Iveco DAILY MCA2014 4x4

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SECTION 5

ELECTRONIC
SUB-SYSTEMS

- Printed 603.95.994 Base 05/2015

- Printed 603.95.994 Base 05/2015

DAILY MCA2014 4x4 BODYBUILDER INSTRUCTIONS


ELECTRONIC SUB-SYSTEMS
Contents

Contents
5.1ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . .

5.2BODYBUILDER CONNECTORS . . . . . . . . . . .

Connector 61071A, blue, 20-pin . . . . . . . . . . . . .

Connector 72075A, black, 12-pin . . . . . . . . . . .

12

5.3ELECTRONIC CONTROL UNITS . . . . . . . . .

18

Precautions to be used with electronic control


units installed . . . . . . . . . . . . . . . . . . . . . . . .

18

Disconnecting electronic control units . . . . . . . .

19

Repositioning electronic control units . . . . . . . . .

20

5.4ELECTRICAL SYSTEM: CURRENT


INTERVENTIONS AND DRAWS . . . . . . . . . . . . .

20

Ground points . . . . . . . . . . . . . . . . . . . . . . .

22

Electromagnetic comparability . . . . . . . . . . . . .

27

Reception/transmission systems . . . . . . . . . . . .

29

Additional equipment . . . . . . . . . . . . . . . . . . .

34

Drawing current . . . . . . . . . . . . . . . . . . . . . .

38

Additional circuits . . . . . . . . . . . . . . . . . . . . .

41

Modifying wheelbase and overhang . . . . . . . . . . .

43

Trailer setup . . . . . . . . . . . . . . . . . . . . . . . .

43

Side Marker Lamp installation . . . . . . . . . . . . . .

45

Reverse gear signal . . . . . . . . . . . . . . . . . . . .

46

Antitheft system . . . . . . . . . . . . . . . . . . . . . .

47

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4

ELECTRONIC SUB-SYSTEMS

Printed 603.95.994 1 Ed. - Base 05/2015

DAILY MCA2014 4x4 BODYBUILDER INSTRUCTIONS


ELECTRONIC SUB-SYSTEMS

5.1ELECTRONIC SYSTEM

ELECTRONIC SUB-SYSTEMS
5.1ELECTRONIC SYSTEM
Below is the location of the ECUs and connectors that can be installed on the vehicle.

It is not permitted to connect devices or electrical circuits directly to the control units described
below. Only the connectors listed in the following paragraphs may be used.

Location of control units

228305

A.
B.
C.
D
E.
F.

Instrument panel
Steering wheel column and ignition switch
Body Computer
CBA2 control unit in the engine compartment
Oil control unit
Glow-plugs preheating control unit

Printed 603.95.994 1 Ed. - Base 05/2015

G.
H.
I.
L.
M
N.

Engine Management control unit


ABS/ESP control unit
Green filter
SCM connection panel (engine)
CBA1 control unit on battery
Expansion Module

Figure 1

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

5.2BODYBUILDER CONNECTORS
Note Given the multiplicity of vehicular variants and of associated wiring, the present chapter only provides information concerning the
basic version of the electrical system; please contact the IVECO Assistance Service should you require more specific information.
The vehicle's electrical system contains specific connectors for connecting the bodybuilder installations; access to these allows the
system's functional integrity and validity of the warranty to be preserved.
The standard connectors are the 61071A and 72075A, interfaced with the cab dashboard cable, which are accessible after removing the panel of the passenger side glove box (see Figure 2).

Any taking of signals from the vehicles to the oufitting must be performed using suitable diodes,
relays and bridles. Direct connection to connectors 61071A and 72075A is strictly forbidden,
otherwise the warranty shall become invalid.

230823

1.
2.

Bodybuilder Connector 61071A


Bodybuilder Connector 72075A

3.
4.
5.

Figure 2

Connector EM 61071B
Connector EM 72075B
Connector EM 72071

In the event in which the vehicle is ready for the optional installation of the Expansion Module, the electrical system in the cab is
also equipped with connectors 61071B, 72071, 72075B, to which another connector ST13 is added inside the engine compartment, on the left side (see Figure 3).
The description of the function of these connectors is contained in the specific manual EM 603.95.826 (currently being updated at
the time of publication of the present document).

Printed 603.95.994 1 Ed. - Base 05/2015

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

230828

1.

Figure 3

Connector ST13

Connector 61071A, blue, 20-pin

101564

A.

Existing part on vehicle (male)

B.

Figure 4

Counterpart to be coupled (female)

Table 5.1
Code

Description

500314817 EZ

20-way male door seal

500314820 EZ

Male contact for 0.35 to 0.5 mm cable

500314825 EZ

Male contact for 0.75 to 1.5 mm cable

1/05907/44 EZ

Male contact for 2.5 mm cable

Printed 603.95.994 1 Ed. - Base 05/2015

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

Table 5.2 - Basic functions of the 20-pin connector 61071A


Pin

Description

Engine start-up

Cable
code

Signal

8888

Input
Max 20 mA

Connected
to

Remarks

BCM A/19

The engine starts only when the key is turned in the


ignition block (K15 ON) (1)
+12 V = engine start-up
Open wire = no action

BCM F/22

The engine only switches off with vehicle speed < 4


km/h (2)
+ 12 V = engine stop
Open wire = no action

Engine shut down

9903

Input
Max 10 mA

Service braking

1176

Output
Max 500 mA
(with decoupling diode)

BCM D/57

+12 V = brake activated


no signal = brake not activated

Stationary vehicle

0000

Output
Max 500 mA
(with decoupling diode)

BCM H/32

Ground = stationary vehicle


no signal = vehicle is not stationary

Parking braking

6662

Output
Max 500 mA
(with decoupling diode)

BCM F/44

Ground = parking brake engaged (3)


no signal = parking brake not engaged

Battery positive

7772

max 15 A

BCM E/19

Positive protected by fuse on Body Computer - F33

3320

Output
Max 500 mA

Relay managed
by BCM

A positive signal is obtained when the side lights are


on (4)
+12 V = side lights active
no signal = side lights inactive

Ignition of side lights

Reserved

(5)

Clutch actuation

9273

Output
Max 500 mA
(with decoupling diode)

EDC K/44

+12 V = clutch not depressed


no signal = clutch depressed

10

Engaging reverse

2268

Output
Max 100 mA
(with decoupling diode)

BCM C/17

+12 V = reverse gear engaged


no signal = reverse gear not engaged

11

Positive with key

8879

Output
max 5 A

BCM G/12

Positive with key protected by fuse on Body Computer F49

12

Cruise Control Command

8156

Input
(...)

BCM H/56

Cruise Control interface

13

Reference ground for


Cruise Control command
transfer box

0000

Input
(...)

