DAILY VEHICLE EXPANSION MODULE

Transcription

1 DAILY VEHICLE MY 2009 RANGE BODYBUILDERS INSTRUCTIONS EXPANSION MODULE L I G H T R A N G E ISSUE 2010

2 Publication Edited by: IVECO S.p.A. Technical Application Strada delle Cascinette, 424/ Torino (TO) - Italy Printed st ed. 12/2010 Publication produced for IVECO by SATIZ TECHNICAL PUBLISHING c/o Iveco - Customer Service Lungo Stura Lazio, Torino - Italy

3 DAILY MY EXPANSION MODULE Bodybuilders instructions Printed st ed. Base - 12/2010 UPDATE DATA Section Description Page Revision date Update data Printed Base - 12/2010

4 Update data Base - 12/2010 Printed

5 Foreword This publication provides the data, features and instructions for vehicle fitting and modifications. It is intended for qualified, skill personnel. The Body Builder is responsible for designing the fitting, its modification and execution, and will have to ensure compliance with the provisions both of this publication and the law regulations in force. Prior to carrying out any work, make sure you have the publication of the vehicle model on which you are about to work. Also make sure that all the accident-prevention equipment such as, for instance, goggles, helmet, gloves, boots, etc. as well as the working, lifting and handling equipment are available and in good working order. Finally, make sure that you operate on the vehicle in such conditions as to ensure maximum safety. The execution of the work by strictly complying with the above provisions, as well as the use of the components shown, ensure that the work is carried out correctly and safely. Any change, modification or fitting not covered by this manual and not expressly authorized in written by IVECO will relieve the latter of any responsibility and make, in particular, the vehicle guarantee null and void. IVECO is available to provide all and every explanation required to carry out the work and also help you handle the cases not dealt with in this publication. After every single intervention, the functioning, efficiency and safety conditions established by IVECO shall be restored. Contact the IVECO service network for vehicle set-up, if necessary. IVECO shall not be responsible for any change, modification or fitting concerning the vehicle. The data and information contained in this publication may not be updated due to the changes made by IVECO, at any time, for technical or commercial reasons, or to make the vehicles comply with the law regulations in force in the different countries. In the event of any discrepancy between the contents of this publication and the actual vehicle, please contact the Product Manager for your market before carrying out any operations. Symbols - Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons safety. Danger of serious damage for the vehicle Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guarantee lapse too.! General danger It includes the dangers of above described signals. Environment protection It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible. It indicates an additional explanation for a piece of information. Foreword Printed Base - 12/2010

6 Page header and footer interpretation Vehicle type Section title Section number - page number Print number Chapter title Basic edition - month year Foreword Base - 12/2010 Printed

7 INDEX OF SECTION Section Expansion Module - PTO 1 Expansion Module - Additional Functions 2 Expansion Module - CANOpen 3 Index of section Printed Base - 12/2010

8 Index of section Base - 12/2010 Printed

9 DAILY MY 2009 EXPANSION MODULE - PTO 1-1 Index SECTION 1 Expansion Module - PTO Page 1. Abbreviations Glossary Principles Types of power take-off (PTO) Power take-off to the gearbox Power take-off to the transmission Power take-off to the engine Transfer case output shaft PTO power take-off Transmission output shaft PTO power take-off Electro-hydraulic power take-off (PTO2 and PTO3) Management of PTOs Activation of the PTO Standard PTO configuration supplied as default by IVECO PTO1 on Manual Gearbox PTO1 on Automatic Gearbox PTO operation when errors are present (Degraded Mode) Custom PTO configurations Engagement restrictions Disengagement conditions Checks on the engine Parameters that can only be set for PTO2 and PTO Standard parameters for PTO1 supplied by IVECO Wiring Diagram Fitters sockets for Expansion Module Electrical connections for PTO2 and PTO3 connection 1-17 Printed Base - 12/2010 Index

