Iveco EuroCargo (12 to 26 t). Manual — part 193
78688
Figure 1
General information
The cab is an advanced one, it can be tipped up hydraulically with a mechanical control.
Tilting angle 57
°.
Pressed and welded steel framework, parts made of electro-galvanized sheet steel.
Sound deadening on the underbody and anticorrosion protection in the boxed compartments.
The cab suspension is mechanical.
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CAB
Elements in synthetic material
Double zinc plated sheets
The choice of materials comprising the body is geared to
achieving an excellent quality standard so as to offer a product
with lasting quality and performance.
The galvanizing is done according to different technological
processes:
- Galvanic plating: the sheet metal is immersed or washed,
depending
on
whether
it
is
bi-galvanization
or
galvanization, in a salt bath providing a high level of surface
finishing.
- Fire plating: the molten zinc gets deposited on the sheet
metal by the effect of the heat. With this process, which
is mainly used for the structural elements of the body,
thicknesses of up to 20 microns can be reached, against 7
microns obtained with the galvanic process.
The wheel arches made of synthetic material also have an
anti-corrosion function.
All the boxes are protected by using galvanized sheet steel that,
after painting, are sprayed on the inside with waxy oil to
prevent internal oxidation.
78692
Figure 2
Single zinc plated sheets
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After assembly, the body undergoes a range of treatments to
cleanse it of grease, oxidation and to preserve it from
corrosion.
The cycle comprises the following phases:
- Pre-degreasing: washing with an acid solution (deoxidine)
to eliminate the oily substances on the metal.
- Degreasing: washing with a water-surfactant solution. This
solution is sprayed at a temperature of approximately
60
°C.
- Rinsing: this is done with industrial water to eliminate the
alkaline residues.
- Activation: washing at ambient temperature with a
titanium salt solution (exposing the crystals, ”pickling”).
- Phosphatizing: washing with zinc phosphates at a
temperature of approximately 55
°C. The electrolytic
plating of these metals forms and multiplies the crystalline
cores, creating a uniform and protective micro-crystalline
layer on the body (decontamination).
- Passivating: washing with a chromium-based solution that
provides an additional layer of protection and levelling of
the crystals.
- Rinsing: using deionized water eliminates the residues of
the previous solutions.
- Drying: in an oven at a temperature of approximately
110
°C.
Applying the protective paint (electrophoresis)
Electrophoresis treatment is performed by dipping the body
in a bath of an electro-conductive solution to which particles
of paint have been added in suspension.
Preparing the sheet metal (bonderizing)
CHECKING
THE
GEOMETRY
OF
THE
CHASSIS FRAME
Before doing any work it is wise to make sure that the chassis
frame is perfectly level, that is with no deformation or stress
due to the weight of the various assemblies.
GENERAL RULES FOR WORKING ON THE
CHASSIS FRAME
The criteria for performing the work permitted by IVECO on
the chassis frames are subordinate to observance of the
following instructions:
- Welding on the flanges of the structural members and on
the structural members of the chassis frame is strictly
prohibited.
- Drilling the flanges of the structural members is not
permitted.
- The characteristics of the chassis frame must not be
altered without IVECO approval.
Preparing the chassis frame for maintenance,
checking and repair work authorized by
IVECO
Parts fitted on the chassis frame that are removed before
checking and repairing the chassis frame must be suitably
stored and protected.
Likewise, the wirings and terminal installations must be well
positioned on the chassis frame to prevent damage (from any
welding, painting or rubbing on the ground).
Protect the entire installation of the chassis frame, placing
suitable protection on it for workers and operators to tread
on.
Should welding be required, keep to the instructions.
Arc welding with weld material
The weld must be good for the effects of penetration with no
cracks or inclusions and with a non-porous appearance.
The thickness of the weld material must be in proportion to
the thickness of the material to weld and must be no less than
2 mm even after any grinding.
When making the weld beads, they must be parallel to the
direction of the stress; transverse beads must be avoided.
For elements that bend, the weld must be located along the
neutral area, with a bead width in proportion to the thickness
of the sheet metal. For elements with axial compression, the
weld must be made at the end and with a concave bead.
Sudden changes in cross-section due to weld accumulation
must be avoided.
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Spot welding
This must be workmanlike. Take special care over the setting of the device so as to make spot welds that ensure a fully efficient
join. Avoid positioning spots near the edge of the parts to weld.
!
The areas of the chassis frame involved in welding must be thoroughly cleaned and, after welding, protected with
two-component epoxy rust-proofing or another similar product, and with another coat of single- or two-component
paint.
The earth cable of the welding system must be connected on the chassis frame as close as possible to the welding zone, and never
near a rotating part (transmission, wheel hubs, etc.) nor above or under an assembly with moving parts (compressor, bearings, etc.).
Welding instructions
Before welding, which must be done so as to minimize the tension and deformation that may be created, remove the paint and
carefully deoxidize the surfaces involved.
Classification of corresponding steels in the EU:
Bodybuilder work on the structural members of the IVECO chassis frame
No modification (lengthening, shortening, drilling and/or welding on a significant scale) is authorized to the frameworks of the IVECO
chassis frame or warranty for the chassis frame is forfeit. If, when specifically requested in writing, IVECO Engineering authorizes
specific work to be performed, there are some rules of a general nature to follow in designing and performing these operations
that are stated on the following pages.
Drilling the chassis frame
When it is necessary to fit auxiliary parts or assemblies on the chassis frame, the existing holes made when making the chassis frame
must, as a rule, be used.
Drilling the flanges of the vehicle’s structural members is strictly prohibited.
In special cases (fitting brackets, angle sections, etc.) where it is necessary to make fresh holes, these must be made on the vertical
rib of the structural member and must be carefully deburred and bored.
The new holes must not be made in the areas of greatest stress (such as the spring mountings for example) and of changes to the
cross-section of the structural member.
The diameter of the holes must be suited to the thickness of the sheet metal; in no case may it exceed 15 mm. The distance from
the axis of the holes from the edges of the structural member must be no less than 40 mm. In any case, the axes of the holes must
be at a distance of no less than 50 mm from each other or from the existing holes. The holes must be staggered as shown in the
figure.
When moving the crosspiece or spring mountings, their drilling patterns must be maintained.
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A 35 501
E 24.2
E 26.3
E 36.4
German standards
DIN 17 100
R-St. 37.2
St. 42.3
St. 52.3
British standards
BS 4360
40 B
43 C
50 D
American standards
A S T M
A 283 gr. D
A 284 gr. C
-
Italian standards
UNI - 7070
Fe 37.B
Fe 42.C
Fe 52.D
Swedish standards
MNC - 810
13.12.00
14.13.00
21.34.01
Spanish standards
UNE - 36 080
A 360.B
A 410.C
A 510.D
Belgian standards
NBN 631
AE 22B or AE24B
AE 26 C
AE 36 D
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