BCM H/45

Ground for Cruise Control interface

14

Reserved

15

Reserved

16
17

(6)

Reserved
Ground

0000

Output
max 15 A

Ground connection

18

Reserved

19

Reserved

20

Reserved

The vehicle does not supply any safety check. The vehicle does not prevent engine start-up with gear engaged, nor
monitors the release of the clutch pedal. The bodybuilder must adopt preventative measures to avoid any unintentional movements of the vehicle.
(1)

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ELECTRONIC SUB-SYSTEMS

5.2BODYBUILDER CONNECTORS

The engine start-up control must be permanently active until the engine starts running.
The engine only functions with the key turned in the ignition block (K15 ON).
Activating the remote signal K15 from pin 5 of connector 72075A and then inserting the key in the ignition block (K15 ON) prevents engine start-up and an Immobilizer Error is signalled. In this case it is necessary to remove both the remote signals K15 and K15 ON.
When the procedure has been performed successfully it remains valid for the entire K15 ON cycle and this allows the bodybuilder to repeatedly stop and restart the engine until K15 stays active.
The starter motor is only activated when the engine is NOT running.

(2)

Stopping the engine is only permitted when the vehicle is stationary or at a speed of < 4 km/h.

The engine stop control must be permanently active until the engine stops.

If the parking brake engaged signal indicates "ground", it means the parking brake has not been fully released.
Therefore a residual braking torque on the rear axle cannot be excluded. IVECO does not recommend use of the signal
as an indication of a stationary vehicle.
(3)

Obligatory insertion of a 10 kOhm pull-up resistor between 61071A / pin 11 (signal K15) and 61071A / pin 05 as outlined in Figure 5.

230048

1.

Outfitting

2.

Figure 5
Connector 61071A

The output signal of the side markers may also be extracted from the chassis connector ST38. If necessary, consult Chapter 5.4 Paragraph "Arrangement of side position lights (Side Marker Lamps) ".
(4)

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

(5)

On the 20-way connector 61071A the D+ signal is not available.

IVECO therefore recommends use of a relay which is able to read the


engine speed from terminal 10 of the 12-way connector 72075A (see
example in Figure 6).
This relay must be set so that, with an engine speed of >400 revs/min, a
12 V output is activated which can be used as the D+ signal.
The speed threshold for which the signal must be present is adjustable
from 400 to 2000 revs/min and can also be used for other applications in
which an engine speed signal is required.
If the RPM output of connector 72075A / pin 10 does not supply a signal, then the ECM programming must be updated; for
this purpose, contact the IVECO Assistance Service.
230049

Figure 6

Connection:

X:

not used

Y:

Signal input connector 72075A / pin 10

Z:

not used

C:

not used

15:

not used

30:

positive shared connector 61071A / pin 11

31:

negative connector 61071A / pin 17

87:

normally open (closing) to be used as D+ signal

87a:

normally closed (opening)

Rated voltage:

9 15 V

Maximum switching current:

10 A

Operating current:

10 100 mA

Protection:

IP52

(6)

Only supported with Cruise Control option.

The resistors must be connected between pin 12 and pin 13. Different functions may be activated depending on the resistor value:

R = 2490 Ohm:

CC stays active, just like the PTO modes (important for vehicles without Cruise Control)

R = 649 Ohm SET+:

the speed increases by +50 revs/min pulse (only when the vehicle is stationary) or adjustment of the CC speed (only at V > 30
km/h)

R = 261 Ohm SET-:

the speed decreases by -50 revs/min pulse (only when the vehicle is stationary) or adjustment of the CC speed (only at V > 30
km/h)

R = 133 Ohm RES:

activation of ISC MEMO speed or resumption of the memorized CC speed

Printed 603.95.994 1 Ed. - Base 05/2015

DAILY MCA2014 4x4 BODYBUILDER INSTRUCTIONS


ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

Figure 7

208225

A.
B.

Pin 12 20-pin body builders connector


Pin 13 20-pin body builders connector (ground)

C.
D.

Pin 4 20-pin body builders connector (ground if V=0)


Pin 11 20-pin body builders connector(+15)

For this purpose IVECO recommends use of a relay which enables utilization of the same functions available on the steering wheel lever.
The Cruise Control option must be configured on both the ECM and BCM
systems.
Please note that the driver must position the Cruise Control switch on
the steering wheel lever to OFF, otherwise the external controls will be
ignored.

Function

Short-cut necessary

CC Resume

Pin 2

Pin 6

CC Set-

Pin 2

Pin 8

CC Set+

Pin 2

Pin 5

CC ON

Pin 2

Pin 4

Printed 603.95.994 1 Ed. - Base 05/2015

230050

Figure 8

11

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

Connector 72075A, black, 12-pin

101554

Existing part on vehicle (male)

Figure 9

Counterpart to be coupled (female)

Table 5.3
Code

Description

500314814 EZ

12 way male connector

500314820 EZ

Male contact for 0.35 to 0.5 mm cable

500314825 EZ

Male contact for 0.75 to 1.5 mm cable

1/05907/44 EZ

Male contact for 2.5 mm cable

Table 5.4 - Basic functions of the 12-pin connector 72075A


Pin

Description

Cable
code

Signal

Connected
to

Remarks

2nd Speed limiter

0000

Input
Max 10 mA

BCM H/41

Activation of 2nd speed limiter (30 km/h by default) (1)


Minimum value 10 km/h, which may be set by the Assistance Service
Ground = 2nd speed limiter activated
Open wire = no action

Programmable speed
limiter;

9968

Input
Max 10 mA

EDC K/22

Activation of programmable speed limiter


Ground = programmable speed limiter activated
Open wire = no action

Ground for Multiple State


Switch

0000

(...)

BCM H/38

Ground for EDC (2)


Multiple State Switch pin 8

Speed signal (B7)

5517

BCM D/56

Obligatory insertion of a 5k pull-up resistor (3)


Use signal K15 of 61071A/pin 11
Pulse signal, see B7 tachograph signal description

BCM G/02

By providing a positive, the first turn of the key is simulated (key


set to ON). Only the main loads are powered but it is not possible
to start the vehicle from outside since the vehicle key recognition is
missing. (4)
+12 V = activation of K15 Remote
Open wire = no action

EM X3/08

PTO 1 feedback
Ground = PTO 1 engaged
Open circuit = PTO 1 not engaged

K15 Remote

8879

Signal of PTO 1 in
operation

6993

Input
Max 500 mA

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ELECTRONIC SUB-SYSTEMS

13

5.2BODYBUILDER CONNECTORS

Pin

Description

Cable
code

Signal

Connected
to
BCM B/28
(t.b.d.)
BCM D/51
(t.b.d.)

Remote activation of horn


Ground = horn active
Open wire = no action

BCM H/36

ISC input (Idle Speed Control) mode 1/2/3 (2)


Note: the ISC mode must be reactivated after every engine startup.

Horn

0000

Output
Max 150 mA

Multiple switch

0000

Output
(...)

5587

Output
(...)

9
10

Remarks

Reserved
Engine speed (rpm)

EDC K/70

Engine speed signal


4 pulses/rev.

11

Not connected

12

Not connected

(1)

(5)

Should you wish to change the value of the 2nd speed limiter, using the tool available at the IVECO Assistance Service, please note that:
The accuracy of the speed limiter is reduced at low vehicle speeds.
The accuracy of the speed limiter is reduced at low engine speeds: interference with the engine idle speed regulator is possible, particularly below 1000 rpm.
The speed limiter must only be used in 1st gear or in reverse gear.
The speed limiter may be adjusted in steps of 1 km/h by the IVECO Assistance Service.
The bodybuilder must check the functionality of the speed limiter for each application and is also responsible for preparing the relative
specific instructions.

