Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions Manual 692.68.887

Description

Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions Manual

This is the complete Iveco Eurocargo MY2016 Bodybuilder Instructions publication, document number 692.68.887, first edition, base 04/2017. It is the reference document issued by Iveco for qualified bodybuilders, converters, and specialist workshops who carry out transformation, fitting, and superstructure work on Eurocargo chassis across Euro III, Euro IV and Euro V engine generations. Everything in this Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions Manual 692.68.887 is written around the actual chassis architecture of the MY2016 Eurocargo range, from the small 110EL and 120EL models through to the heavier 180E, 190EL and the /P air suspension variants.

File Details

• Manual type: Bodybuilder Instructions / Conversion and Fitting Guidelines
• Brand: Iveco
• Model range: Eurocargo MY2016 (Euro III, Euro IV, Euro V)
• Document number: 692.68.887
• Edition: 1st Edition, Base 04/2017
• Language: English
• File format: PDF
• Page count: 231 pages
• Sections: 6 (General Information, Chassis Interventions, Applications of Superstructures, Power Take-offs, Electronic Sub-Systems, AdBlue and SCR System)

Chapters Covered

• Section 1 – General Information: Scope of the Guidelines, Technical Documentation Available Electronically, Iveco Authorisation, Authorisation Request, Responsibilities, Legislative Requirements, Multi-Stage Type Approval Collaboration, Guarantees, Quality System Management, Accident Prevention, Choice of Materials (Ecology and Recycling), Vehicle Management on the Part of the Bodybuilder, Vehicle Names, Trademarks and Symbols, Dimensions and Ground, Instructions for Proper Functioning of the Vehicle Parts and Accessibility, General Regulation for the Prevention of Fire Risk.
• Section 2 – Chassis Interventions: General Chassis Modification Standards, Drills on the Chassis, Rust and Paint Protection, Wheelbase Modification, Rear Overhang Modification, Installing the Tow Hook, Assembling an Additional Axle, Gearbox Modification, Modifying the Engine Air Intake and Exhaust Systems, Work on the Engine Cooling System, Installing an Additional Heating System, Installing an Air Conditioning System, Work on the Cab, Changing Tyre Size, Work on the Braking System, Electrical System Current Interventions and Draws, Part Relocation and Anchorage of Additional Units and Equipment, Transport of Hazardous Materials (ADR), Installing a Retarder, Rear Under-run Protection, Rear Mud Guards and Wheel Arches, Rain Flap, Side Protections, Front Under-run Protection, Rear-view Mirrors.
• Section 3 – Applications of Superstructures: Construction of the Subframe, Elements Making Up the Subframe, Connection Between Chassis and Subframe, Container Application, Tractor for Semi-Trailer, Transport of Inseparable Materials, Installation of Tanks and Loose Material Containers, Installing a Crane, Installation of Tail Lifts, Interchangeable Outfits, Construction of Box Truck Bodies, Tilt Beds, Vehicles for Council and Fire Service, Front Installation of Snow Plough Attachments, Application of a Winch, Concrete Mixer Installation.
• Section 4 – Power Take-offs: General Specifications, PTO from Gearbox, Power Take-off from Transfer Box, Power Take-off from Drive Line, Power Take-off from Engine (front and rear), PTO Management, Standard Configurations, EM Expansion Module.
• Section 5 – Electronic Sub-Systems: Electronic Systems, Bodybuilder Connectors, FMS Fleet Management System, Configurations for Tail Lifts, Operator’s Footboard, Electrical Circuit Modifications, Electrical System Operations, Additional Equipment.
• Section 6 – AdBlue and SCR System (Euro V versions only): General Information, Nitrogen Oxide Catalytic Reduction Principle, Instructions, Pipes, Positioning the Dosing Module, Wiring for Positioning SCR System Components.

Across its six sections, this Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions Manual sets out the approved engineering rules for adding a body, structure or driven equipment to the Eurocargo chassis without compromising the vehicle’s structural, braking or electrical integrity. The document deals with the practical realities of a working conversion shop: where you may and may not drill the side members, what weld preparations are permitted, how to reposition the rear crossbar after a chassis shortening, which vehicles can accept an additional third axle and what reinforcement that requires, and how the bodybuilder-supplied electrical loads must be wired so the multiplex network does not throw faults.