10 1-2 EXPANSION MODULE - PTO DAILY MY 2009 Index Base - 12/2010 Printed

11 DAILY MY 2009 EXPANSION MODULE - PTO 1-3 Abbreviations 1. Abbreviations The following abbreviations are used in this section: Table 1 Abbreviation PTO EM B-CAN C-CAN VDB ECU VF EDC16 ESV1 ABS8 ESP8 TBD TBC Meaning Power take-off Expansion Module Low speed CAN (50 kbit/s) High Speed CAN (500 kbit/s) Vehicle Data Bus Electronic Control Unit Vehicle Function Engine Control Unit Automatised gearbox Anti Blocking System Electronic Stability Program To be defined To be confirmed General instructions for chassis modifications 2. Glossary The following terms and symbols are used in this section: Table 2 Terms and Symbols Body Computer Instrument Cluster Body Electronics Data Bus (B-CAN) Vehicle Data Bus (VDB) Definition The main component of a Body electronics system. It acquires inputs from the body electric/electronic components and it drives the body electric/electronic components. It is also the gateway between the driveline data bus and the body data bus. The display component. It is a low speed CAN (50 kbit/s), compliant with the FIAT Norm It is the data bus that connects all the Body electronic systems (Body Computer, Instrument Clusters, AirBag, Infotainment Nodes, etc.) A high speed CAN (250 kbit/s), compliant with SAE J1939. It is the data bus that connects all the Powertrain electronic systems (Engine management, Automatic transmission, Braking systems, etc.) Abbreviations Printed Base - 12/2010

12 1-4 EXPANSION MODULE - PTO DAILY MY 2009 Principles 3. Principles Refer to Bodybuilders Instruction. 4. Types of power take-off (PTO) Only one PTO can be fitted for each type of power take-off. 4.1 Power take-off to the gearbox Refer to Bodybuilders Instruction. The power take-off on the gearbox is only electromechanical. There are two PTO management methods, to be defined with IVECO: management with own control unit or with EM. 4.2 Power take-off to the transmission Refer to Bodybuilders Instruction. 4.3 Power take-off to the engine Refer to Bodybuilders Instruction. 4.4 Transfer case output shaft PTO power take-off To define with IVECO. 4.5 Transmission output shaft PTO power take-off To define with IVECO. 4.6 Electro-hydraulic power take-off (PTO2 and PTO3) Principles Base - 12/2010 Printed

13 DAILY MY 2009 EXPANSION MODULE - PTO 1-5 Management of PTOs 5. Management of PTOs! Operations performed in a manner that does not comply with IVECO s instructions as set out below or carried out by non-qualified staff can result in serious damage to the on-board systems. This may compromise safety, reliability and the correct operation of the vehicle and may cause associated damage that is not covered by the contractual warranty. The PTO s are managed directly by the Expansion Module (EM) control unit in Figure 1. The EM is able to manage up to three different PTOs. Power take-off PTO1 can be fitted solely and exclusively on the gearbox. Figure 1 EM CONTROL UNIT (located in the centre of the dashboard on the right-hand side) Different parameters can be configured for each PTO by IVECO Customer Service: engagement restrictions disengagement conditions control on engine (engine rpm request of maximum torque limit configuration or maximum rpm limit configuration) The control parameter on the engine cannot be configured for a CNG engine. Management of PTOs Printed Base - 12/2010

14 1-6 EXPANSION MODULE - PTO DAILY MY Activation of the PTO A button in the middle of the dashboard in the driver s cab engages and disengages the PTO1 (Figure 2). This is a rocker button. A warning light on the button indicates the status of PTO1: - warning light fixed off (a): PTO1 disengaged; - warning light fixed on (b): PTO1 engaged; - warning light flashing: transient stage from (a) (b) or from (b) (a) in which the EM searches, respectively, to engage or disengage PTO1. Since the EM can control up to three PTO s, up to three PTO controls (one button for PTO1 and two switches for PTO2 and PTO3) can be included in the dashboard. The switches for PTO2 and PTO3 are stable type and the responsibility of the Fitter. The Fitter must also see to the connections between PTO2 (and/or PTO3) and the Fitter connectors. For a more detailed description, refer to par. 6: Wiring Diagram. Figure 2 Warning light PTO1 button If the PTO1 button is faulty, a new one can be purchased directly through IVECO. The associated item code is given in the table. Management of PTOs Base - 12/2010 Printed