The signals to the Multiple State Switch may also be simultaneous to requests coming from the Expansion Module through CAN open
(object 0x2001, sub 0x0C) or through activation of "PTO1/PTO2/PTO3 Memo Speed". The highest value prevails in the event of contemporaneity.
(2)

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

Figure 10

230827

For this purpose IVECO recommends use of a relay (not identical to that
for the Cruise Control interface) which enables utilization of the same
functions available on the steering wheel lever.
The Cruise Control option must be configured on both the ECM and BCM
systems.
Please note that the driver must position the cruise control switch on
the steering wheel lever to OFF, otherwise the external controls will be
ignored.

Function

Short-cut necessary

ISC Mode 1

Pin 2

Pin 6

ISC Mode 2

Pin 5

Pin 6

ISC Mode 3

Pin 8

Pin 6

Figure 11

230826

(3)

Obligatory insertion of a 5 k pull-up resistor in addition to a diode as outlined in Figure 12.

The pull-up resistor and the diode must be fitted by the Bodybuilder.
The resistor must be inserted between 72075A / Pin 4 and 61071A / Pin 11.
Without the pull-up resistor no B7 signal is available.

Printed 603.95.994 1 Ed. - Base 05/2015

DAILY MCA2014 4x4 BODYBUILDER INSTRUCTIONS


ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

Figure 12

230825

1.

2.
3.

Outfitting

Connector 61071A
Connector 72075A

The B7 output supplies the signal relating to the speed according to [ISO16844-2].
Table 5.5 - Tachimetric signal characteristics
Function

Parameter

min

Voltage Ulow
Tachograph output B7

Voltage Uhigh

Printed 603.95.994 1 Ed. - Base 05/2015

Unit of
measurement

1.5

I = 1 mA

I = 1 mA

5.5

Frequency (1/T)
Pulse duration (t)

max

0.64

1.6

kHz

ms

Remarks

Square wave

15

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ELECTRONIC SUB-SYSTEMS
5.2BODYBUILDER CONNECTORS

230830

1. Speed signal (terminal B3) of the movement sensor fitted


on the reduction unit

Figure 13

2. Temporal diagram and form of the pulse speed signal


(terminal B7) from tachograph
a. Pulse delay: max 40 s 10 s jitter

(4)

WARNING:

If the K15 Remote control was activated and the operator removed the ignition key with the engine running, the engine would not stop and it would be possible to move the vehicle with the steering locked. Therefore:

The K15 Remote control must not be activated with the engine running.
Similarly, to avoid unexpected movements of the vehicle with gear engaged, the engine must not be running when
the K15 Remote control is activated.

If, in spite of such requirements, engine operation must still be possible, IVECO recommends using the RunLock function offered by the Expansion Module (if present): please consult the specific manual EM 603.95.826 (currently being updated at the time of publication of the
present document).

(5)

Rpm signal

The rpm signal is a square wave.


The characteristics of the rpm signal are:

4 pulses for each revolution of the crankshaft;


frequency field 0 400 Hz (corresponding to 06000 revs/min);
duty-cycle fixed at 50%.

Printed 603.95.994 1 Ed. - Base 05/2015

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17

5.2BODYBUILDER CONNECTORS

Table 5.6 - Engine speed signal characteristics


Characteristics

Condition

Minimum

Maximum

Unit of measurement

C_EMI

3.76

5.64

nF

C_IO

3.76

6.14

nF

I_Out

2.2

I_Out_SC

I_Leak_Off

20

I_Out_Diag

980

3.77

V_OC

3.23

V_THR

4.7

5.4

V_Out_Low

1.76

R_ON

800

E_Clamp

mJ

V_Out_Clamp

60

R_Load_Diag

4.69

Legend:

C_EMI:

EMI capacity at the connector terminals

C_IO:

capacity between input and output (in the event of output stage: C_IO is valid if the output stage is turned off)

I_Out:

output current

I_Out_SC:

output current

I_Leak_Off:

loss of current if the ECU is no longer powered

I_Out_Diag:

loss of current with ECU powered, but PS no longer powered. This parameter defines the ability of the hardware to provide a diagnostic current. The actual existence of the diagnostic current depends on the software configuration

V_OC:

voltage between CON_PIN and ground with open circuit

V_THR:

open load threshold voltage

V_Out:

output voltage

V_Out_High:

output voltage, HIGH level

V_Out_Low:

output voltage, LOW level

R_ON:

output resistor ON

E_Clamp:

energy at the output terminals

V_Out_Clamp: voltage at the output terminals

R_Load-Diag:

Maximum diagnosable load resistance

t_Fall:

signal fall time from 90% to 10%

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ELECTRONIC SUB-SYSTEMS
5.3ELECTRONIC CONTROL UNITS

208224

1. Body builders connector


2. Separation diode REQUIRED

Figure 14

3. Interface responsibility of the designer of the processor


4. Signal processor

The bodybuilder must install a special separation diode so as not to lower the VON voltage.
The designer of the signal processor must ensure an input interface equal to that represented with a max. voltage VCC of 5 V and pull-up /
pull-down so as not to lower the voltage VON and to raise the response time set by the vehicle interface.

5.3ELECTRONIC CONTROL UNITS


Precautions to be used with electronic control units installed
In order to avoid operations that could permanently damage or degrade the functioning of the vehicle ECUs, it is advisable to:

remember that connection and disconnection from battery terminals may generate voltages that adversely affect vehicle electronic systems and control units;
do not disconnect and/or connect connectors from/to the control units with engine running or control units powered;
detach the electronic control units where particular processing operations involve temperatures above 80C;
absolutely never employ a rapid battery charger for emergency start-up because it could damage the electronic systems, particularly the control units that manage the ignition and power supply functions;
do not supply current to components served by electronic modules with jumper cables
connect the control units equipped with metal casing to the ground of the system using a screw or bolt unless otherwise specified.

In case of any work on the chassis requiring arc welding:

disconnect CBA1 from the battery positive terminal and do not connect it to the chassis ground;
disconnect the control unit connector;
disconnect the control unit from the chassis (in case of welding near the control unit itself);
perform welding with continuous current;
ground the welding machine as close as possible to the welding point;
do not place the battery cables parallel to the vehicle's electric cables.

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19

5.3ELECTRONIC CONTROL UNITS

Use only fuses with the features prescribed for the specific function. NEVER USE FUSES WITH
A CAPACITY HIGHER THAN THE PRESCRIBED. Replace using only keys and disconnected
users.

Restore the original conditions of the wiring (paths, protections, strips, completely preventing the cable from coming into contact
with the surface of the metal structure that can affect its integrity), if operations have been carried out on the system.
Warning
The vehicles are equipped with sophisticated electrical/electronic systems that monitor their operation (e.g. ABS, EDC, etc.).
Therefore, before installing additional heaters, power take-offs, speed limiters, anti-theft devices, mobile phones or refrigerator
compressors for systems that can interact with these electronic systems, it is advisable to verify the feasibility of the application with
IVECO.
In addition, it is necessary that adequate diagnostic checks are carried out to verify the proper construction of the system.
For more detailed information on the vehicle's electrical system, refer to the specific Repair Manuals.

