct and facilitates any repair operations. Precautions The vehicles are equipped with sophisticated electric/electronic systems that control their operation. Work on the system (e.g. removing set of wiring, construction of additional circuits, replacing equipment, fuses, etc.) not done in compliance with IVECO directions or done by unqualified personnel can cause serious damage to the vehicle’s systems (control units, wirings, sensors, etc.), jeopardizing driving safety, proper operation of the vehicle and causing significant damage (e.g. short circuits with possible fire and destruction of the vehicle) not covered by contractual warranty. No modifications or connections are allowed to the data connection line between control units (CAN line), where any change is strictly prohibited. Any troubleshooting and maintenance operations can be carried only by authorised personnel, with IVECO approved equipment. It is always necessary to isolate the batteries before doing any work on the electric system, disconnecting the power cables, first the negative pole then the positive one. Use fuses with the prescribed capacity for the specific function, never use fuses of greater capacity; make the replacement with keys and services disconnected, only after eliminating the trouble. Restore the original conditions of the wirings (routes, protection, clamps, absolutely preventing the cable from coming into contact with metal surfaces of the structure that can affect its integrity) if any work has been done on the system. For work on the chassis frame, to protect the electric system, its appliances and the ground connections, respect the precautions stated in points 2.1.1 and 2.3.4.

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In addition, definitely respect the following precautions for the protection of the vehicle’s electronic components: Never disconnect the connectors of the control units with the engine running and control units powered. Do not power the components interlocked with electronic modules with the vehicle’s nominal voltage via movable cables. The control units provided with a metal casing must be connected to the ground of the system with screws or bolts, unless specified otherwise. When required by the application of additional equipment, it is necessary to install diodes to protect against any inductive surges in current. The ground signal from the analogue sensors must be wired solely on the specific receiver; further ground connections could distort the output signal from these sensors. The bundle of cables for electronic components with low signal strength must be arranged in parallel to the metal surface of reference, that is sticking to the chassis frame/cab structure, in order to reduce the parasite capacities to a minimum; separate the route of the bundle of cables added to the existing one as far as possible. The added systems must be connected to the ground of the system with the greatest care (see point 2.1.1); the related wirings must not be set alongside the existing electronic circuits on the vehicle, so as to avoid electromagnetic interference. Make sure that the wirings of the electronic devices (length, type of conductor, location, clamps, connection of the shielding, etc.) are in compliance with the original IVECO setup. Carefully restore the original system after doing any work.

5.8.2

Electromagnetic Compatibility

It is recommended to use electric, electromechanical and electronic appliances that meet the prescriptions of electromagnetic emission and immunity at both the radiated and carried level, described below: At a distance of one metre from the transmitting antenna there must be: - immunity of 50V/m for devices that perform secondary functions (they do not impact the direct control of the vehicle), for variable frequencies from 20 MHz to 2 GHz -

immunity of 100V/m for devices that perform primary functions (they impact the direct control of the vehicle), for variable -frequencies from 20 MHz to 2 GHz.

The maximum permissible amplitude of the transitory voltage for equipment powered at 24V is +80V measured at the terminals of the artificial network (L.I.S.N.) if bench tested, otherwise if tested on the vehicle it must be measured at the most accessible point near to the interfering device.

NOTE

The devices supplied at 24V must be immune to negative interference such as spikes of -600V, positive spikes of +100V, bursts of ± 200V. They must work correctly during the phases of lowering the voltage to 8V for 40mS and to 0V for 2 ms. In addition they must withstand the phenomenon of load dumping to values of 58V.

The maximum levels measured at the bench of the radiated and carried emissions produced both by the devices and at 24V are given in the following Table 5.24.

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Table 5.24 Range of frequency and acceptable limits of the interference in dBuV/m Type of emission

radiated radiated

Type of transducer

Type of interference

Antenna posip ti tioned d att 1 metre

Broadband

Almost peak

Broadband

Peak

Narrowband

Peak

Broadband

Almost peak

Broadband

Peak

Narrowband

Peak

radiated carried carried

LISN 50 ohm 5 uH/ H/ 0.11uF

carried

Type of sensor

150KHz 300KHz

530KHz 2 MHz

5.9MHz 6.2MHz

30 -54 MHz

68 - 87 MHz only mobile services

76 - 108 MHz only broadcast

142175 MHz

380 512 MHz

820 960 MHz

63

54

35

35

24

24

24

31

37

76

67

48

48

37

37

37

44

50

41

34

34

34

24

30

24

31

37

80

66

52

52

36

36

93

79

65

65

49

49

70

50

45

40

30

36

Not applicable p

Unit of meas urement

dBuV/ m

dBuV

Use electric/electronic equipment in conformity with the UE directives on electromagnetic compatibility; that is use components suited for applications on the vehicle and marked ”e.”, the ”CE” mark is not sufficient. Below there is an example of a mark as prescribed by the current European directive 2004/104EC valid for electromagnetic compatibility in the automotive sector: Figure 5.8

114476

a ≥ 6 mm In case of doubt, refer to the IVECO Support network. These levels are assured if the device comes from ”IVECO spare parts” or is certified according to the related international standards such as ISO, CISPR, VDE, etc.... If equipment is employed that as its primary or secondary source of power uses the civil electric mains (220V AC), it must have characteristics in line with the IEC regulations. Transceiver systems The most frequent applications concern: -

ham transceiver equipment for the cb and 2 metre bands;

-

transceiver equipment for cell phones;

-

gps satellite navigation and receiver equipment.

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Choosing an antenna installation is of considerable importance to assure the transceiver apparatus the greatest performance. It must be of excellent quality and installed with the greatest care, also the position in which it is fixed is of fundamental importance; it determines the efficiency of the antenna and therefore the capacity of the transmission. Therefore the characteristics of SWR (Standing Wave Ratio), gain and electromagnetic field generated must be assured within certain limits, while the parameters of impedance, effective height, efficiency and directivity are deduced from the manufacturer’s technical information sheet. The installation of c.b. ham 2m appliances, mobile phones (gsm) and satellite navigation systems (GPS) must use the supply system already set up on the vehicle, making the connection directly to terminal 30 of connector ST40 (and 15 where necessary). This equipment must be type approved according to the law and be the fixed type (not portable). Using transceivers that have not been type approved or applying additional amplifiers could seriously jeopardize the correct operation of the electric/electronic devices normally supplied, with negative effects on the safety of the vehicle and/or of the driver.

CB and 2m band ham radio appliances The installation of C.B. (27 MHz), 2m (144 MHz) appliances must use the supply system already set up on the vehicle, making the connection to terminal 30 of connector ST40. This equipment must be type approved according to the law and be the fixed type (not portable). Install the transmitting part in a flat and dry zone separated from the electronic components of the vehicle sheltered from moisture and vibration. The antenna must be installed outside the vehicle, preferably on a large metal base fitted as vertically as possible with the connecting cable turned downwards, observing the assembly prescriptions and the instructions of the manufacturer (see Figure 5.9). • The value of the SWR must be as near as possible to unity, the recommended value is 1.5 while the maximum acceptable value must in no case be greater than 2. • The values of the ANTENNA GAIN must be as high as possible and assure a sufficient characteristic of spatial uniformity, characterized by deviations from the mean in the order of 1.5dB in the typical cb band (26.965-27.405 MHz). • The value of the RADIATED FIELD IN THE CAB must be as low as possible, as a quality objective we recommend < 1V/m. In any case the limits set by the current European directive must not be exceeded. • For this reason the antenna must be always be set outside the cab. To determine proper operation of the radio-cable-antenna system and allow evaluating whether the antenna is calibrated, it is recommended to take account of the following indications: 1) if the SWR is higher on the low channels than on the high ones it is necessary to lengthen the antenna; 2) if the SWR is higher on the high channels than on the lower ones it is necessary to shorten the antenna. After calibrating the antenna it is advisable to recheck the value of the SWR on all the channels. Installation in the middle of the roof is considered the best since the ground surface is proportional in every direction, while assembly on a side or on any other part of the vehicle makes the ground surface proportional to its ground. The connection and positioning of the cables that involve the installations must be done taking care to: - use a coaxial antenna cable of excellent quality with low loss and having the same impedance as the transmitter and the antenna (see Figure 5.10); -

for the aforesaid coaxial cable make a route that, so as to avoid interference and malfunctioning, has a suitable distance (min. 50 mm) from the pre-existing wiring and from other cables (TV, Radio, Telephone, Amplifiers and other electronic equipment), saving the minimum distance from the metal structure of the cab; application is preferable on the left or right side;

-

when installing the fixed antenna it is necessary to clean the bottom of the hole made in the bodywork, so that the antenna support is properly connected to the ground of the vehicle;

-

the coaxial cable joining the antenna to the radio must be mounted with great care, it is necessary to avoid bends or folds that can crush or deform. If the cable is too long, avoid pointless tangles, and preferably shorten it as much as possible. It is wise to remember that any imperfection in the coaxial cable always causes serious trouble for the transceiver;

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5-23

for the cable passage use the existing holes; if necessary and essential make an additional hole; take the precautions to preserve the bodywork (rustproofing, liner, etc..); assure a good connection with the structure of the vehicle (ground), both of the base of the antenna and of the containers of the appliances, to achieve the maximum transfer of power.