15 DAILY MY 2009 EXPANSION MODULE - PTO Standard PTO configuration supplied as default by IVECO IVECO supplies the EM control unit standard with just PTO1 configured, the wiring and PTO button. Power take-off PTO1 can be fitted solely and exclusively on the gearbox PTO1 on Manual Gearbox Engagement of the PTO The purpose of this action is to prepare equipment for work. During execution of the operating sequence the driver is assisted to prevent steering errors. The correct operations to perform to engage the PTO are: a) stop the motion of the vehicle b) check/ engage neutral gear if the operation is prepared with the vehicle at a standstill or engage the gear that the equipment must operate in c) depress the clutch pedal d) press and release the button on the dashboard that controls engagement of the power take-off (Figure 2 - Page 1-6) e) the warning light that indicates that power take-off is engaged begins to flash until it becomes permanently on. PTO is engaged when the warning light (Figure 2 - Page 1-6) is permanently on f) at this point the clutch can be released. Power take-off is correctly engaged. If there is an Engagement Restriction (engagement restriction conditions, see paragraph 5.4.1) the PTO will not engage. An error message will appear on the instrument panel to advise the driver. The error will be displayed at each subsequent attempt to engage PTO as long as the cause(s) of the restriction remains. When the cause of the restriction has been eliminated PTO can be engaged by following the procedure described above. Disengagement of the PTO The correct operations to be carried out are: a) stop the operation of the equipment b) press the button that controls engagement of the power take-off (Figure 2 - Page 1-6) c) the warning light that indicates that power take-off is engaged begins to flash it switches off. PTO is disengaged when the warning light (Figure 2) is permanently off g) at this point the power take-off is correctly disengaged. If there is Shutoff Condition (disengagement condition, see paragraph 5.4.2) the PTO will automatically disengage. An error message will appear on the instrument panel to advise the driver. When the cause of the disengagement condition has been eliminated PTO can be engaged by following the procedure described above and keeping it switched on.! The power take off can be switched off only when no torque is applied to it (either engine or transmission). Management of PTOs Printed Base - 12/2010

16 1-8 EXPANSION MODULE - PTO DAILY MY PTO1 on Automatic Gearbox Engagement of the PTO The purpose of this action is to prepare equipment for work. During execution of the operating sequence the driver is assisted to prevent steering errors. The correct operations to perform to engage the PTO are: a) stop the motion of the vehicle b) check/ engage neutral gear c) press the button on the dashboard that controls engagement of the power take-off (Figure 2 - Page 1-6) d) the warning light that indicates that power take-off is engaged begins to flash until it becomes permanently on. PTO is engaged when the warning light (Figure 2 - Page 1-6) is permanently on e) power take-off is correctly engaged. Disengagement of the PTO The correct operations to be carried out are: a) stop the operation of the equipment b) press the button that controls disengagement of the power take-off (Figure 2- Page 1-6) c) the warning light (Figure 2 - Page 1-6) that indicates that power take-off is engaged switches off. PTO is disengaged d) at this point the vehicle can be moved.! The power take off can be switched off only when no torque is applied to it (either engine or transmission). 5.3 PTO operation when errors are present (Degraded Mode) Degraded Mode allows the driver to progress the PTO operation despite an error being present. The system enters Degraded Mode only if at least one disengagement condition has previously been configured. The errors that start Degraded Mode are: - a missing CAN message - an engagement signal in which the value is outside of the permitted range In this mode, the error detected is displayed on the instrument panel. When the error message appears the driver must press the MODE button. A message will then be displayed on the instrument panel inviting the driver to decide whether they wish to continue to operate the PTO under their own command or terminate the operation, automatically disengaging the PTO. If no instruction is given within the Degraded_Mode_Timeout period (20 seconds), the PTO operation will be interrupted automatically. Management of PTOs Base - 12/2010 Printed