Electrical work (e.g. removing cables, adding circuits, replacing equipment or fuses, etc.), performed in a manner inconsistent with the IVECO instructions or by unqualified personnel, can
cause serious damage to electronic control units and compromise driving safety.

Any electrical work that is carried out in non-compliance with regulations may cause substantial
damage (e.g. short circuits with the possibility of fire and destruction of the vehicle) and authorises IVECO to annul the warranty.

Note For any exception to mounting instructions, IVECO's written authorisation is necessary.
Lack of observance of above described prescriptions involves guarantee lapse.
Disconnecting electronic control units

Interventions which do not comply with the instructions specified by IVECO or which are performed by unqualified personnel may cause severe damage to on-board systems, affect driving
safety, reliability and vehicle functioning and cause considerable damage which is not covered by
the warranty.

The following instructions must be strictly observed before disconnecting an electronic control unit:

turn the ignition key to OFF and remove it;


switch off the additional heaters and wait for the end of the cooling down cycle (the warning light of the corresponding key
will go out);
switch on the reading spotlights centrally positioned on the cross member;
isolate the battery by disconnecting the power cables: first the negative pole followed by the positive pole; the aforesaid spotlights are now off;
disconnect the control unit.

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ELECTRONIC SUB-SYSTEMS
5.4ELECTRICAL SYSTEM: CURRENT INTERVENTIONS AND DRAWS

Repositioning electronic control units


IVECO recommends avoiding modifications which entail the repositioning of the electronic control units. However, if repositioning
is unavoidable, please follow the instructions below:

the electronic control units must be positioned on the chassis or in the cab and secured with a fastening similar to the original
one (i.e. suitable bracket);. The device must not be rotated in relation to the chassis so as to avoid potential malfunctions (eg.
infiltration of water). Therefore the original positioning must also be maintained;
the electronic control units must not be fitted on the counter chassis;
the covering must always be reinstalled;
the control units must not be subjected to impact from road debris or stones coming from the vehicle's wheels when in motion.

5.4ELECTRICAL SYSTEM: CURRENT INTERVENTIONS AND DRAWS


General information
Vehicles are set to function normally with a 12 V electrical system.
The chassis represents the grounding (it acts as a current return conductor between the components located on it and the battery power source/alternator) and it is connected to the negative pole of the battery and components, if an isolated return is not
provided for this.
When installing additional equipment or additional circuits, the following indications must be taken into account and, depending on
the complexity of the operation, there must be proper documentation (e.g. wiring diagram) to match that of the vehicle.
The use of cables and connections with colours/codes identical to those used on the original vehicle makes installation correct and
facilitates any repair work.
For effective and proper use of the electrical system, specific connection points for additional equipment have been prepared. This
was necessary to exclude any type of alteration of the basic design, so as to ensure its functional integrity and therefore maintain
the vehicle guarantee.
Note For more detailed information on the vehicle's electrical system, please consult the NEW DAILY 4x4 Repair Manual, printout no.
603.95.979.
This manual is available at the Service Network and can also be obtained from Sales Agencies.
Precautions for work on the system

Interventions on the electrical system (e.g. removal of cables, addition of circuits, replacement
of equipment or fuses etc.) carried out in a manner which is not compliant with IVECO's instructions or carried out by non qualified personnel, can cause severe damage to on-board systems
(control units, wiring, sensors etc.), affect driving safety and good operation of the vehicle and
cause serious damage to the vehicle (e.g. short circuits with the possibility of fire risk or destruction) which is not covered by warranty.

Before removing any electrical/electronic equipment, disconnect the ground cable from the battery negative pole and then the
positive cable.
To prevent damage to the vehicle's electrical system, follow the instructions of the cable manufacturer.

The cables must have suitable sectioning for the type of load and the position of the load in the vehicle.
The power cables (+ direct) must be:
individually intubated in conduits (of suitable diameter) and not together with other different cables for signal and negative;

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5.4ELECTRICAL SYSTEM: CURRENT INTERVENTIONS AND DRAWS

placed at least 100 mm (reference value = 150 mm) from high heat sources (turbine, engine, exhaust manifold, etc.);
placed at least 50 mm from containers of chemical agents (batteries, etc.);
placed at least 50 mm from moving parts.
The path of the cables must be defined with brackets and clamps dedicated and reconciled, to avoid hanging parts and to be
able to restore the same installation after repairs or interventions.
The cables must have a suitable sectioning for the type of load and the position of the load in the vehicle.
The passage of cables through holes and on the edges of metal sheets must be protected by cable gaskets in addition to the
corrugated tube
It is not possible to specially drill the chassis to allow the cables path.
The corrugated tubing must completely protect the entire cable and be connected (with heat shrinking or taping) to the rubber caps on the terminals.
All the positive terminals and cable terminals must be protected by rubber caps (for hermetic in areas exposed to weathering
or with possible stagnation of water).

Use fuses with the prescribed capacity for the specific function, and do not under any circumstances use higher capacity fuses.
Restore the original condition of the wiring (paths, protections, strips) making absolutely certain that the cable does not come into
contact with any metal surfaces of the structure which could affect its integrity.
Precautions for work on the chassis
For work on the chassis, to protect the electrical system, its equipment and ground connections, respect the precautions shown in
Chapter 2.1 - Paragraph "Special precautions ( Page 5)" and Chapter 2.3 - Paragraph "precautions ( Page 11)".
In cases where the application of additional devices requires it, the installation of protective diodes for inductive current spikes must
be provided for.
The ground signal from the analogue sensors must be wired exclusively on the specific receiver; additional ground connections may
distort the output signal from this sensor.
The cable bundles for low signal intensity electronic components must be arranged parallel to the metal plane of reference, that
is adherent to the chassis/cab structure, in order to minimise parasitic capacities; space the path of the cable bundle added to the
existing one as much as possible.
The added systems must be connected to the ground of the system with the utmost care (see Chapter 5.4 - Paragraph "Ground
points ( Page 22)"); the related wiring harnesses should not be coupled to the electronic circuits that already exist on the vehicle
in order to avoid electromagnetic interference.
Ensure that the wiring of the electronic devices (length, type of conductor, dislocation, strips, cable shielding connection, etc..) comply with the original IVECO provision.
Carefully restore the original system after any operations.
Starting the engine

If the engine fails to start because of the battery and not because of problems with the electrical system, do not try to start
the engine by towing.
The battery must be disconnected from the vehicle's electrical system before recharging it.
Starting the engine with auxiliary methods must only be carried out using an external battery trolley.

It is strictly FORBIDDEN to use a quick battery charger for emergency start-up: due to the high
voltages applied, the electronic systems and the control units could be seriously damaged. Any
damage to the electronic control units is not covered by the warranty.

The tanks must contain sufficient fuel during the engine start-up phase, in order to avoid serious damage to the injection system.

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Ground points
In general, original vehicle ground connections are not to be modified; in cases where these connections must be moved or new
connections added, use the holes present on the chassis to the extent possible, taking care to:

mechanically remove - either by filing and/or with a suitable chemical based solution - the paint on both the chassis and terminal side, thus creating a contact surface free of indentations and edges;
paint the area between the terminal and metal surface with a suitable high conductivity paint
connect to earth within 5 minutes after application of the paint.