The typical installation positions of transceiver equipment are those of the dashboard-gearbox or roof assembly zone - driver side (see Figure 5.11). The electric supply of the appliances, if requiring a different voltage to that of the system, must be obtained via a suitable DC/DC 24-12V converter if not already contemplated. The supply cables must be as short as possible, avoiding any coils (twisting) and observing the minimum distance from the reference surface. Figure 5.9

98915

1. Antenna support - 2. Gasket (code for spare parts 244614) - 3. Cap covering fixed joint (spare parts code 217522) 4. Retaining bolt M6x8.5 (screw on with a tightening torque of 2 Nm) - 5. Antenna (spare parts code of the rod assembly 675120) - 6. Roof assembly - 7. Antenna extension cable

Figure 5.10

99349

1. Antenna connector - 2. Ground brush - 3. Insulation - 4. Signal brush - 5. Capacitor (100pF) - 6. Cable RG 58 (characteristic impedance = 50 Ω) - 7. Clamp - 8. Protective cap - 9. Connector (N.C. SO -239) transceiver side 10. Adhesive tape for testing performed - 11. The 100pF capacitor must be welded with the lower brush and crimped with the ground braid - 12. The lower brush must be welded to the internal conductor of the cable - 13. Nut

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Figure 5.11

130602

1. Location of the transceiver equipment for CB (City Band) Transceiver systems for mobile phones The installation of mobile phones and appliances must use the supply system already set up on the vehicle, making the connection to terminal 30 via an additional fuse. This equipment must be type approved according to the law and be the fixed type (not portable). Install the transmitting part in a flat and dry zone separated from the electronic components of the vehicle sheltered from moisture and vibration. • The value of the SWR must be as near as possible to unity, the recommended value is 1.5 while the maximum acceptable value must ion no case be greater than 2. • The values of the ANTENNA GAIN must be as high as possible and assure a sufficient characteristic of spatial uniformity, characterized by deviations from the mean in the order of 1.5 dB in the 870-960 MHz band and 2 dB in the 1710-2000 MHz band. • The value of the RADIATED FIELD IN THE CAB must be as low as possible, as a quality objective we recommend < 1V/m. In any case the limits set by the current European directive must not be exceeded. • For this reason, the antenna must always be installed outside the vehicle cab, preferably on a large metal base fitted as vertically as possible with the connecting cable turned downwards, observing the assembly prescriptions and the instructions of the manufacturer. An optimal location of the antennas is the front of the cab roof at a distance of no less than 30 cm from other antennas.

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The connection and positioning of the cables that involve the installations must be done taking care to: - use a good quality antenna cable, particularly for the effects of visual coverage of the protective screen; -

for the aforesaid cable make a route that has a suitable distance (min. 50 mm) from the pre-existing wiring, saving the minimum distance from the metal structure of the cab, taking care that the cable is not too taut and preventing the cable getting folded and crushed; application is preferable on the left or right side;

-

never shorten or lengthen the coaxial antenna cable;

-

use the existing holes for the cable passage. If necessary and essential make an additional hole; take the precautions to preserve the bodywork (rustproofing, liner, etc..);

-

assure a good connection with the structure of the vehicle (ground), both of the base of the antenna and of the containers of the appliances, to achieve the maximum transfer of power.

The typical installation positions of equipment are those of the dashboard-gearbox or roof assembly zone - driver side. The electric supply of the appliances, if requiring a different voltage to that of the system, must be obtained via a suitable DC/DC 24-12V converter if not already contemplated. The supply cables must be as short as possible, avoiding any coils (twisting) and observing the minimum distance from the reference surface.

Installations of GPS antenna cables and navigation receiving equipment Correct and careful assembly of the GPS antennas on the vehicle is extremely important to accomplish correct operation and obtain top performance. The antennas must be mounted, preferably, in hidden places, out of sight. The position of the GPS antenna is delicate. The signal levels received from the satellite have very low power (approximately 136 dBm), so that any obstacle for the antenna can affect the quality and performance of the receiver. • The value of the SWR must be as near as possible to unity, the recommended value is 1.5 while the maximum acceptable value must in no case be greater than 2 in the GPS frequency range (1575.42 ±1.023 MHz). • The values of the ANTENNA GAIN must be as high as possible and assure a sufficient characteristic of spatial uniformity, characterized by deviations from the mean in the order of 1.5 dB in the band 1575.42 ±1.023 MHz. The GPS antenna must be installed in such a way that it has the greatest possible view of the sky. It is recommended to have 90° as the absolute minimum angle of vision of the sky. This view of the sky must not be obscured by any object or metal structure. The position has to be Horizontal. An ideal location for the GPS antenna is under the plastic dashboard in the centre and at the base of the vehicle’s windscreen. It must not be installed below any metal that belongs to the cab structure. Position the GPS antenna at a distance of no less than 30 cm from another antenna. The connection and positioning of the cables that involve the installations must be done taking care to: - use a good quality antenna cable, particularly for the effects of visual coverage of the protective screen; -

for the aforesaid cable make a route that has a suitable distance (min. 50 mm) from the pre-existing wiring, saving the minimum distance from the metal structure of the cab, taking care that the cable is not too taut and preventing the cable getting folded and crushed; application is preferable on the left or right side;

-

never shorten or lengthen the coaxial antenna cable;

-

use the existing holes for the cable passage. If necessary and essential make an additional hole; take the precautions to preserve the bodywork (rustproofing, liner, etc..);

-

assure a good connection with the structure of the vehicle (ground), both of the base of the antenna and of the containers of the appliances, to achieve the maximum transfer of power.

The installation of navigator appliances must use the supply system already set up on the vehicle, making the connection to terminal 30 via an additional fuse. This equipment must be type approved according to the law and be the fixed type (not portable). Install the transmitting part in a flat and dry zone separated from the electronic components of the vehicle sheltered from moisture and vibration.

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The electric supply of the appliances, if requiring a different voltage to that of the system, must be obtained via a suitable DC/DC 24-12V converter if not already contemplated. The supply cables must be as short as possible, avoiding any coils (twisting) and observing the minimum distance from the reference surface.

!

In case of installation of devices that can interact with other electronic systems such as: Retarders, additional heaters, power take-offs, air conditioners, automatic gearboxes, Telematics and speed limiters, contact IVECO in order to optimize the application.

NOTE For operations that could cause interference with the standard system, it is necessary to perform diagnostic checks in order to ensure correct assembly of the system. These checks can be made using the diagnostic ECUs [Electronic Control Units] on the vehicle or the IVECO service. IVECO reserves the right to have warranty on the vehicle elapse if any work not conforming to its directives is carried out.

5.8.3

Additional equipment

The vehicle system is designed to supply the necessary power to the equipment provided, for each piece of which, within its respective function, the specific protection and the correct sizing of the cables are ensured. The application of additional equipment must make provision for suitable protection and must not overload the vehicle’s system. The connection to ground of the added services must be made with a cable of suitable cross-section, as short as possible and made so as to allow movement of the added equipment in relation to the vehicle’s chassis frame. Needing batteries of greater capacity, for the demands of added loads, it is wise to request the option with uprated batteries and alternators. In any case it is recommended not to exaggerate in increasing the capacity of the batteries over 20-30% of the maximum values supplied as an option by IVECO, so as not to damage any components of the system (e.g. starter motor). When higher capacities are necessary, use additional batteries, taking the necessary precautions for recharging, as indicated below. Additional batteries and alternators The installation of electric appliances with a high power input (e.g. electric motors operated often or even more rarely for long periods and without using the vehicle’s engine, such as the tail lifts), or a large number of additional electrical appliances can require powers that the vehicle’s normal system is not able to deliver. In these cases additional batteries of suitable capacities must be used. Their insertion in the vehicle’s circuit must make provision for a separate recharging system (see Figure 5.12) integrated with that of the vehicle. In this case it is a good rule to use additional batteries of the same capacity as the ones originally mounted in order to recharge all the batteries correctly.