17 DAILY MY 2009 EXPANSION MODULE - PTO Custom PTO configurations Depending on foreseen vehicle use Fitters are required to contact IVECO Customer Service, for carrying out the necessary Expansion Module control unit programming for operation of a PTO. Keeping to the following instructions the Fitter will be able to organise system configuration in advance. If special adjustments are necessary, the Fitter can programme them, for each individual power take off, by contacting IVECO Customer Service. Except for express warnings, the following instructions apply to each individual power take-off Engagement restrictions Engagement restrictions are used if the user wishes to impede engagement of the PTO to check (or not) the set conditions. The restriction conditions are considered as such only if they have a temporary duration of a few seconds or more. When this time has elapsed the EM control unit will detect the presence of the restriction. A warning message will be displayed and engagement will not take place. The table below provides a list of all possible engagement restrictions. The user chooses which restrictions to enter for their own application from those indicated. Table 3 Parameter Possible Possible Restriction 1 Restriction 2 Brake Depressed Not depressed Hand brake Activated Not activated Clutch pedal (#) Depressed Not depressed Coolant temperature C Neutral gear engaged (+) In neutral Gear engaged Reverse Engaged Not engaged Open circuit on the pressure switch if fitted on PTO2( ) Shortcircuit to earth on the pressure switch if fitted on PTO2( ) Open circuit on the relevant pressure switch fitted on PTO3( ) Shortcircuit to earth on the pressure switch if fitted on PTO3( ) Low engine oil pressure Min rpm for engagement Max rpm for engagement Min vehicle speed Max vehicle speed Lower gear engaged(+) Higher gear engaged(+) (#) only for manual gearbox (+) for automatic gearbox only ( ) for electrical connections see chapter 6: Wiring Diagram These conditions can be modified only by IVECO Customer Service. Management of PTOs Printed Base - 12/2010

18 1-10 EXPANSION MODULE - PTO DAILY MY Disengagement conditions The disengagement conditions are those in which the PTO switches itself off automatically. The disengagement conditions are considered as such only if they have a temporary duration of a few seconds or more. When this time has elapsed the EM control unit will detect the presence of the disengagement condition. A warning message will be displayed on the instrument panel and the PTO will automatically disengage. The automatic disengagement by the EM depends on the PTO load. In some situations, when the warning message is displayed in the instrument panel, the PTO is not switched off automatically. In this case it is necessary to: a) with a manual transmission with the vehicle stationary, operate the clutch with the vehicle moving, engage neutral b) with an automatic transmission with the vehicle moving, engage neutral The table below contains the list of possible disengagement conditions; the user chooses the one for their application. Table 4 Parameter Possible condition Possible condition disengagement 1 disengagement 2 Brake Depressed Not depressed Hand brake Activated Not activated Clutch pedal (#) Depressed Not depressed Coolant temperature C Neutral gear engaged (+) In neutral Gear engaged Reverse Engaged Not engaged Open circuit on the pressure switch if fitted on PTO2( ) Shortcircuit to earth on the pressure switch if fitted on PTO2( ) Open circuit on the relevant pressure switch fitted on PTO3( ) Shortcircuit to earth on the pressure switch if fitted on PTO3( ) Low engine oil pressure Min rpm for disengagement Max rpm for disengagement Min vehicle speed Max vehicle speed Lower gear engaged(+) Higher gear engaged(+) Clutch slipping percentage(@) (#) only for manual gearbox (+) for automatic gearbox only ( ) for electrical connections see chapter 6: Wiring Diagram (@) condition applicable only with automaticgearboxandonlyforstationarypto These conditions can be modified only by IVECO Customer Service. Management of PTOs Base - 12/2010 Printed