As regards the signal related ground connections (e.g. sensors or low-absorption devices), do not use the standardized points Under no circumstances use standardized points for engine ground connection and chassis ground connection.
Additional signal grounds must be positioned at different points from the power ground.

191316

1.

Ground connections: (A) connection is correct; (B) connection is incorrect

2.
3.

Figure 15

Correct cable fastening to the ground point using: (A)


screw, (B) cable terminal, (C) washer, (D) nut
Cable connected to ground

228306

Position of ground points on vehicle


m1. Ground for battery/body
m2. Ground for body/chassis
m3/ms3.Engine compartment ground under servobrake
m4. Ground for engine compartment behind the front right
headlight

Figure 16

Ground for engine compartment behind the front left


headlight
m6/ms6.Cab interior ground, central section
m7. Cab interior ground, central section
m8. Ground on chassis behind the cab
m9. Ground on left side rear cross member
m10. Ground on chassis
m5.

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230821

m1.

Ground for battery-body

m2.

Figure 17

Ground for body-chassis

208941

m3/ms3.Engine compartment signal/power ground below servobrake

Printed 603.95.994 1 Ed. - Base 05/2015

Figure 18

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m4.

208942

Figure 19

208943

Figure 20

Engine compartment ground near front right headlight

m5.

Engine compartment ground near front left headlight

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208944

m6/ms6.Signal/power ground inside cab on the central body


panel below the tachograph

m7.

Figure 21
Ground inside cab on the central body panel below the
tachograph

230822

m8.

Ground on chassis behind the cab

Printed 603.95.994 1 Ed. - Base 05/2015

Figure 22

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m9.

120383

Figure 23

230829

Figure 24

Ground on left side rear cross member

m10. Ground on chassis


The negative leads connected to a ground point in the system must be as short as possible and must be connected to each other in
a "star" formation, while tightening must be done in an orderly and adequate manner.
As far as electronic components are concerned, the following instructions should be followed:

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electronic control units must be connected to the system ground when equipped with metal housings
the negative cables of the electronic control units are to be connected to a system ground point, connected to the negative
terminal of the battery;
the analogue grounds (sensors), while not being connected to the system ground/negative terminal of the battery, are to have
good conductivity. Consequently, particular care should be given to terminal parasitic resistances: oxidation, scratches, etc
the metal braid of the shielded circuits must be in electrical contact only at the control unit side to which the signal is to be
sent
In the presence of junction connectors the unshielded section d, near them, should be as short as possible;
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

191317

Figure 25

"STELLA connections of various negatives with the system ground

191318

Figure 26

Shielding by means of a metal braid of a cable leading to an electronic component


Electromagnetic comparability
It is recommended that electrical, electro-mechanical and electronic devices which comply with the following immunity requirements for electromagnetic emissions, both irradiated and conducted, are used, as shown below:
The level of electromagnetic immunity of the electronic devices equipping the vehicle at a distance of one metre from the transmitting aerial must be:

50 V/m immunity for devices performing secondary functions (not impacting on direct vehicle control), for frequencies varying from 20 MHz to 2 GHz
100 V/m immunity for devices primary secondary functions (not impacting on direct vehicle control), for frequencies varying
from 20 MHz to 2 GHz;.

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The maximum excursion allowed for transient voltage with appliances powered at 12 V is +60 V, measured at the terminals of the
artificial network (L.I.S.N.) if tested at the bench; otherwise, if tested on the vehicle, the excursion must be recorded in the most
accessible location close to the disruptive device.
Note Devices powered at 12 V be immune to interferences such as negative spikes of -300 V, positive spikes of +100 V, bursts of +/150 V.
They must operate correctly during the phase when voltage drops to 5 V for 40 ms and to 0 V for 2 ms.
They must also resist the load dump phenomena up to 40 V.
The maximum radiated emission levels measured at the bench and the levels of conducted emissions generated by devices and also
by 12 V power supplies are given in the following table:
Table 5.7 - Electromagnetic emission levels
Frequency range and limits acceptable in dBV/m
Type of
emission

Type of
transducer

radiated

Aerial at
a
distance
of 1
metre

radiated
radiated
conduit
conduit
conduit

LISN
50
5 H
0.11 F

150300
kHz

0.532
MHz

5.96.2
MHz

3054
MHz

68-87
MHz
mobile
services
only

almost
peak

63

54

35

35

24

24

24

31

37

Broadband

peak

76

67

48

48

37

37

37

44

50

Narrow
band

peak

41

34

34

34

24

30

24

31

37

Broadband

almost
peak

80

66

52

52

36

36

Broadband

peak

93

79

65

65

49

49

Narrow
band

peak

70

50

45

40

30

36

Type of
disturbance

Type
of detector

Broadband

76-108
MHz
broadcast
only

142175
MHz

380512
MHz

820960
MHz

Not applicable

Unit of
measurement

dBV/m

dBV

Use electrical/electronic equipment in compliance with the UNECE directive on electromagnetic compatibility.
Only components with certified approval and with mark "e are allowed: the "CE marking is not sufficient.
By way of example, the mark prescribed by the current UNECE 10R3 on electromagnetic compatibility in the automotive field is
shown below:

191312

Figure 27

a 6 mm
The values in the table are only to be considered respected if the device comes form "IVECO Spare Parts or it has been certified
as per the international standards ISO, CISPR, VDE etc.

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Whenever equipment is used which runs on mains power (220 V AC) for its primary or secondary source of power, it must be
checked to ensure that its characteristics are in line with IEC regulations.
Reception/transmission systems
The most frequent applications include:

amateur receiver-transmitter units for CB (City Band) and 2 m bands.


GPS receiver and satellite navigation units.

General instructions
1.

2.

3.

4.

5.

The equipment must be approved according to the law and be of a fixed nature (not potable).
The use of non approved transmitters or supplementary amplifiers could seriously impede the correct functioning of the
electrical/electronic devices normally supplied, with negative effects for the safety of the vehicle and/or the driver.
The system already provided on the vehicle must be used to power the transmitters and they must be connected to terminal
K30 of the connector ST40 (and K15 where necessary) via a supplementary fuse.
Any additional power lines must be created respecting the correct sizing of cables and protection.
The coaxial antenna cable must be positioned taking care to:
use a low loss, top quality product with the same impedance as the transmitter and the antenna (see Figure 29);
in order to avoid interference and malfunctioning, create a path (the shortest possible) which maintains a suitable distance (min. 50 mm) from pre-existing cabling or from other cables (radio, amplifiers and other electronic equipment),
keeping the minimum distance from the metal structure of the cab and using existing holes in the sheet metal;
do not shorten or lengthen; avoid unnecessary tangles, tension, folds and crushing.
Outside the cab, the antenna must be installed on the vehicle on a metal base with a wide surface; it must also be fitted as vertically as possible with the connection cable pointing downwards and, in any case, following the manufacturer's fitting instructions and warnings (see Figure 28).
Installation at the centre of the roof is to be considered the absolute best as the ground plane is proportional in all directions.
Inside the cab, the transmitter equipment must be positioned as shown in Figure 30.
The quality of the antenna, the mounting position and a perfect connection to the vehicle structure (ground) are factors of
fundamental importance to guarantee the best performance of the transmitter equipment.