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Figure 5.12 Installation of supplementary batteries

117412

1. Standard batteries - 2. Supplementary batteries - 3. Alternator with incorporated regulator - 4. Starter motor 5. Ignition key - 6. Contactors - 7. Body Computer - 8. Instrument Cluster The installation of additional batteries requires checking the ability of the alternator to do the recharging. If it is necessary you must use an alternator of greater power or another additional one; in this case make the connection as indicated in Figure 5.13. By using electric motors that are controlled only with the vehicle engine running, instead of the additional batteries, it can be enough to use a more powerful alternator or an additional alternator. These alternators will have to be of the type with Zener diode rectifiers, so as to avoid the possibility of damage to the installed electric/electronic equipment due to accidental disconnection of the batteries.

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Figure 5.13 Installation of a supplementary alternator

To control unit IC - pin B18 (Battery not charging warning light)

Supplementary alternator DPT

BATTERY

To IBC control unit - pin C2 wiring colour: 8876 (+15 alternator)

131001

DPT: Shunt located near the battery.

Note: Installation of a supplementary alternator is possible only once the ’double alternator’ configuration has been enabled by IVECO Customer Service. Supplementary electric units Special attention must be paid when refrigeration units are installed that for a power source use a second alternator mounted on the engine (additional generator). These generators, according to the speed, supply voltage in the order of 270 to 540 V that comes through the wiring to the refrigerator unit installed on the vehicle. There is a clear danger of diaphony (electromagnetic interference between near cables) that can be generated between the aforesaid wiring and that already on the vehicle. In these cases it is necessary to use cables with high insulation, using a preferential route, however not near the standard wiring of the vehicle. For these units observe the levels of electromagnetic emissions indicated above. In case of malfunction of the standard alternator (e.g. low voltage, no signal), an error message will be signalled on the instrument panel. An additional alternator cannot be connected to the MUX and therefore in case of malfunctioning the MUX is not able to detect which alternator is not working correctly.

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5.8.4

SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS

5-29

Electrical power draw-off

The information related to the points where it is possible to draw off the available power (see Figure 5.14) and the indications to be respected are given below. Precautions Where necessary use suitable fuses applying them near the draw point. Protect the added cables in special sheaths or corrugation, installing them in compliance with point 5.8.6. Current must not be taken from: A) junction unit; D) battery terminal; E) the points indicated on the supplementary fuse box. Power can be drawn off from the following points: B) from the 21 pin connector; C) position connector for the side marker lamps. Figure 5.14

130603

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a) Junction unit The following table shows the available types of batteries. Table 5.25 Model 60 - 80EL 80 - 120 EL 120 - 190 110W - 150W

70 Ah standard -

88 Ah -

Batteries 110 Ah opt. 567 standard standard standard

Alternator 143 Ah opt. 568 (1) opt. 568 (1) opt. 568 opt. 568

170 Ah opt. 5031 opt. 5031

70 A

90 A

standard

opt 6315 opt.

(1) no for wheelbase 3105 mechanical susp.

Figure 5.15

116423

Junction unit M1. Electric supply from the bulkhead connector + or IGC / TGC M2. Electric supply output to the starter motor M3. Output to the Grid Heater relay M4. Electric supply output fuse box M5. Bodybuilder electric supply output

The current must be taken off via the special terminal M5 specially provided on the terminal block.. With engine stationary: With engine running:

Up to 10% of the nominal capacity of the batteries. Possible draw of a further 20% of the nominal capacity of the batteries, on the basis of the power of the alternator and the speed of the engine.

For higher power inputs it is necessary to have uprated batteries and alternator. The supply of high loads (e.g. tail lifts), when use is frequent, requires using batteries of sufficient capacity (at least 110 Ah) and 90 A uprated alternator. Note: On models ML120E.. to ML190EL.. with automatic transmission, the only alternator available (standard) is 90A.

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Maxifuses and Megafuses Available from IVECO Shop there is a set of five kits of fuse boxes, for high power draw-off protection. Their positioning (always as near as possible to the draw terminal on the batteries) will be done by the Bodybuilder according to the available space on the vehicle. Figure 5.16 Battery box MAXIFUSE

MEGAFUSE

91511

Capacity

Ref. IVECO No.

Set 40 A Set 60A

4104 0110 KZ 4104 0111 KZ

Cable cross-section 10mm2 10mm2

Capacity

IVECO Ref. No.

Set 100A Set 125A Set 150A

4104 0112 KZ 4104 0113 KZ 4104 0114 KZ

Cable section 25mm2 35mm2 50mm2

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b) 21 pin connector 61071 (brown) From the 21 pin connector, located in the electronic control unit compartment (under the panel at the bottom on the passenger side), it is possible to take current from pins 11 and 21. This current draw is protected by two fuses: FUSES F9 F15

MAXIMUM LOAD 10A 3A

DESCRIPTION K30 (pin 21) K15 (pin 11)

For further details see point 5.2.

c) Connector for Side Marker Lamps In some Countries the regulations (national or EC) require the outfitted vehicle to be provided with side marker lamps, depending on its overall length. Vehicles in the Eurocargo Euro 4-5 Range are provided with a specific super seal type female connector to make the electric supply connection for the side lights. Making the connections and installing the lights must be done by external Bodybuilders on the added structures (box-bodies, vans, etc.). The positions of the aforesaid terminals are given below.

!

In order to keep the electric characteristics of the contacts of the female connector unchanged over time, it is important to leave the cap supplied by IVECO attached.

5.8.5

Main switch of the batteries (optional)

IGC (Master current switch): It is mounted on the battery box and is manually controlled. It is the single pole type, its operation disconnects the battery from the vehicle’s system, leaving in operation the body computer, refrigerator, Webasto timer and, for requirements of the law, the tachograph. TGC (Master current relay): It is possible to close the circuit by opening the doors, with the ignition key, ignition of the ceiling lights, marker lamps, hazard lights, electric trap control, timer of the additional heater, the TGC ON button on the fascia. For special outfits (e.g., haulage of fuel, dangerous goods, etc.), a specific switch is required to A.D.R. standard.

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5.8.6

SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS

5-33

Additional circuits

They must be separate and protected with a special fuse from the vehicle’s main circuit. The added electric cables must be connected to the original electric system with watertight junctions equivalent to the original ones. The added cables must be protected in special sheaths (not PVC) or corrugated pipes appropriately fixed with brackets, protected from bumps and sources of heat. The cables must have a minimum distance of: - 150 mm from sources of high heat (turbine, engine, exhaust manifold,...) - 50 mm from containers of chemical agents (batteries, etc...) - 20 mm from moving parts. Take the utmost care to avoid any rubbing of the cables with other components and particularly with any sharp edges of the bodywork. The route of the cables must be defined as much as possible with dedicated brackets and clamps and moved closer (around 350 mm), to avoid hanging parts and provide the possibility (and obligation) to rebuild the same installation in the case of repairs or outfits. The passage of cables in holes and on edges of various panels must be protected by cable glands (besides the covering of the corrugation). It is forbidden to perforate the chassis frame for the passage of the cables. The corrugated pipe must protect the whole cable completely and must be joined (with heat shrink sections or taping) to the rubber caps on the terminals. In addition the corrugated pipe clamps (cut longitudinally) must not deform it, to avoid the cables being able to come out or anyhow be in contact with the sharp edge of the pipe. All the terminals (+) for connecting the aforesaid cables and their lugs must be protected by rubber caps, (airtight for zones exposed to the weather or with any stagnation of water). The fastening of the lugs on the terminals (also negative) must be assured to avoid loosening, applying a tightening torque where possible and fanning out the lugs in the case of multiple connections (preferably to avoid). It is wise where possible, to make provision for a different route for the cables passing between interfering high-intensity signals (e.g. electric motors, solenoid valves) and susceptible low-intensity signals (e.g. sensors) anyhow keeping for both a position as close as possible to the metal structure of the vehicle. In the case of chassis frame-tipping cab connection, the position of the set of wiring must be checked with the cab in its seat and tipped, to trace any interference and the tensioning to be corrected.

!

Depending on the drawn current, use fuses and cables of suitable cross-section, as shown in the Table 5.26. The fuse must be connected as near as possible to the point of drawing off the current.

