Iveco Daily MCA 2014 Bodybuilder Instructions Manual – 603.95.789 2nd Edition PDF

Description

Iveco Daily MCA 2014 Bodybuilder Instructions Manual – 603.95.789

This is the complete IVECO Daily MCA 2014 Bodybuilder Instructions manual, document number 603.95.789, 2nd Edition, dated November 2015. It is the definitive technical reference for bodybuilders, converters, and specialised workshops carrying out transformation, fitting, or superstructure installation work on the IVECO Daily MCA 2014 range. Every intervention described in this 272-page PDF has been deliberated, approved, and tested by IVECO and forms part of normal production guidance.

File Details

• Manual type: Bodybuilder Instructions / Vehicle Conversion Guidelines
• Brand: IVECO
• Model: Daily MCA 2014 (33S, 35S, 35C, 40C, 45C, 50C, 60C, 65C, 70C)
• Language: English
• Page count: 272 pages
• File format: PDF
• Document number: 603.95.789
• Edition: 2nd Edition
• Publication date: 11/2015

Chapters Covered

• Section 1 – General Information: scope of the guidelines, technical documentation, IVECO authorisation, authorisation request, responsibilities, legislative requirements, multi-stage approval (EU/Switzerland/Turkey), guarantees, quality system management, accident prevention, choice of materials (ecology/recycling), vehicle management, vehicle names, identifications, dimensions and ground, centre of gravity determination, permitted masses, accessibility, fire risk prevention, conventions
• Section 2 – Chassis Interventions: general chassis modification standards, drills on the chassis, hole position and size, screws and nuts, welds, sealing holes, rust and paint protection, wheelbase modification, rear overhang modification, installing the tow hook, drawbar couplings for centre axle trailers, assembling an additional axle, gearbox modification, work on suspensions, modifying engine air intake and exhaust, engine cooling system, heating/conditioning plant, bodywork interventions, changing tyre size, work on the braking system, load sensing valve, ESP system, electrical system current interventions and draws, part relocation, transport of hazardous materials (ADR), installing a retarder, rear under-run protection (RUP), rear mud guards and wheel arches, rain flap, side protections
• Section 3 – Applications of Superstructures: construction of the subframe, aluminium subframe, elements making up the counter chassis, longitudinal profiles, cross members, connection between chassis and counter chassis, choosing the type of connection, connection with brackets, connections with greater elasticity, connections with clevis fasteners or clamps, connection with longitudinal and transverse sealing plates, mixed connection, container application, fixed bodies, tipper bodies, tractor for semi-trailer, fifth wheel supporting structure, fifth wheel, brake system, electric system, transport of inseparable materials, installation of tanks and loose material containers, installing a crane, crane behind cab, crane at rear overhang, removable cranes, installation of tail lifts, tilt beds, vehicles for council/fire service/special uses, front installation of snow plough attachments, application of a winch, special outfits, cowl chassis versions, motor home, installation of aerial platforms
• Section 4 – Power Take-offs: general specifications, power take-off on the gearbox, direct application of pumps, power take-off from transfer box, power take-off from drive line, power take-off on the engine, settings, PTO management on gearbox, Multiple State Switch, adjust engine speed for removing the engine
• Section 5 – Electronic Sub-systems: electronic system, location of control units, bodybuilder connectors, 20-way bodybuilder connector 61071A, 12-pin bodybuilder connector 72075A, electronic control units, disconnecting and repositioning ECUs, electrical system current interventions and draws, ground points, electromagnetic compatibility, reception/transmission systems, additional equipment, additional batteries, additional alternators, current draw and fuses, cable path between cab and engine compartment, additional circuits, modifying wheelbase and overhang, trailer setup, side marker lamp installation, predisposition for an additional rear central door lock system, antitheft system
• Section 6 – AdBlue and SCRT System: general information, nitrogen oxide catalytic reduction principle, instructions, materials, AdBlue tank, moving AdBlue system components, representative vehicles, AdBlue piping, AdBlue refuelling inlet, type-approved layout, AdBlue tank position
• Section 7 – Expansion Module: general information, PTO management, standard configuration, customized PTO configurations, standard parameters for PTO1, parameters for PTO2, wiring diagram, optional connectors (61071B, 72075B, 72071, ST13), electrical connections for PTO2, additional functions (Run-Lock, Safety/Alarm, Additional Lights)
• Appendix A – Daily People Carrier: chassis transport, lifting, delivery, storage, weights, general standards for securing the body to the chassis, bodywork construction, main dimensions, internal configuration and vehicle capacity, driver’s seat characteristics, fire protection materials, structure and securing seat mounts, rear baggage compartment, side access, replicated structure and securing handrails, wheelchair lift, soundproofing, climate control and thermal insulation, current draws, bodybuilder connectors, road tests
• Appendix B – CNG Natural Power: general information, main safety regulations (refuelling, gas leaks, fire), general warnings, tightening torques, gas pipes, repainting outfitted chassis, emptying the gas system, power take-offs, connectors for bodybuilders, additional alternator
• Appendix C – Hi-MATIC Automatic Gearbox: general information, layout, requirements (gearbox release lever, Bowden cable, additional devices, propeller shaft, supplementary structures, cooling), warning indicators (gear oil temperature, reverse gear engagement signal)