98915

1. Antenna support
2. Gasket
3. Fixed joint cover

Printed 603.95.994 1 Ed. - Base 05/2015

Figure 28

4. Fastening screw M6x8.5 (tighten to a tightening torque of


2 Nm)
5. Aerial
6. Roof panel
7. Antenna extension cable

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99349

1. Antenna connector
2. Ground wire
3. Insulator
4. Signal wire
5. Condenser (100 pF)
6. Cable RG 58 (characteristic impedance = 50 )
7. Clamp
8. Protection cap

Figure 29

9. Connector (N.C. SO - 239) transreceiver side


10. Test executed sticker
11. The 100 pF condenser must be soldered on the lower pin
and crimped to the ground braid
12. The lower pin must be soldered to the core conductor of
the cable
13. Nut

Some specific instructions are given below for each type of equipment.
Amateur equipment for CB (27 MHz) and 2 m band (144 MHz)
The transmitter part must be installed in a separate area from the vehicle's electrical components; if the transmission is impulsive it
must be at a distance of least one metre away from other devices.

The ROS value (Stationary Wave Ratio) must be as close as possible to the unit (the recommended value is 1.5), while the
maximum acceptable value must never be greater than 2.
The ANTENNA GAIN values must be as high as possible and guarantee a sufficient level of spatial uniformity, characterised
by deviations in relation to the average value to the order of 1.5 dB in the typical CB band (26.965-27.405 MHz).
The IRRADIATED FIELD in cab value must be as low as possible, and however < 1V/m.
In any case, limits set by the applicable European legislation must never be exceeded.

To determine whether the system is functioning well and to check that the antenna is calibrated, it is suggested that the following
information is taken into account:
1.
2.

if the ROS (Stationary Wave Ratio) is higher on the lower channels than on the higher ones, the antenna should be
lengthened
if the ROS (Stationary Wave Ratio) is higher on the higher channels than on the lower ones, the antenna should be shortened

After having calibrated the antenna, it is advisable to re-check the ROS (Stationary Wave Ratio) value on al the channels.

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208937

1. Location of the CB receiver-transmitter equipment


Bluetooth setup
The Bluetooth setup consists of:

specific control unit, positioned above the radio and hidden by a plastic cover,
buttons on the steering wheel;
ceiling fixture with microphone;
USB socket;
wiring.

Printed 603.95.994 1 Ed. - Base 05/2015

Figure 30

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208938

1. Buttons on the steering wheel

Figure 31

2. USB socket

For cowl version vehicles the ceiling fixture with microphone is provided in the box of accompanying material.
If installation in the cab requires it, the microphone can be removed and recovered; its position, however, must be made at a point
as far away as possible from sources of noise and with respect to the reception area described in the following image.

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208949

1. Driver's side

Figure 32

2. Passenger side

208947

Figure 33

1. Bluetooth microphone
Table 5.8
Pin

Description

Cable

Ground

White

Signal + Vcc

Shielded

The connector of the microphone connection, on the cab wiring side, is located in correspondence with the ceiling connectors.

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GPS reception and satellite navigation equipment


Install the transmitting part in a flat, dry area, separate from the electronic components of the vehicle, away from humidity and
vibrations. If the transmission is impulsive it must be at a distance of at least one meter away from other devices.
The GPS antenna must be installed so as to have the maximum visibility possible of the sky.
In fact, as the signals received from the satellite are at very low power (approximately 136 dBm), almost any obstacle can influence
the quality and performance of the receiver.
The following should therefore be guaranteed:

an absolute minimum angle of vision of the sky of 90


a distance no less than 30 cm from any other antenna
a horizontal position and never underneath any metal which makes up part of the cab structure.

Moreover:

the ROS value (Stationary Wave Ratio) must be as close as possible to the unit (the recommended value is 1.5), while the
maximum must never be greater than 2 in the GPS frequency range (1575.42 1.023 MHz).
the ANTENNA GAIN values must be as high as possible and guarantee a sufficient level of spatial uniformity, characterised by
deviations in relation to the average value to the order of 1.5 dB in the 1575.42 1.023 MHz band.

Radio installation
Refer to the information contained in the Use and Maintenance Manual

Additional equipment
Power for the equipment, when the voltage required is different to that for the system, must be obtained using a suitable DC/DC
12-24V converter if not already provided. The power cables must be as short as possible, avoiding any twists (coils) and maintaining
the minimum distance from the reference plane.
Note If devices are fitted which could interact with the electronic systems already present (retarders, additional heaters, power take-offs,
air conditioners, automatic gearboxes, telematics and speed limiters) please contact IVECO in order to establish the compatibility
checks.

The use of non approved transmitters or supplementary amplifiers could seriously impede the
correct functioning of the electrical/electronic devices normally supplied, with negative effects
for the safety of the vehicle and/or the driver.

Any damage caused by the use of non-certified transceivers or by the application of additional
amplifiers is not covered by the warranty.

The vehicle system is set up to supply the necessary power to the equipment provided, for each of which, as part of their function,
the specific protection is assured as well as the correct sizing of cables.
The installation of additional equipment must include suitable protections and should not overload the vehicle system.
The connection of the added users to ground must be made with an adequately sectioned cable, as short as possible and made to
allow for any movements of the added equipment with respect to the chassis of the vehicle.
Having the need for higher capacity batteries, due to added loads, it is appropriate to request the optional with increased batteries
and alternators.

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In any case, when increasing battery capacity, it is advisable not to exceed 20-30% of the maximum values provided as optional by
IVECO, so as not to damage some of the components (e.g. starter motor). When higher capacities are necessary, use additional
batteries, making the necessary provisions for recharging as indicated below.

Additional batteries
The addition of a battery in the vehicle electrical system requires the provision of a circuit that, during start-up, makes it possible to
section this battery with respect to the original. Given the new "smart" recharge strategies, the auxiliary battery must be equivalent
to the originally installed battery and must have the same capacity (110 Ah).
In cases where it is necessary to use an additional battery in parallel with the series, we recommend the use of a larger alternator or
the installation of an extra alternator.
The batteries can be traditional or "recombination" (AGM or gel).
Due to the normal chemical reaction that generates acid vapours during charging, installation must be performed in a way that
ensures the safety of people and the protection of the vehicle.
Therefore, regardless of the type of battery, if you do not already have a segregated compartment, it is necessary to:
a)provide an airtight container corresponding to the passenger compartment, equipped with a system that vents vapours to the
outside of the vehicle,
or
b)use a battery equipped with a lid with a vapour extraction system, anti-backfire (flame arrestor) system and a vent tube to the
outside of the housing.
Also bear in mind that:

vent systems should not cause depression inside the battery;


the vapour release point must not be in areas where sparks can be triggered or near hear sources;
the maximum allowable temperatures, for a short period of time, are 50C for conventional batteries and 40C for AGM or
gel batteries.

Ground connection of the additional battery must be made using a cable (the shortest possible)
of adequate section.

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Figure 34

208936

1. Standard battery
2. Additional batteries
3. Alternator with built-in regulator
4. Starter motor
5. Ignition switch
6. Contactor switches

7. Body Computer
8. Engine Management control unit
9. Auxiliary load
10. Vehicle load
11. LIN bus

All the lines downstream of all batteries are to be adequately protected, under any fault condition. Failure to ensure adequate protection may pose a fire hazard and a danger to persons.