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5-34

SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS

EUROCARGO M.Y. 2008

Table 5.26 Continuous max current 1) (A) 4 10 20 25 35 50 70 90 120 150 1)

Cable cross-section (mm2) 0.5 1 2.5 4 6 10 16 25 35 50

For uses longer than 30 seconds

Depending on the position and therefore the temperature that can be reached in the housing compartment, choose fuses that can be loaded up to 70% - 80% of their maximum capacity. It is wise to keep in mind that in grouping a number of cables, it will be necessary to have a reduction in the strength of the current compared to the nominal value of a single cable to compensate for the less heat dispersion. On vehicles where frequent engine starts are done, with current drawing and limited engine rotation times (e.g. vehicles with cold storage), plan for periodical battery charging to keep it efficient. The jack connections and terminals will have to be of the protected type, resistant to the weather, using components of the same type as those originally used on the vehicle.

5.8.7

Operations for changing the wheelbase and the overhang

If the length of the cables must be changed for the new size of the wheelbase and/or of the overhang, there must be a watertight box of the same characteristics as those on our vehicles. The components used such as cables, couplings, terminal blocks, corrugated pipes, etc. must be of the same type as the ones originally used and be correctly installed.

5.8.8

Drawing power at a different voltage to that of the system

With the 24V system, if a 12V electric supply is required, it is necessary to use a suitable voltage reducer that draws on the normal circuit; drawing from a single battery is not allowed for the negative effects that it would have on the batteries when recharging.

NOTE

Auxiliary 12V+24V connectors on fuse 70601/5. Both the 24V connector, via a converter, and the three 12V connectors are connected to fuse 70601/5. If 20A are drawn from the 12V connectors, only 5A is available from the 24V connector (to specify that 20A on the 12V converter means 14A on the electric supply fuse). 5A are always available on the 24V connector; if the 12V connectors are not used, 20A can be reached on 24V. The converter is protected from overloads and short-circuiting. If 20A are used on the 12V and 20A on the 24V, fuse 70601/5 will get damaged.

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5.8.9

SPECIAL INSTRUCTIONS FOR ELECTRONIC SUBSYSTEMS

5-35

Arrangement of Side Marker Lamps

In some Countries the regulations (national or EC) require the outfitted vehicle to be provided with side marker lamps, depending on its overall length. Vehicles Eurocargo are equipped with a special super seal female connector for connecting the electrical power required to supply side marker lamps. Making the connections and installing the lights must be done by external Bodybuilders on the added structures (box-bodies, vans, etc.). The positions of the aforesaid terminals are given below.

!

In order to keep the electric characteristics of the contacts of the female connector unchanged over time, it is important to leave the cap supplied by IVECO attached.

Figure 5.17

4 3 2 1

8869 3331 3332 0000

15 Key (5A max) Rh side Lh side (cable cross-section 1 mm2) Ground

116424

Use the sole kit: 504172783 The pin 1 can support a maximum load of 10A; pins 2 and 3 a maximum load of 6A. From pin 4 of this connector it is possible to draw an electric supply (24 V) with the key switch (+15) that can be used for outfits with a power input of no more than 5A.

Electrical system: modifications and drawing-off power Print 603.95.003

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-1

Index

SECTION 6 Special instructions for -SCR- exhaust system Page 6.1

General specifications

6-3

6.2

The nitrogen oxide catalytic reduction principle. AdBlue

6-4

6.3

On-board instruments

6-7

6.4

Distribution of the ecological additive AdBlue

6-8

6.5

Specifications for installation and removal

6-9

6.5.1

Operations for positioning the AdBlue tank

6-9

6.5.2

Operations on AdBlue pipes and heating water

6-11

6.5.3

Altering the supply module position

6-17

6.5.4

Operations on the dosing module

6-21

6.5.5

Operations on exhaust pipes

6-24

6.6

Wiring for positioning of SCR system components

6-25

6.7

OBD 1 - Stage 2

6-26

Index Print 603.95.003

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6-2

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Index Base - January 2009

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-3

6666.6

General specifications

6.1

General specifications

This chapter contains important information on the -SCR- exhaust systems fitted on the IVECO series (Eurocargo - Stralis Trakker). In order to comply with Euro4 Euro5 standards, IVECO has chosen the SCR (selective catalyst reduction) system to reduce the nitrogen oxide (NOx) emissions produced by exhaust gas. SCR is an exhaust gas post-treatment system that uses a catalyzer which, by means of a chemical reaction, transforms NOx nitrogen oxyde into nitrogen and water. This chemical reaction is produced by an additive called AdBlue (a solution of urea + water). Figure 6.1

125526

1. Engine coolant diverter valve - 2. Temperature sensor for exhaust gas coming out of the catalytic converter - 3. Sensor signal amplifier (5) - 4. Pump module - 5. Nitrogen oxide sensor - 6. Tank for reagent solution (coolant, urea: AdBlue) 7. AdBlue fluid level indicator control - 8. Intake air humidity sensor - 9. Mixing and injection module - 10. Temperature sensor for exhaust gas entering the catalytic converter - 11. Catalytic converter

General specifications Print 603.95.003

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6-4

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

The nitrogen oxide catalytic reduction principle. AdBlue

6.2

The nitrogen oxide catalytic reduction principle. AdBlue

The additive is sent from a dedicated reservoir by means of supply module (1) to dosing module (3), which injects AdBlue into the exhaust pipe. The mixture thus obtained is then fed to the SCR catalyzer that transforms the NOx into nitrogen and water. Post-treatment is based on a simple principle: the chemical reaction of ammonia NH3 with nitrogen oxides NO and NO2 produces two harmless substances: water vapour H2O and nitrogen N2. The whole system is managed by an electronic control unit. Figure 6.2

114734

1. Pumping module - 2. Catalyzer - 3. Dosing module - 4. AdBlue reservoir

The nitrogen oxide catalytic reduction principle. AdBlue Base - January 2009

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SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-5

Main system components

Pump module

Figure 6.3

108128

1. Ad Blue return Pipe to the tank - 2. Ad Blue return Pipe from Dosing module - 3. Ad Blue solution outlet 4. Ad Blue solution inlet - 5. Electrical connection - 6. DCU control unit - 7. Filter - 8. Pre-filter

Dosing module

Figure 6.4

108128

1. Ad Blue inlet - 2. Electrical connection - 3. Ad Blue outlet Its task is to meter the Ad Blue solution sent to the exhaust pipe upstream of catalyst.

The nitrogen oxide catalytic reduction principle. AdBlue Print 603.95.003

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6-6

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Catalyzer

Figure 6.5

126332

Catalyst, equipped with sound-proofing material, replaces the exhaust silencer. Inside the catalyst, the exhaust gas nitric oxides are, by reacting with ammonia, converted into free nitrogen and water vapour. Temperature sensors (1 and 2) and nitric oxide detecting sensor (3) are fitted onto catalyst. AdBlue reservoir

Figure 6.6

108508

The nitrogen oxide catalytic reduction principle. AdBlue Base - January 2009

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SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-7

On---board instruments

6.3

On-board instruments

The on board diagnostic system checks the tank level continuously and informs the driver on the current quantity. Figure 6.7

116718

On-board instruments Print 603.95.003

Base - January 2009

6-8

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Distribution of the ecological additive AdBlue

6.4

Distribution of the ecological additive AdBlue

The ’AdBlue’ denomination is recognized internationally; it is an aqueous solution consisting of high purity urea according to the DIN 70070 standard. It is absolutely safe, non-toxic and non-flammable. AdBlue manufacturers can assure the product direct distribution to the transporters with huge vehicle fleets, and the oil companies are also planning to install AdBlue pumps close to diesel fuel pumps within a short time. In this case it will also be available in tanks. A detailed list of sales outlets throughout Europe is available on the internet site: www.findadblue. com Figure 6.8

114735

Figure 6.9

Figure 6.10

114736

114737

Distribution of the ecological additive AdBlue Base - January 2009

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SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-9

Specifications for installation and removal

6.5

Specifications for installation and removal

The instructions that follow are intended for the AdBlue injection system of the Bosch DENOX2 type, within the SCR system. If Bodybuilders make changes to the frame, the following procedures must be followed under all circumstances: - disassembly: disconnect the hydraulic connectors first and then the electric connectors; - assembly: connect the electric connectors first and then the hydraulic connectors. Compliance with this assembly/disassembly procedure will ensure that AdBlue does not come into contact with the electric connectors.