This Iveco Daily MCA 2014 Bodybuilder Instructions manual gives a technician the complete framework for transforming the Daily MCA chassis into any number of special-purpose vehicles. It is not a generic guide. It is the document that IVECO expects bodybuilders to follow, and it covers the exact procedures, stress limits, material specifications, and approval requirements that apply to this specific platform. From the permitted static stress on the chassis (120 N/mm2) and the correct drilling offsets on side members, to the formulas for determining the centre of gravity of a superstructure, to the ESP reprogramming and derating rules, the manual is structured to keep the converted vehicle safe, functional, and within warranty.

What This Manual Enables You To Do

With this Iveco Daily MCA 2014 conversion guidelines document, a bodybuilder or workshop can confidently plan and execute:

• Wheelbase modifications (shortening or lengthening) within approved limits, including cross member placement, drive shaft adaptation, and chassis stress verification
• Rear overhang modifications with correct reinforcement and connection methods
• Installation of tow hooks, drawbar couplings, and fifth wheel structures for semi-trailer tractor conversions
• Installation of cranes behind the cab or at the rear overhang, with correctly sized counter chassis and stabiliser requirements
• Installation of tail lifts, tilt beds, tipper bodies, and fixed bodies on cab and van versions
• Construction of counter chassis and subframes using the correct materials, profile sizes, and connection types (elastic, rigid, or mixed)
• Work on braking systems, load sensing valves, and ESP system management including reprogramming and derating
• Modifications to the engine air intake, exhaust, cooling system, and heating/air conditioning plant
• Electrical system interventions, current draws, additional circuits, and trailer socket installation
• Power take-off installation on the gearbox, engine, or driveline, including PTO management and Expansion Module configuration
• AdBlue/SCRT system component relocation following one of the 17 type-approved layouts
• CNG (Natural Power) vehicle safety procedures, including partial and total gas system emptying
• Hi-MATIC automatic gearbox requirements for bodybuilders

Why This Manual Matters

Modifying a commercial vehicle without the manufacturer’s instructions is a fast way to void warranties, fail type approval, and create safety hazards. The 603.95.789 bodybuilder manual exists because IVECO has approved and tested specific procedures for the Daily MCA 2014. It tells you what can be done without authorisation, what requires a formal IVECO authorisation request, and what is strictly forbidden. It gives you the material grades, the tightening torques, the welding techniques, the hole spacing rules, and the electrical connection points that keep the finished vehicle compliant with national and international law. For any professional converter, this manual is not optional. It is the baseline.

Delivery

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This Iveco Daily MCA 2014 Bodybuilder Instructions PDF is available for instant download after payment. There is no shipping, no waiting, and no physical book to lose. You can access the file on any device, search the text, and print only the pages you need for the job at hand. Whether you are working on a single conversion or running a bodybuilding operation, having the document on hand in digital form means you can check the exact specification before you cut, drill, or weld.