Additional alternators
The NEW DAILY 4x4 is equipped with an advanced smart alternator controlled by the engine ECU.
This alternator is capable of delivering electrical current only when it is really necessary, and is able to always guarantee a correct
state of battery charge through the sensor on the negative pole.
In cases where there are very onerous electrical loads a second alternator may be used, and it must be installed (with all the mechanical requirements necessary for compatibility with the vehicle and under the responsibility of the bodybuilder) according to the
diagram in Figure 35.
The additional alternator must be of the traditional type, with pin L connected in order to ensure excitation with a current
between 150 and 200 mA. The diagnostic light is optional, but a resistance is still necessary to ensure excitation.
Dual alternator operation requires that the additional traditional alternator is the one that delivers in any condition (as it is not controlled), while the original "smart" alternator intervenes when the electrical balance becomes negative (the battery charge status is
monitored)

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The diagnosis of the two alternators is ensured by:

a battery indicator on the instrument panel, with regard to the first alternator
an external diagnostic light (if installed) for the additional alternator

208950

1. "Smart" first use alternator


2. Additional standard alternator
3. Battery
4. Electrical loads
5. Signal +15 from ignition switch

Figure 35

6. Body Computer
7. Instrument panel
8. Diagnostics Lamp or LED +Res. (current between 150
and 200 mA)
9. Engine Management control unit

The installation of additional equipment must include suitable protections and should not overload the vehicle system.
The additional alternators must be the type with Zener diode rectifiers to avoid damaging electric/electronic equipment due to
accidental battery disengagement. Each alternator must also have a light or LED indicating low battery charge.
The additional alternator must have electrical features identical to those of the standard alternator and the cables must be correctly
sized.
If you need to modify the system in a way other than described in this manual (for example, adding batteries in parallel), it is necessary to share the operation with IVECO.

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Drawing current
Information about the points where you can take samples of available current and directions to be followed are below.

Figure 36

228307

1.
2.

CBA2
Cable path between cab and engine compartment

3.

Body builders Connector (inside cab)

Current sample from the CBA2 control unit in the engine compartment
There are two fuses (FF and FG) installed in CBA2, reserved for the body builders; the terminals (HI) and (MI) downstream of
these fuses are the only two points reserved and authorised for sampling currents.

209810

HI. Current take off point protected by Body builders fuse FF

Figure 37

MI. Current take off point protected by Body builders fuse FG

The fuses for body builders supplied with the original equipment have a capacity of 30 A each.

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5.4ELECTRICAL SYSTEM: CURRENT INTERVENTIONS AND DRAWS

If necessary they can be replaced with ones of a higher load respecting the indication of a maximum total withdrawal (sum of the
two fuses) equal to 130 A.

Precautions
In general it is advisable to:

adopt, where necessary, adequate protection fuses applied in the vicinity of the sample;
protect cables inserted into the proper sheathing or corrugated cables, installing according to the recommendations in
Chapter 5.4 ( Page 20) - Paragraph: "Precautions for operations on the system".

And in CBA2 installation it is necessary to:

avoid removing the fuses from their position;


put the terminals on the studs and secure them with the nuts (M5 flanged nut, self-locking, etc.), tightening to torque (4 to 6
Nm);
It is absolutely forbidden to draw current from unauthorised points. FIRE HAZARD.

Fuses on CBA1 control unit on battery

208221

Figure 38

Table 5.9 - List of fuses on CBA1


Location

Amperage [A]

150

Power supply CBA2

200

Power supply SCM and Body builders

500

Starter and Retarder

80

Body Computer power supply

Printed 603.95.994 1 Ed. - Base 05/2015

Description

TGC (opt)

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Fuses on CBA2 control unit in the engine compartment

209812

Figure 39

Table 5.10 - List of fuses on CBA2


Location

Amperage [A]

Description

150

Retarder

150

SCM Power supply

30

Body builders pre-installation

30

Body builders pre-installation

60

Pre- / post- heating unit

30

Urea module

100

PTC power supply

40

ABS

Passage of cables from cab interior to cab exterior


In the engine compartment, close to the servo brake, through the five premade 10 mm holes in the bulkhead, it is possible the to
pass the electric cables from the cab to the engine compartment. Adequately seal the cable passage area to avoid passing fumes
from the engine compartment to the cab.

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Figure 40

119355

Any damage caused by failure to comply with procedure is not covered by warranty.

Additional circuits
The additional circuits must be separated from the vehicle and protected by means of a specific fuse
As already seen in the Paragraph "Precautions for work on the system", the used cables must be:

of appropriate sizes and equipped with good original insulation;


connected to the original system by means of tin joints equivalent to the original ones, protected with sheaths (not PVC) or
intubated in polyamide conduits of type 6;
installed protections from shock, heat, rubbing with other components (in particular with the sharp edges of the bodywork);
secured separately with insulated cable clamps (e.g. nylon) and at suitable intervals (approx. 200 mm).

The passage through crossbars and/or sections must provide special fairleads or protections; it is not possible to drill the chassis
and/or the bodywork.
In case of external panels, use a specific sealant both on the cable and on the panel to prevent water, dust and fumes from infiltrating.
Where possible it shall also be provided a different cable path that transfers interference signals with high absorbed intensity (e.g.
electric motor, solenoid valves) and low absorbed intensity susceptible signals (e.g. sensors); for both must be remained a positioning as close as possible to the metallic structure of the vehicle.
Plug and terminal connections must be protected, resistant to weathering, and executed using components of the same type as
those utilised originally on the vehicle.
Use cables and fuses with the characteristics shown in the following table in accordance with the current draw:
Table 5.11- Use of cables and fuses according to the current drawn
Max. continuous current

Printed 603.95.994 1 Ed. - Base 05/2015

(1)

[A]

Cable cross-section [mm]

Fuse capacity

04

0.5

4-8

10

8 16

2.5

20

16 - 25

30

25 - 33

40

33 40

10

50

40 - 60

16

70

60 - 80

25

100

(2)

[A]

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Max. continuous current

(1)

(1)

[A]

Cable cross-section [mm]

Fuse capacity

80 100

35

125

100 - 140

50

150

(2)

[A]

For uses of more than 30 seconds.

Depending on the position and therefore the temperature that may be reached in the housing, choose fuses that can be loaded to up to
70%- 80% of their maximum capacity.
(2)

The fuse must be connected as close as possible to the current take-off point.

Precautions

Incorrect installation of electrical accessories may affect occupant safety and cause severe damage to the vehicle. Contact
IVECO if you have any questions.
It is necessary to avoid coupling with the signal transmission cables (eg. ABS), for which preferential routing has been provided
in order to meet electromagnetic requirements (EMI).
It should be noted that when grouping several cables together, in order to compensate for lower heat dispersal capacity, the
current intensity must be reduced with respect to the nominal value of a single cable.
In vehicles with frequent engine start-ups, with limited current drawn and engine rotations (e.g.vehicles with refrigeration
chambers), provide for periodic battery charging to maintain efficiency.
Plug and terminal connections must be protected, resistant to weathering, and executed using components of the same type
as those utilised originally on the vehicle.
In the event that a component has to be installed just next to the route of a cable belonging to the original system, make sure
that its remains integral and avoid any cuts.

