2-6 CHASSIS MODIFICATIONS E UROCARGO Euro 4/5 Regarding the electrical equipment remember to: a) Take precautions concerning the alternator and the electrical/electronic components. In order to avoid damaging the diode rectifier, never disconnect the batteries (or open the isolator) when the engine is running. If the vehicle has to be tow started make certain that the batteries are connected. Should it be necessary to charge the batteries, disconnect them from the vehicle circuit.
In order to run the engine with external means and in order to avoid current peaks which might damage the electric/electronic components, do not use the ”start” function in conjunction with external charge devices if such devices are equipped with this function. Starting will have to be carried out only with the external battery trolley ensuring correct polarity. b) Checking the earth connections. As a general rule the original earth connections of the vehicle must not be changed. If it is necessary to move these connections or to implement further earth points use the existing holes on the chassis as far as possible and:
- Remove, mechanically, and/or with an appropriate chemical product, the paint on the chassis side and on the terminal side creating a resting plane free from indentations or ridges. - Apply appropriate high conductivity paint between the cable terminal and the metal surface (e.g. galvanizing paint IVECO Part number 459622 by PPG). - Connect the earth cables within 5 minutes from the application of the paint. Do not use the IVECO standardised M1 (battery earth connection) M2, M8 (earth connection for starter motor depending on the driving position) points for the earth connections for control switches (e.g. sensors or low absorption devices).
With regard to the electronic devices, avoid linking earth connections between the devices; only use single wireearths with optimised lengths (as short as possible). For further information regarding the braking and electronic system, refer to points 2.15 and 2.16.
c) Specifications and standards for correct installation of wires in electrical systems - Power cables (+ direct) must be fed on their own into corrugated piping (of appropriate diameter) and not together with other smaller cables (signal and negative cables); - they must be spaced a minimum distance of 100 mm apart (reference value = 150 mm) from high heat sources (engine turbine, exhaust manifold,...); - a distance of at least 50 mm must be maintained from chemical agent containers (batteries, etc.); - the same prescription is applicable with regard to the proximity to moving parts; - the passage of cables through openings and over sharp edges of sheet metal must be protected by means of cable glands (in addition to the flexible conduit covering); - the flexible conduit must protect the cable entirely and it must be joined (with shrink wraps or by taping) to the rubber caps on the terminals.
In addition, the clamps securing the flexible conduit (cut longitudinally) must not deform it; this precaution prevents the risk of cables coming out of the conduit or coming into contact with the cut edge of the conduit; - all connection clamps (+) for the above cables and their terminals must be protected by sealed rubber in areas exposed to atmos- pheric agents with the possible risk of standing water; - fixing of the cable lugs to the terminals (including negative terminals) must be assured in such a way as to prevent them working loose, applying tightening torque wherever possible and arranging the lugs in a star configuration in the case of multiple connec- tions (to be avoided if possible); - the route of the cables in question must be defined as far as possible with dedicated brackets and ties that are close enough together to avoid loose sections and provide the possibility (and obligation) to reconstruct the same installation in the event of repairs or the installation of additional equipment; - in the case of connection between the chassis-tilting cab, the position of the cable harness must be checked with the cab in its driving position and when tipped, in order to identify any points of interference or pulling, which must be corrected.
General instructions for chassis modifications Base - January 2008 Print 603.93.431