19 DAILY MY 2009 EXPANSION MODULE - PTO Checks on the engine When the PTO is engaged the following checks on the engine are connected: - rpm request (not available on CNG engine) - configuration of maximum rpm limit (not available on CNG engine) - configuration of maximum torque limit (a limit at lower torque values than necessary to support idling should not be set for CNG engines, otherwise the engine will cut out). During the rpm request check the engine speed cannot be changed using the Cruise Control and/or the accelerator pedal. The engine control ends when the PTO is disengaged. The parameter PTO[x]_SwActCfg (x = 1, 2, 3 represents the PTO involved) defines whether to associate the control on the engine with the pressure of the button for PTO engagement: Table 5 Parameter PTO[x]_SwActCfg Configuration No control requested Engine control requested as soon as the PTO engagement button is pressed! When the aforementioned parameter is set and when there are engagement restrictions, the engine control is applied for a certain period of time (a few seconds) until the EM control unit no longer detects the restriction. These conditions can be modified only by IVECO Customer Service. The parameter PTO[x]_FbkActCfg (x = 1, 2, 3 refers to the PTO involved) defines whether to associate the engine control to the successful engagement of the PTO, therefore only after the engine has sent a positive feedback to the EM. Table 6 Parameter PTO[x]_FbkActCfg Configuration No control requested Engine control requested only after the PTO has been successfully engaged. These conditions can be modified only by IVECO Customer Service. Management of PTOs Printed Base - 12/2010

20 1-12 EXPANSION MODULE - PTO DAILY MY 2009 The parameter PTO[x]TSC1field1_4 (x = 1, 2, 3 represents the PTO involved) defines the type of control to be requested. Specifically: Table 7 Parameter PTO[x]TSC1field1_4 Type of request No request/ Disabled Rpm request Torque request Torque limit request/ rpm limit request These conditions can be modified only by IVECO Customer Service. The parameter PTO[x]TSC1field5 (x = 1, 2, 3 represents the PTO involved) based on the configuration set through PTO[x]TSC1field1_4, indicates: Parameter Table 8 Type of control selected through PTO[x]TSC1field1_4 Meaning of PTO[x]TSC1field5 PTO[x]TSC1field5 Control in rpm Engine speed value requested Torque/rpm limit request Engine speed limit value requested If the PTO is not stopped, the control in rpm is not performed. These conditions can be modified only by IVECO Customer Service. Management of PTOs Base - 12/2010 Printed

21 DAILY MY 2009 EXPANSION MODULE - PTO 1-13 The parameter PTO[x]TSC1field6 (x = 1, 2, 3 represents the PTO involved) based on the configuration selected through PTO[x]TSC1field1_4, indicates: Parameter Table 9 Type of control selected through PTO[x]TSC1field1_4 Meaning of PTO[x]TSC1field5 PTO[x]TSC1field6 Control in torque Engine torque value requested Torque/rpm limit request Limit value required by the engine torque These conditions can be modified only by IVECO Customer Service Parameters that can only be set for PTO2 and PTO3 Engagement Timeout If power take-offs PTO2 and PTO3 require a greater engagement time than two seconds, it is possible to act on the Engagement Timeout parameter PTO[x]_ERtimeout (x = 2, 3 represents the PTO involved) that stabilises the time level outside of which an engagement restriction condition (if configured) is considered as such. The EM control unit assesses the outcome of the PTO[x] engagement and, if engagement has not been successful, displays any Engagement Timeout errors only once the Engagement Timeout. time has elapsed. The PTO[x]_ERtimeout parameter can be set by IVECO Customer Service. Disengagement Timeout If power take-offs PTO2 and PTO3 require a greater disengagement time than two seconds, it is possible to act on the Disengagement Timeout parameter PTO[x]_SCtimeout (x = 2 or 3 represents the PTO involved) that stabilises the time level outside of which a disengagement restriction condition (if configured) is considered as such. The EM control unit assesses the outcome of the PTO[x] disengagement and, if disengagement has not been successful, displays any Disengagement Timeout errors only once the Disengagement Timeout. time has elapsed. Therefore, the EM control unit will detect the presence of the disengagement condition only once the Disengagement Timeout time has elapsed Within 10 seconds a warning message will be displayed on the Instrument Panel and the PTO will automatically disengage. The PTO[x]_SCtimeout parameter can be set by IVECO Customer Service. Management of PTOs Printed Base - 12/2010