209813

Figure 41

Any damage caused by failure to comply with procedure is not covered by warranty.

Printed 603.95.994 1 Ed. - Base 05/2015

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Modifying wheelbase and overhang


Should it be necessary to lengthen the wires on the chassis owing to the new dimensions of wheelbase and overhang, a watertight
junction box must be used which has the same characteristics as those used on the standard vehicle. The electrical components
used such as wires, connectors, terminal blocks, conduits etc. must be of the same type as those used originally and must be correctly fitted.
As for the functionality of the electronic control devices, junctions are not permitted: the cable must be replaced with a new one
with similar characteristics to the one used on the vehicle and of adequate length.
Trailer setup
If the repetition of rear lights is necessary, the vehicle must be fitted with the 13-pin trailer socket.
Do not hook up directly to the vehicle's light cables. This results in current overloads which are recognised as malfunctions by the
on-board computer.
If the vehicle is not equipped with a trailer socket, it is possible to order a special kit comprising of:

control unit with fastening bracket and guard;


chassis cable with trailer configuration;
rear bridle for trailer socket.

For proper instillation it is necessary to:

mount the electronic control unit onto the bracket; on the cab version also mount the guard;
mount the entire bracket plus control unit onto the chassis as shown in Figure 42;
replace the chassis cable with the new cable configured for the trailer socket (see Figure 43);
fit the connection bridle for the 13-pin socket compatible with the type of hook (high or low) (see Figure 44).

209814

A. Side view
B. Rear view

Printed 603.95.994 1 Ed. - Base 05/2015

1. Trailer electronic control unit


2. Support bracket
3. Guard

Figure 42

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Figure 43

209816

Chassis cable with 13 pin socket and trailer control unit


1. Chassis cable
4. 13-pin trailer socket
2. Connections with cab wiring
5. Tail lights
3. Trailer electronic control unit

Note The graphic is for illustration purposes only.

209815

1. Connector 86046_1 to connect to connector 1 (OUT) of


trailer control unit

Figure 44

2. Connector ST63 to connect to chassis wiring


3. 13-pin trailer socket 72016

For further details on connections and installation, request wiring diagrams from IVECO.

Any damage to the light system caused by failure to comply with procedure is not covered by
warranty.

Printed 603.95.994 1 Ed. - Base 05/2015

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Table 5.12 - 13-pin trailer socket


Pin

Description

Cable code

Remarks

Rear left turn indicator

1120

1 21 W- 12 V lamp

Rear fog lamp power supply

2283

2 21W - 12V lamps

Ground

0000

Rear right turn indicator

1125

1 21 W- 12 V lamp

Front left and rear right parking light


Left license plate light and left side marker light

3335

3 5 W - 12V lamps

Stop signal lights power supply

1175

2 21W - 12V lamps

Front right and rear left parking light.


Right license plate light and right side marker light

3334

3 5 W - 12V lamps

Power supply for reverse light

2268

2 21W - 12V lamps

After fuse F67 present on SCM1/B

7777

Battery positive

10

After fuse F49 present on Body Computer

8879

Positive with key

11

Ground

0000

1.

12

Trailer connection signal (Ground)

6676

13

Ground

0000

2.

Signal to be supplied through connection on the trailer,


to permit trailer lights and parking sensor diagnostics (if
present)
Pin 12 could be absent as it may have been replaced
by a switch integrated in the socket; in this case it is not
necessary to perform any connection on the trailer

The electrical connection of a trailer entails a considerable increase in the length of the cables
and results in a larger voltage drop on the line. Therefore the use of cables with the biggest possible cross-section is recommended, which are compatible with the system layout and with the
13-pin socket; on this it is then necessary to divide the ground return by using all three pins 3, 11
and 13.

Side Marker Lamp installation


The installation of the lateral lights must be performed on the additional structures (containers, vans, etc.), while the electric power
supply must be obtained by the specific ST38 connector on the chassis (see Figure 45).
In order to keep the electrical characteristics of the contacts of the female socket unchanged, the hood supplied by IVECO must be
left attached.

It is not possible to draw current from side marker lights.

Printed 603.95.994 1 Ed. - Base 05/2015

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ELECTRONIC SUB-SYSTEMS
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228308

Figure 45

Table 5.13 - Connector ST38 for Side Marker Lamps


Description

Cable
code

Max. current [A]

Connected
to

Ground

0000

10

ST43/1

Ground for left and right side clearance lights

Vehicle left side clearance


lights

3390

10

ST43/2

+12 V = vehicle left side clearance lights on


no signal = vehicle left side clearance lights off

Vehicle right side


clearance lights

3390

10

ST43/2

+12 V = vehicle right side clearance lights on


no signal = vehicle right side clearance lights off

Pin

Remarks

Installation of side markers requires the intervention of the IVECO Service Network in order to enable the Body Computer.

Reverse gear signal


For safety reasons, certain vehicle versions must emit an external reversing warning sound which is activated when the vehicle is
reversing.
This safety device may be originally requested as opt. 7638.
In the event of a subsequent or alternative realization, its application is recommended inside the rear cross member of the number
plate holder, as in Figure 46.

Printed 603.95.994 1 Ed. - Base 05/2015

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5.4ELECTRICAL SYSTEM: CURRENT INTERVENTIONS AND DRAWS

230824

1.

2.

Reverse buzzer

Figure 46

Reverse gear signal cable

This device is operated by a two terminal connector with safety cap.


Table 5.14 - Connector for reverse gear signal
Pin

Description

Cable
code

Reverse

2226

Ground

0000

(1)

Max. current [mA]

100

(1)

100

Connected
to

BCM/F01

Remarks
Signal logic: in parallel with the reversing lights
+12 V = reverse gear engaged
no signal = reverse gear not engaged
Add a protection diode
Ground for reverse gear

With reverse gear warning sound indicator IVECO (opt. 7638) the maximum current is limited to 70 mA.

Antitheft system
In combination with the central locking, the vehicle can be equipped with an alarm system controlled by the Body Computer and a
peripheral system.
This system consists of:

a key with remote control, buttons for distance locking/unlocking;


actuators for closing the cab doors and sliding side doors in the case of a van;
open door sensors and engine bonnet opening perimeter sensor (Figure 48 left);
alarm siren (12 V) (Figure 48 right).

The antitheft current absorption is 30-40 mA.


The body builder must provide a "closed door" signal so that the antitheft system can also detect engine bonnet break-ins.

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Figure 47

208227

Engine bonnet button connection diagram


A. Engine bonnet socket
B. Body builder button switch
(2)

(2)

1.
2.

Pin 1: door closed signal


Pin 2: door closed signal

Only for versions with reduced cowl, cowl, reduced cowl for camper with opt 5865

Open circuit when the door is closed


Closed circuit when the door is open

208229

1.
2.

Bonnet open sensor


Engine bonnet socket

3.

Figure 48

Alarm siren

For the operation mode refer to the Use and Maintenance Manual.

Printed 603.95.994 1 Ed. - Base 05/2015

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