6.5.1

Operations for positioning the AdBlue tank

As regards the AdBlue tank, ensure that: the tank ventilation pipe is never closed; the reservoir must contain at least 5 l of AdBlue at the end of each operation to ensure the dosing module is cooled; after each operation, the tank does not contain more than 85% of AdBlue (corresponding to the max reading of the level sensor) with respect to the tank total volume, so as to guarantee enough room for AdBlue to expand during freezing at temperatures below -11 °C; - when fitting equipment onto the chassis, there is enough room for the AdBlue fill gun (1, Figure 6.11) to fit completely and correctly into the tank filler. If specific-shaped tanks are available, these must be made out of polyethylene or stainless steel 1.4301, 1.43, in each case the tank height must be respected.

-

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6-10

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Removal and refitting of the AdBlue tank

Figure 6.11

102940

1. Cover - 2. Breather pipe - 3. AdBlue pipe - 4. Engine coolant pipe - 5. Electrical connection - 6. AdBlue pipe 7. Engine cooling pipe - 8. Level gauge

Remove cover (1) and remove the water/AdBlue pipes shown in the figure.

Specifications for installation and removal Base - January 2009

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SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-11

Water/AdBlue connectors Figure 6.12

114742

1. H2O infeed/outfeed connectors for AdBlue heater - 2. AdBlue infeed/outfeed connectors The temperature and level sensors are connected to the DCU (Dosing Control Unit); the level sensor is specific to each type of tank, therefore its dimensions cannot be modified.

6.5.2

!

Operations on AdBlue pipes and heating water After turning off the engine, the outlet ducts (PL/UPL) and the inlet ducts (IL/UIL) must be drained to prevent the AdBlue freezing in the ducts and components if temperatures are low. The time that elapses is approximately 2 minute and must not be interrupted by premature disconnection or the battery or disconnector. The process may clearly be heard because the AdBlue pump keeps working even after the engine has been turned off.

As far as the pipes connecting reservoir, supply module and dosing module are concerned, ensure that: -

the connection pipes between the AdBlue reservoir and the supply module (delivery or inlet line or return or return line) must be 5 m;

-

the connection pipes between the supply module and the dosing module (delivery or pressure line and return or cooling line) must be 3 m. The pipes may only be modified using the ”Voss” fittings described in Table 6.1.

Specifications for installation and removal Print 603.95.003

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6-12

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Table 6.1 - AdBlue VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 4 62 07 00 00 4128 3733 EZ 50-7499 114489

5 4 62 07 56 00 4128 3734 EZ 50-7499 114490

5 4 62 08 89 00 4128 3735 EZ 50-7499 114490

5 4 62 23 26 00 4128 3736 EZ 50-7499 114492

5 4 62 23 49 00 4128 3737 EZ 50-7499 114493

5 4 62 23 50 00 4128 3738 EZ 50-7499 114494

5 4 62 24 70 00 4128 3739 EZ 50-7499 114495

5 4 62 27 60 00 4128 370 EZ 50-7499 114496

5 4 66 12 06 49 4128 3741 EZ 50-7499 114497

5 4 64 11 16 00 4128 3742 EZ 50-7499

Winkelkupplung SV241 5/16” Ausführung links; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV241 5/16” VERSION LEFT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Winkelkupplung SV241 5/16” Ausführung rechts; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV241 5/16” VERSION RIGHT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

RACCORDO ANGOLO SV241 5/16” VERSIONE SINISTRA; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA RACCORDO ANGOLO SV241 5/16” VERSIONE DESTRA; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA

Geradekupplung SV241 5/16”; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

CONNECTOR SV241 5/16”; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

RACCORDO SV241 5/16”; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA

Winkelkupplung SV241 3/8” Ausführung links; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV241 3/8” VERSION LEFT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Winkelkupplung SV241 3/8” Ausführung rechts; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse Geradekupplung SV241 3/8”; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV241 3/8” VERSION RIGHT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

RACCORDO ANGOLO SV241 3/8” VERSIONE SINISTRA; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA RACCORDO ANGOLO SV241 3/8” VERSIONE DESTRA; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA

CONNECTOR SV241 3/8”; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Winkelstecker SV246 NG 8 Öffnungselement weiss; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV246 NG 8 RELEASE CLIP WHITE; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Winkelstecker SV246 NG 8 Öffnungselement schwarz; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

ELBOW CONNECTOR SV246 NG 8 RELEASE CLIP BLACK; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Set Verbinder MLT; 1 Verbinder NW6 2 1-Ohr Schellen 1 Montageanleitung

RACCORD ANGLE SV241 5/16” VERSION DROITE, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION EN ANGULO SV241 5/16” VERSION IZQUIERDA; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA CONEXION EN ANGULO SV241 5/16” VERSION DERECHA; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

RACCORD SV241 5/16”, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION SV241 5/16”; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

RACCORD ANGLE SV241 5/16” VERSION GAUCHE, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

RACCORD ANGLE SV241 3/8” VERSION DROITE, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION EN ANGULO SV241 3/8” VERSION IZQUIERDA; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA CONEXION EN ANGULO SV241 3/8” VERSION DERECHA; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

RACCORDO SV241 3/8”; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA

RACCORD SV241 3/8”, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION SV241 3/8”; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

RACCORD ANGLE SV241 8/16” ELEMENT D’OUVERTURE BLANC, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE RACCORD ANGLE SV241 8/16” ELEMENT D’OUVERTURE NOIR, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION EN ANGULO SV246 NG 8 ELEMENTO DE APERTURA BLANCO; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA CONEXION EN ANGULO SV246 NG 8 ELEMENTO DE APERTURA NEGRO; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

SET CONNECTOR MLT; 1 CONNECTOR NW6 2 RETAINING CLIP 1 ASSEMBLY INSTRUCTION ATTENTION TAKE NOTICE OF ASSEMBLY INSTRUCTION 9 1 77 00 02 20

RACCORDO ANGOLO SV246 NG 8 ELEMENTO DI APERTURA BIANCO; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA RACCORDO ANGOLO SV246 NG 8 ELEMENTO DI APERTURA NERO; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA SET DI RACCORDO; 1 RACCORDO NW6 2 FASCETTA 1 ISTRUZIONE DI MONTAGGIO PRESTARE ATTENZIONE A L’ISTRUZIONE DI MONTAGGIO 9 1 77 00 02 20

SET DE RACCORD ; 1 RACCORD NVV6 2 COLLIER 1 INSTRUCTION DE MONTAGE RESPECTER LES INSTRUCTIONS DE MONTAGE 9 1 77 00 02 20

JUEGO DE CONEXION; 1 RACOR NW6 2 ABRAZADERAS 1 INSTRUCCIONES DE MONTAJE PRESTAR ATENCION A LAS INSTRUCCIONES DE MONTAJE 9 1 77 00 02 20

Rohr MLT 8.8x1.4 PA0.2 Länge 10m

TUBE MLT 8.8x1.4 PA0.2 LENGTH 10m

TUBO MLT 8.8x1.4 PA0.2 LUNGHEZZA 10m

TUBE MLT 8.8x1.4 PA0.2 LONGUEUR 10m

TUBO MLT 8.8x1.4 PA0.2 LONGITUD 10 m

Stecker Trennstelle; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

CONNECTOR SECTION POINT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

Kupplung Trennstelle; mit MLT 8.8x1.4 PA 0.2 Länge 3m und Quetschhülse

CONNECTOR SECTION POINT; WITH MLT 8.8x1.4 PA0.2 LENGTH 3m AND COMPRESSED SLEEVE

RACCORDO PIASTRA DI SEZIONAMENTO; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA RACCORDO PIASTRA DI SEZIONAMENTO; CON MLT 8.8x1.4 PA0.2 LUNGHEZZA 3m E BOCCOLA PRESSATA

RACCORD PLAQUE DE SECTIONNEMENT, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE RACCORD PLAQUE DE SECTIONNEMENT, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

CONEXION CHAPA DE SEPARACION; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA CONEXION CHAPA DE SEPARACION; CON MLT 8.8x1.4 PA0.2 LONGITUD 3 m Y BOQUILLA PRENSADA

ACHTUNG Montageanleitung 9 1 77 00 02 20 beachten

RACCORD ANGLE SV241 3/8” VERSION GAUCHE, AVEC MLT 8.8x1.4 PA0.2 LONGUEUR 3 m ET BAGUE PRESSEE

114498

5 4 62 35 74 00 4128 3743 EZ 50-7499 114500

5 4 62 35 75 00 4128 3744 EZ 50-7499 114501

Specifications for installation and removal Base - January 2009

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SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-13