22 1-14 EXPANSION MODULE - PTO DAILY MY Standard parameters for PTO1 supplied by IVECO Parameters Engagement restrictions Disengagement conditions Table 10 Description Manual Automatic gearbox Unit gearbox Unit Brake depressed no - no - Brake not depressed no - no - Hand brake activated no - no - Hand brake not activated no - no - Low engine oil pressure no - no - Clutch pedal depressed no - no - Clutch pedal not depressed yes - no - Neutral gear not engaged n.a - no - Reverse n.a - no - Open circuit on the pressure switch if fitted on PTO2 no - no - Shortcircuit to earth on the pressure switch if fitted on PTO2 no - no - Open circuit on the relevant pressure switch fitted on PTO3 no - no - Shortcircuit to earth on the pressure switch if fitted on PTO3 no - no - Min rpm for engagement 750 rpm 750 rpm Max rpm for engagement 1300 rpm 1300 rpm Min vehicle speed no km/h no km/h Max vehicle speed no km/h no km/h Lower gear engaged no gear no gear Higher gear engaged no gear no gear Maximum coolant temperature 110 C 110 C Brake depressed no - no - Brake not depressed no - no - Hand brake activated no - no - Hand brake not activated no - no - Low engine oil pressure no - no - Clutch pedal depressed yes - no - Clutch pedal not depressed no - no - Neutral gear not engaged n.a. - no - Reverse n.a. - no - Min rpm for disengagement 500 rpm 500 rpm Open circuit on the pressure switch if fitted on PTO2 no - no - Shortcircuit to earth on the pressure switch if fitted on PTO2 no - no - Open circuit on the relevant pressure switch fitted on PTO3 no - no - Shortcircuit to earth on the pressure switch if fitted on PTO3 no - no - Max rpm for disengagement 2000 rpm 2000 rpm Min vehicle speed no km/h no km/h Max vehicle speed no km/h no km/h Lower gear engaged no gear no gear Higher gear engaged no gear no gear Maximum coolant temperature 110 C 110 C Clutch slipping percentage no % no % Management of PTOs Base - 12/2010 Printed

23 DAILY MY 2009 EXPANSION MODULE - PTO 1-15 Parameters Description Table 11 Manual gearbox Unit Automatic gearbox No control requested yes yes Engine management - requested with PTO1 Engine control requested only after the no no PTO has been successfully engaged. - Engine management No control requested yes yes requested on PTO1 Engine control requested only after the - - engagement feedback no no PTO has been successfully engaged. No request/ Disabled yes yes Type of engine Rpm request no no - management Torque request no no - Torque limit request/ rpm limit request no no PTO[X]TSC1FIELD5 Control in rpm/ rpm limit request no rpm no rpm PTO[X]TSC1FIELD6 Control in torque/ torque limit request no % no % Unit Key: n.a. = not applicable On CNG engines checks cannot be carried out on the engine (rpm request, configuration of the maximum rpm limit, configuration of the maximum torque limit). During the rpm request check the engine speed cannot be changed using the Cruise Control and/or the accelerator pedal. Management of PTOs Printed Base - 12/2010

24 1-16 EXPANSION MODULE - PTO DAILY MY 2009 Wiring Diagram 6. Wiring Diagram For effective and correct use by Fitters, IVECO has arranged specific connection points to be used for the added systems. This is necessary to exclude any type of tampering or manipulation of the system to ensure the operating condition and thus the maintenance of the warranty itself. 6.1 Fitters sockets for Expansion Module The Expansion Module control unit pins are available through two BLACK connectors shown below. 20 pin BLACK connector Figure Wiring Diagram Base - 12/2010 Printed

25 DAILY MY 2009 EXPANSION MODULE - PTO pin BLACK connector Figure Electrical connections for PTO2 and PTO3 connection The following figure shows the connections the Fitter must make for installing PTO2 and/or PTO3. The Fitter must see to: - fitting the switches (remember that these must be a stable type) - the wiring between the PTO and the Fitters connectors For the ground connection, the Fitter can choose to use: - pin 17 of the Fitters BLUE connector - the grounding points available on the vehicle as indicated in the Bodybuilders Manual Wiring Diagram Printed Base - 12/2010