Chassis, Subframe and Superstructure Engineering

The chassis intervention rules in this manual are unusually detailed. Section 2 covers allowable hole positions and diameters on the side member web, minimum edge distances, screw classes and torques, weld preparations with bevel geometry, and the corrosion protection cycles that must be reapplied to any modified area. Wheelbase modification is broken down into extension and shortening cases with specific limits and reinforcement requirements, and there are dedicated chapters for adding a third or steering axle, repositioning or reinforcing the rear crossbar, and installing tow hooks for both conventional and centre-axle trailers. There is also a full treatment of RUP and FUP adjustment, side protections, mudguards and other legislative accessories.

Section 3 then takes the same engineering approach to the superstructure itself. It explains how the subframe is sized for each model, how the chassis-to-subframe connection is chosen between elastic brackets and shear-resistant plates, and how different bodies – fixed box bodies, tipping bodies, tanks, roll-off containers, cranes behind the cab or on the rear overhang, tail lifts, tilt beds, concrete mixers, snowplough attachments and winches – each impose their own reinforcement and connection requirements. Tables give recommended minimum section moduli for each model and wheelbase so the bodybuilder can size the counter-chassis correctly rather than guessing.

Power Take-offs and Vehicle Electronics

Section 4 handles power take-off selection and installation, covering gearbox, transfer box, drive line and front or rear engine PTOs. The manual provides tested torque values for each gearbox/PTO combination, transmission ratio data, driveshaft angle limits, and the maximum permitted lengths of sliding and intermediate shafts. It also explains PTO management through the Expansion Module and VCM, including the different PTO modes and their configurable parameters – torque limiting, overspeed regulation, intermediate engine speed memory, and activation conditions for manual, automated and Allison gearboxes.

Section 5 is the electronics reference. It lists the locations and functions of the Eurocargo control units, documents the Bodybuilder connectors in the cab and on the chassis pin by pin, and covers the base and VEHH tail lift configurations, the operator’s footboard pre-configuration for refuse collection, electrical circuit modification rules, grounding points, electromagnetic compatibility limits, additional batteries and alternators, current draw points, and the safe current limits for added circuits. This is the section a converter will keep coming back to when wiring an added body.

AdBlue and SCR System Work

Section 6 is dedicated to Euro V vehicles and the AdBlue/SCR after-treatment system. It explains the SCR reduction principle, then sets out the restrictions on relocating the supply module, dosing module and AdBlue tank, the maximum intake and pipe lengths, the orientation angles for the dosing module in the exhaust pipe, and the rules for lengthening cables and AdBlue or coolant pipes when the chassis layout changes. This is essential reading before extending a wheelbase on a Euro V Eurocargo, because it defines how far the SCR components may be moved and how the pipes must be routed.

Who This Manual Is For

This Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions Manual is aimed squarely at bodybuilders, converters and specialised workshops rather than at the general owner-driver. It assumes the reader is designing or carrying out a conversion project and is responsible for the compliance of the finished vehicle. The content is technical and procedural, with tables, formulas and diagrams rather than step-by-step beginner guidance. Anyone fitting a tipper, crane, tail lift, tank, box body, refuse body, concrete mixer or winch to a Eurocargo, or repositioning an axle, lengthening the wheelbase or rewiring the chassis, will find the specific guidance and the limits they need to stay within.

Why the Bodybuilder Instructions Matter

Conversion work that is not done to the manufacturer’s instructions can affect the structural integrity of the chassis, the braking balance, the stability of the vehicle, and the behaviour of the multiplexed electrical system. It can also invalidate the vehicle’s guarantee and, in the case of safety-related systems such as braking, steering or stability control, require re-approval. Having the correct limits in front of you means the difference between a conversion that passes inspection and one that has to be stripped back and redone. The manual also defines where Iveco authorisation is required before work begins, so the bodybuilder knows in advance which modifications are permitted as standard and which need written approval.

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Instant PDF Delivery

The Iveco Eurocargo MY2016 Euro III-V Bodybuilder Instructions is delivered as an instant-download PDF once payment is complete. There is no shipping and no waiting for a physical book. The file can be opened on a workshop PC, laptop, tablet or smartphone, printed for the bench if you prefer paper, and referred to repeatedly through the life of a conversion project. Because it is a digital file, you can search the section you need, print only the pages relevant to a particular job, and keep a copy on every device your team uses.

Whether you are quoting a new body, planning a wheelbase change, sizing a subframe, wiring a tail lift or repositioning an SCR module on a Euro V chassis, this manual provides the approved procedures, the permitted limits and the technical data you need to carry out the work correctly.