Table 6.1 - (cont.) Cooling water VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 4 62 28 42 00 4128 3745 EZ 50-7499

Winkelstecker SV246 NG 12 Öffnungselement weiss; mit Rohr Grilamicl 13x1.5 Länge 3m

ELBOW CONNECTOR SV246 NG 12 RELEASE CLIP WHITE; WITH GRILAMID TUBE 13x1.5 LENGTH 3m

RACCORDO ANGOLO SV246 NG 12 ELEMENTO DI APERTURA BIANCO; CON TUBO GRILAMID 13x1.5 LUNGHEZZA 3m

RACCORD ANGLE SV246 NG 12 ELEMENT D’OUVERTURE BLANC, AVEC TUBE GRILAMID 13x1.5 LONGUEUR 3m

CONEXION EN ANGULO SV246 NG 12 ELEMENTO DE APERTURA BLANCO; CON TUBO GRILAMID 13x1.5 LONGITUD 3 m

Winkelstecker SV246 NG 12 Öffnungselement blau; mit Rohr Grilamid 13x1,5 Länge 3m

ELBOW CONNECTOR SV246 NG 12 RELEASE CLIP BLUE; WITH TUBE GRILAMID 13x1.5 LENGTH 3m

RACCORDO ANGOLO SV246 NG 12 ELEMENTO DI APERTURA BLU; CON TUBO GRILAMID 13x1.5 LUNGHEZZA 3m

RACCORD ANGLE SV246 NG 12 ELEMENT D’OUVERTURE BLEU, AVEC TUBE GRILAMID 13x1.5 LONGUEUR 3m

CONEXION EN ANGULO SV246 NG 12 ELEMENTO DE APERTURA AZUL; CON TUBO GRILAMID 13x1.5 LONGITUD 3 m

Verbinder NW 10

CONNECTOR NW 10

RACCORDO NW 10

RACCORD NW 10

CONEXION NW 10

Rohr GRILAMID 13x1.5 Länge 10m

TUBE GRILAMID 13x1.5 LENGTH 10m

TUBO GRILAMID 13x1.5 LUNGHEZZA 10m

TUBE GRILAMID 13x1.5 LONGUEUR 10m

TUBO GRILAMID 13x1.5 LONGITUD 10 m

Stecker Trennstelle; mit Rohr Grilamid 13x1,5 Länge 3m

CONNECTOR SECTION POINT; WITH TUBE GRILAMID 13x1.5 LENGTH 3m

RACCORDO PIASTRA DI SEZIONAMENTO; CON TUBO GRILAMID 13x1,5 LUNGHEZZA 3m

RACCORD PLAQUE DE SECTIONNEMENT AVEC TUBE GRILAMID 13x1,5 LONGUEUR 3m

CONEXION CHAPA DE SEPARACION; CON TUBO GRILAMID 13x1,5 LONGITUD 3 m

Kupplung Trennstelle; mit Rohr Grilamid 13x1,5 Länge 3m

CONNECTOR SECTION POINT; WITH TUBE GRILAMID 13x1.5 LENGTH 3m

RACCORDO PIASTRA DI SEZIONAMENTO; CON TUBO GRILAMID 13x1,5 LUNGHEZZA 3m

RACCORD PLAQUE DE SECTIONNEMENT AVEC TUBE GRILAMID 13x1,5 LONGUEUR 3m

CONEXION CHAPA DE SEPARACION; CON TUBO GRILAMID 13x1,5 LONGITUD 3 m

114502

5 4 62 29 49 00 4128 3746 EZ 50-7499 114503

0 0 26 11 50 00 4128 3747 EZ 50-7499 114504

5 4 64 19 08 00 4128 3748 EZ 50-7499 114505

5 4 62 35 76 00 4128 3749 EZ 50-7499 114506

5 4 62 35 77 00 4128 3750 EZ 50-7499 114507

Table 6.1 - (cont.) Corrugated pipe VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 4 66 11 37 00 4128 3751 EZ 50-7499

Wellrohr NW37 Länge 3m

CORRUGATED HOSE NW37 LENGTH 3m

TUBO CORRUGATO NW37 LUNGHEZZA 3m

TUBE CANNELE NW37 LONGUEUR 3m

TUBO CORRUGADO NW37 LONGITUD 3 m

Wellrohr NW26 Länge 3m

CORRUGATED HOSE NW26 LENGTH 3m

TUBO CORRUGATO NW26 LUNGHEZZA 3m

TUBE CANNELE NW26 LONGUEUR 3m

TUBO CORRUGADO NW26 LONGITUD 3 m

Wellrohr NW22 Länge 3m

CORRUGATED HOSE NW22 LENGTH 3m

TUBO CORRUGATO NW22 LUNGHEZZA 3m

TUBE CANNELE NW22 LONGUEUR 3m

TUBO CORRUGADO NW22 LONGITUD 3 m

114479

5 4 66 12 10 00

114480

4128 3752 EZ 50-7499

5 4 66 12 09 00 4128 3753 EZ 50-7499 114481

Table 6.1 - (cont.) Breather pipe VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 4 66 09 65 00 114511

4128 3757 EZ 50-7499 5 4 64 19 09 00

114512

4128 3758 EZ 50-7499

Verbinder NW 6

CONNECTOR NW 6

RACCORDO NW6

RACCORD NW6

CONEXION NW6

Rohr 6x1 PA12PHLY Länge 10m

TUBE 6x1 PA12PHLY LENGTH 10m

TUBO 6x1 PA12PHLY LUNGHEZZA 10m

TUBE 6x1 PA12PHLY LONGUEUR 10m

TUBO 6x1 PA12PHLY LONGITUD 10 m

Verbinder NW 10

CONNECTOR NW 10

RACCORDO NW10

RACCORD NW10

CONEXION NW10

Rohr 10x1 PA12PHLY Länge 10m

TUBE 10x1 PA12PHLY LENGTH 10m

TUBO 10x1 PA12PHLY LUNGHEZZA 10m

TUBE 10x1 PA12PHLY LONGUEUR 10m

TUBO 10x1 PA12PHLY LONGITUD 10 m

5 4 66 10 21 00 4128 3759 EZ 50-7499 114513

5 4 64 19 10 00 4128 3760 EZ 50-7499 114478

Specifications for installation and removal Print 603.95.003

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6-14

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Table 6.1 - (cont.) Components VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 0 99 11 64 00 4128 3761 EZ 50-7499

Schutzkappe Tank 0°

PROTECTION CAP TANK 0°

CAPPA DI PROTEZIONE SERBATOIO 0°

CAPUCHON DE PROTECTION RESERVOIR 0°

COBERTURA DE PROTECCION DEPOSITO 0°

Schutzkappe Tank 90°

PROTECTION CAP TANK 90°

CAPPA DI PROTEZIONE SERBATOIO 90°

CAPUCHON DE PROTECTION RESERVOIR 90°

COBERTURA DE PROTECCION DEPOSITO 90°

Faltenbalg

CONVOLUTED RUBBER GAITER

SOFFIETTO

SOUFFLET

RESPIRADERO

T-Stück für Wellrohr NW37

T-CONNECTOR FOR CORRUGATED HOSE NW37

DISTRIBUTORE A T PER TUBO CORRUGATO NW37

DISTRIBUTEUR EN T POUR TUBE ANNELE NW37

DISTRIBUIDOR EN T PARA TUBO CORRUGADO NW37

Deckplatte Trennstelle

COVERPLATE SECTION POINT

PIASTRA DI COPERTURA PUNTO DI SEZIONAMENTO

PLAQUE DE COUVERTURE POINT DE SECTIONNEMENT

CHAPA DE COBERTURA PUNTO DE SEPARACION

Grundplatte Trennstelle

BASE PLATE SECTION POINT

PIASTRA DI BASE PUNTO DI SEZIONAMENTO

PLAQUE DE BASE POINT DE SECTIONNEMENT

CHAPA DE BASE PUNTO DE SEPARACION

114477

5 0 99 11 71 00 4128 3762 EZ 50-7499 114488

5 4 66 09 30 00 4128 3763 EZ 50-7499 114499

5 4 66 09 64 00 4128 3764 EZ 50-7499 114508

5 3 49 03 21 00 4128 3765 EZ 50-7499 114509

5 3 49 03 20 49 4128 3766 EZ 50-7499 114510

Table 6.1 - (cont.) Tools VOSS/IVECO Teil -Nr: Part -No:

Benennung

Itemname

Descrizione

Description

Descripción

Codice: 5 9 94 52 14 00

Kunststoffrohr Montagezange

NYLON TUBE MOUNTING PLIERS

PINZA DI MONTAGGIO PER TUBO PLASTICA

PINCE DE MONTAGE POUR TUBE PLASTIQUE

ALICATES DE MONTAJE PARA TUBO DE PLASTICO

Spannbacken für Rohr MLT 8.8x1.4

CLAMPING JAWS FOR TUBE MLT 8.8x1.4

MORSA PER TUBO MLT 8.8x1.4

GRIFFE DE SERRAGE POUR TUBE MLT 8.8x1.4

MORDAZA PARA TUBO MLT 8.8x1.4

Spannbacken für Rohr GRILAMID 13x1.5 (08/ 010/ 012/ 013)

CLAMPING JAWS FOR TUBE GRILAMID 13x1.5 (08/ 010/ 012/ 013)

MORSA PER TUBO GRILAMID 13x1.5 (08/ 010/ 012/ 013)

GRIFFE DE SERRAGE POUR TUBE GRILAMID 13x1.5 (08/ 010/ 012/ 013)

MORDAZA PARA TUBO GRILAMID 13x1.5 (08/ 010/ 012/ 013)

Werkzeugeinsatz Aufnahme für Verbinder NW6 (Harnstoff)

TOOLING INSERT COLLET FOR CONNECTOR NW 6 (AD-BLUE)

Werkzeugeinsatz Aufnahme für Verbinder NW10 (Kühlwasser)

TOOLING INSERT COLLET FOR CONNECTOR NW 10 (COOLING WATER)

INSERTO STAMPO ALLOGIAMENTO PER CONNETTORI NW6 (UREA) INSERTO STAMPO ALLOGIAMENTO PER CONNETTORI NW10 (AQUA DI RAFFREDDAMENTO)

EMPREINTE MOULE LOGEMENT CONNECTEURS NVV6 (UREE) EMPREINTE MOULE LOGEMENT CONNECTEURS NW10 (EAU DE REFROIDISSEMENT)

UTIL ESTAMPACION ALOJAMIENTO PARA CONEXIONES NW6 (UREA) UTIL ESTAMPACION ALOJAMIENTO PARA CONEXIONES NW10 (AGUA DE REFRIGERACION)

Aufweitdorn für Rohr MLT 8.8x1.4

WIDENING SPIKE FOR TUBE MLT 8.8x1.4

MANDRINO ALLARGATUBI MLT 8.8x1.4

MANDRIN A DUDGEONNER MLT 8.8x1.4

MANDRIL PARA AVELLANAR TUBOS MLT 8.8x1.4

9 7 51 00 00 08

Klemmzange für Einohrschelle

CLAMPING PLIERS FOR CLIP RETAINER

5 9 94 84 72 00

Kunstoffrohr-Schneidezange

NYLON TUBE SCISSORS

5 9 94 84 74 00

Ersatzklinge für Kunstoffrohr-Schneidezange (2 Stück)

SPARE BLADE FOR NYLON TUBE SCISSORS

MORSETTO PER FASCETTA TRONCHESE PER TUBO IN PLASTICA LAMA DI RICAMBIO PER TRONCHESE PER TUBO IN PLASTICA

CLIP POUR COLLIER DE SERRAGE TRICOISES POUR TUBE EN PLASTIQUE LAME DE RECHANGE DE TRICOISES POUR TUBE EN PLASTIQUE

UTIL PARA ABRAZADERAS CORTADOR DE TUBO DE PLASTICO CUCHILLA DE RECAMBIO PARA CORTADOR DE TUBO DE PLASTICO

Iveco: 99387101 50-7499 114482

5 9 94 71 53 49 Iveco: 99387102 50-7499 5 9 94 65 41 00 Iveco: 99387103 50-7499 114484

5 9 94 71 55 00 114485

Iveco: 99387104 50-7499 5 9 94 69 16 49 Iveco: 99387105 50-7499

114486

5 9 94 71 56 00 Iveco: 99387106 50-7499 114487

-

When working on the pipes, it is compulsory to work in a completely dust-free environment to prevent dust reaching the injector.

-

Restore all the pipe insulation (water and Urea pipes) to prevent freezing.

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-15

6.5.2.1 Instructions for lengthening and shortening the AdBlue ducts on the vehicle 1) Mark the delivery and returns ducts before separating them to ensure that they are correctly positioned during subsequent assembly. The maximum permitted length for ducts must not exceed 5 m from the reservoir to the supply module and 3 m from the supply module to the dosing module. 2) Cut the AdBlue duct (MLT Rehau - VOSS HWL 8.8 x 1.4 PA wall thickness 0.2 mm and 0.4 mm PA/PUR) with the appropriate pipe cutting clippers in order to ensure an accurate cutting area. For reasons of space, it is advisable to divide the AdBlue delivery and return ducts along the length of the line. Figure 6.13

123261

3) The special band is pushed by the fitting toward the end of the pipe. 4) The pipe is inserted in the pipe jaws and secured by clips. The end of the duct should extend 4-5 mm from the clips. The tightening force must be adjusted using adjustment screw (A) (the distance of the jaws without the pipe must be approximately 1-2 mm). Figure 6.14

123262

A 5) Fit expanding pin (B) in the tool element and push the transport bar mechanically toward the pipe until the pin cone fits fully into the pipe. Then pull the bar back and remove the expansion plug.

Specifications for installation and removal Print 603.95.003

Base - January 2009

6-16

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

Figure 6.15

EUROCARGO M.Y. 2008

B

C 123263

6) The expanded side of the joint on the duct to be fitted must be moistened with water to above the O-Ring and fitted into the tool insert. The connector must be pressed toward pipe by hand through the transport bar until the profile of the pipe expander is centred within the inner diameter of the pipe. 7) Use the appropriate lever to push the connector into the pipe to the end of the expansion pin. It is advisable to exercise continuous pressure while doing this. 8) Release the locking jaws, position the special bands up to 5+1 mm from the collar and press using the manual pliers (C).

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

6.5.3

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-17

Altering the supply module position

On some body models or for some types of service, it is necessary for components of the AdBlue system such as the AdBlue tank, the dosing module or the supply module to be fitted in another part of the vehicle. When moving the AdBlue components, take particular care over the height differences between them. Relevant examples are shown in the following figures. Figure 6.16

117474

1. AdBlue reservoir - 2. Pumping module - 3. Dosing module - 4. Siphon compulsory The supply module must be fitted on a fixed base. The preferred fitting position of the supply module is vertical with the attachments facing down. A different position is possible within the measurements shown below. The fitting position on Stralis vehicles corresponds to layout in version b. When connecting the AdBlue pipe to the DM, ensure that the pipe is fitted leading upwards just before the DM (illustration below). Figure 6.17

117474

Specifications for installation and removal Print 603.95.003

Base - January 2009

6-18

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

If the position of the supply module (SM) is altered, a check must be carried out to ensure that the environmental temperature corresponds to that of the original installation. In case of doubt, it is advisable to re-check the temperatures. The following abbreviations may be used in the description of the component position: Figure 6.18 • • • • • • •

AdBlue reservoir (T) Supply module(SM) Dosing module (DM) AdBlue delivery pipe (UIL) AdBlue pressurised pipes (UPL) AdBlue cooling pipes (UCL) AdBlue return pipe (URL)

123265

1. Reservoir ventilation - 2. Residual air - 3. Return line - 4. Temperature sensor - 5. AdBlue level sensor 6. Delivery line - 7. Reservoir minimum level - 8. Reservoir heater The AdBlue reservoir is lower than the supply module(SM): The maximum intake height corresponds to the difference between reference point (6) = lower edge of the supply module and the lower edge of the intake duct (5). The intake height must not exceed 1 m. Figure 6.19

123266

1. Supply module (SM) - 2. Supply line - 3. AdBlue reservoir - 4. AdBlue minimum level - 5. Intake duct lower edge 6. Lower edge of supply module

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-19

The AdBlue reservoir is higher than the supply module(SM): The maximum intake height corresponds to the difference between the lower edge of intake pipe (5) and the highest point of intake duct (2). This height must not exceed 1 m. Figure 6.20

123267

1. AdBlue reservoir - 2. Upper edge of intake pipe - 3. Level of AdBlue in reservoir - 4. Supply module 5. Lower edge of intake pipe Dosing module (DM) is lower than supply module (SM): The upper edge of delivery duct (2) must be located above reference point (8). Figure 6.21

123268

1. Supply module - 2. Upper edge of intake duct - 3. AdBlue reservoir - 4. Level of AdBlue in reservoir 5. AdBlue minimum level - 6. Siphon - 7. Dosing module (DM) - 8. Lower edge of supply module

Specifications for installation and removal Print 603.95.003

Base - January 2009

6-20

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

The AdBlue reservoir is higher than the supply module (SM): The upper edge of delivery duct (1) must be located above reference point (5). Figure 6.22

123269

1. Pressurised pipe - 2. AdBlue level - 3. AdBlue reservoir - 4. Minimum level of AdBlue - 5. Lower edge of supply module

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

6.5.4

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-21

Operations on the dosing module

When the dosing module requires repositioning, note some important precautions. Figure 6.23

114743

STRUCTURE OF THE MEASURING MODULE 1. Heatshield - 2. Temperature sensor - 3. Valve holder - 4. AdBlue connectors - 5. Dosing valve - 6. Cooling adapter 7. Insulation

Figure 6.24

A -

158 mm

"

117475

Inside the exhaust gas pipe is placed a diffuser (1) therefore the pipe interested CANNOT be modified.

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Base - January 2009

6-22

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

Orientation of dosing module (DM) in the exhaust pipe: When positioning the DM, a distinction is drawn between the positioning rotation angle in the exhaust pipe and the exhaust pipe installation angle (see following figure). Figure 6.25

Exhaust pipe installation angle

Angle of rotation of DM in exhaust pipe

123270

Orientation of dosing module (DM) in relation to angle of rotation in exhaust pipe: To prevent operating errors and damage to the DM, the following positions must be respected during installation: - 315° - 45° (A) The increasing heat in the exhaust pipe may damage the DM or cause it to malfunction. In this case, a heat shield must be installed under all circumstances. - 90° - 270° (D) The AdBlue fluid contained in the dosing module. In If temperatures are very low, this may freeze and damage the module. - 45° - 90° and from 270° to 315° (C - E) In this position installation is possible, a minimum quantity of AdBlue remains in the module. - 60° - 70° (B) This is the idea position for installing the DM and must be absolutely preferred if conditions permit.

123271

Exhaust gas pipe installation angle: The installation angle must be between +45° and -90°.

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-23

Installation of the form of dosing in relationship to the catalyst SCR: Figure 6.26

Mixer pipe length Silencer Example of DM installation: - exhaust pipe angle of inclination 45°. - rotation of DM +90°

SCR catalytic converter

The exhaust pipe input into the SCR catalytic converter must be as low as possible

NOTE

123272

The exhaust pipe input into the SCR catalytic converter must be located as low as possible. If the catalytic converter is turned so that the exhaust pipe input is located in the upper part, there is a danger of the hot exhaust gases going back into the dosing module if the engine stalls, with a consequent risk of damage.

Distance of the DM from the SCR catalytic converter: On IVECO Cursor engines, the distance of the DM from the SCR catalytic converter must not be less than 1200 mm. Lower distances must be checked and authorised in each individual case. In some conversions, it may be necessary to locate the SCR catalytic converter in a new position on the vehicle. Taking into consideration the above conditions, the exhaust gas (start or mixer pipe to the inlet of the SCR plug) may be extended up to 3 m. A further extension of the exhaust gas pipe makes it absolutely necessary to insulate the pipe to avoid excessive heat dispersion with a possible consequent malfunction of the SCR system SCR. An overall exhaust pipe length of 6 m must not be exceeded under any circumstances. The distance ( X ) between the DM and the next bend depends on the angle and the following distances must be complied with: - 30° bend > distance 150 mm - 45 bend > distance 200 mm - 90° bend > distance 300 mm If an adaptation should be necessary due to the tubomixer, the following requirements must be observed: To prevent the formation of sediment in the exhaust pipe behind the mixer due to sharp edges or welds, a connection to the mixer must be created at least 10 mm before the end of its internal duct.

123273

Specifications for installation and removal Print 603.95.003

Base - January 2009

6-24

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

NOTE

If the dosing module is moved, the pipes and electrical wiring must be modified.

6.5.5

NOTE

-

-

EUROCARGO M.Y. 2008

Operations on exhaust pipes

The exhaust pipe layout cannot be changed without the approval of IVECO.

The exhaust pipe can be modified paying attention to the following warnings: type approved (homologated) counter-pressures must be respected when determining the exhaust pipe route. Form bends with angles greater than 90° and radius of curvature greater than 2.5 times the pipe diameter. Keep the exhaust pipe far enough away from rubber or plastic parts and fit heat shields if necessary. it is not permitted to use pipes with diameters, thicknesses and materials other than those used for the original equipment. it is permitted to use hoses with limited lengths. in some conversions, it may be necessary to locate the SCR catalytic converter in a new position on the vehicle. Taking into consideration the above conditions, exhaust gas pipe (start of mixer pipe to the SCR plug intake) may be extended up to 3 m. a further extension of the exhaust gas pipe makes it absolutely necessary to insulate the pipe to avoid excessive heat dispersion with a possible consequent malfunction of the SCR system.

An overall exhaust pipe length of 5 m must not be exceeded under any circumstances. Electrical wiring: - it is only possible to lengthen cables for the temperature sensors. - it is not possible to alter the length of the Nox sensor cable.

Specifications for installation and removal Base - January 2009

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EUROCARGO M.Y. 2008

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

6-25

Wiring for positioning of SCR system components

6.6

Wiring for positioning of SCR system components

If the SCR system components are moved (e.g. total or partial movement of the rails and lengthening of wheelbase), Iveco makes available replacement material and wiring to ensure final product quality.

Replacement of cables for repositioning SCR system components Chassis wiring C-MET / UDS ORIGINAL WIRING

COMPONENTS

SUBSTITUTIVE WIRING

MARKING

SCR dosing module solenoid valve

L = 800 mm

78266

Catalytic converter sensor out connection (4-way super seal)

L = 250 mm

st 59

Urea tank temperature and level sensor with SCR

L = 300 mm

85142

C-EFM/UDS to CILC connection cable (4-way super seal)

L = 1000 mm

Engine water circulation solenoid valve for UREA heating with SCR

L = 500 mm

78267

UREA filter outlet heater with SCR

L = 400 mm

61150

Control for SCR pumping module

L = 800 mm

85140

L = 5000 mm

44030

Wiring E-A/MET Bridle for connection from NOx sensor to EFM control unit Bridle length 2 m. (to be added to standard cable, in longer wheelbases and/or in case of wheelbase lengthening)

des. n° 504279753

Bridle length 2.6 m. (to be added to standard cable, in longer wheelbases and/or in case of wheelbase lengthening)

des. n° 504280652

Wiring for positioning of SCR system components Print 603.95.003

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6-26

SPECIAL INSTRUCTIONS FOR -SCR- EXHAUST SYSTEMS

EUROCARGO M.Y. 2008

OBD 1 --- Stage 2

6.7

OBD 1 - Stage 2

As of 1 October 2007, the Directive on emissions requires makers of industrial vehicles to provide for a reduction of engine performance if, during vehicle use, NOx emissions do not meet the requirements fixed by the standard. Therefore, in case of driving with the AdBlue tank empty (AdBlue level below doser minimum operation quantity), or other causes not allowing the vehicle to respect the NOx emissions prescribed by the standard, the engine will undergo a reduction in performance (derating), signalled in advance by lighting up of the yellow OBD indicator on the instrument panel. CONDITION AdBlue remains approximately 10% below the tank capacity Non-compliance with Nox values established in standards: • AdBlue tank empty • Dosing stopped • Any deviation greater than 50% of average AdBlue consumption

CONSEQUENCE Driver notified (warning light flashes) AdBlue warning light comes on with continuous light, reduction in engine performance and fault code stored for 400 days or 9600 hours of engine operation

SYMBOL YELLOW warning light

125201

This decrease in performance is activated the first time the vehicle is brought to null speed and lasts until restoration of antipollution devices normal operating conditions, allowing the vehicle to again respect the NOx emissions (e.g. if the AdBlue tank is empty just refill it) and has no effect on the reliability of the vehicle. The on board control unit records (compulsory by law) these events so that they are also available for checks by the Police.

OBD 1 - Stage 2 Base - January 2009

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