26 1-18 EXPANSION MODULE - PTO DAILY MY 2009 Figure 5 Solenoid Feedback Pressure switch EM Fitters BLACK 20-pin socket Switch Switch Solenoid Feedback Pressure switch Non electro-hydraulic power take-offs can also be used. However, it must be remembered that: - PTO activation control pins (pins 5 and 6) remain high active (12 V) until the relevant PTO engagement switch is ON. - the feedback pins must always be present and equal to: 1 PTO engaged 0 PTO disengaged - The status of the pressure switch (pins 9 and 10) can be used to configure a restriction on the engagement or a disengagement condition. In both cases the condition is that the pin is either connected to the ground or open (see paragraphs: Engagement restrictions and Disengagement conditions ). Wiring Diagram Base - 12/2010 Printed

27 DAILY MY 2009 EXPANSION MODULE - PTO WAY BLACK EM CONNECTOR PIN Table 12 BLACK connector Pin 5 6 Description PTO2 actuator (solenoid control for solenoid) PTO3 actuator (solenoid control for solenoid) 7 PTO2 feedback 8 PTO3 feedback 9 PTO2 pressure switch 10 PTO3 pressure switch 16 Switch requested PTO2 engagement 17 Switch requested PTO3 engagement Signal High active output Maximum deliverable current 1.5 A High active output Maximum deliverable current 3 A Low active input Maximum current 10 ma Low active input Maximum current 10 ma Low active input Maximum current 10 ma Low active input Maximum current 10 ma Low active input Maximum current 10 ma Low active input Maximum current 10 ma Wiring Diagram Printed Base - 12/2010

28 1-20 EXPANSION MODULE - PTO DAILY MY 2009 Wiring Diagram Base - 12/2010 Printed

29 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS 2-1 Index SECTION 2 Expansion Module - Additional Functions Page 1. Abbreviations Glossary Other functions Compatibility between PTO and additional functions Run-Lock Connections Run-Lock engagement procedure with manual gearbox Run-Lock disengagement procedure with manual gearbox Run-Lock engagement procedure with automatic gearbox Run-Lock disengagement procedure with automatic gearbox Safety/Alarm function Connections Flashing of dipped/main beam headlights Speed limit Additional Lights Connections Additional lights Flashing of additional lights Flashing of dipped/main beam headlights Speed limit Additional lights Flashing of additional lights Flashing of dipped/main beam headlights Speed limit Scene lights Speed limit Tail lights 2-17 Printed Base - 12/2010 Index

30 2-2 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY 2009 Index Base - 12/2010 Printed

31 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS 2-3 Abbreviations 1. Abbreviations The following abbreviations are used in this section: Table 1 Abbreviation PTO EM KL15 C-CAN VDB ECU VF EDC16 ESV1 ABS8 ESP8 TBD TBC Meaning Power Take OFF Expansion Module Ignition Key High Speed CAN (500 kbit/s) Vehicle Data Bus Electronic Control Unit Vehicle Function Engine Control Unit Automatic gearbox Anti Blocking System Electronic Stability Program To be Defined To be Confirmed General instructions for chassis modifications 2. Glossary The following terms and symbols are used in this section: Table 2 Terms and Symbols Body Computer Instrument Cluster Body Electronics Data Bus (B-CAN) Vehicle Data Bus (VDB) Vehicle Functions Definition It is the main component of a Body electronics system. It acquires inputs from the body electric/electronic components and it drives the body electric/electronic components. It is also the gateway between the driveline data bus and the body data bus It is the visualisation component. It is a low speed CAN (50 kbit/s) compliant to the FIAT Norm It is the data bus that connects all the Body electronic systems (Body Computer, Instrument Clusters, AirBag, Infotainment Nodes, etc.) A high speed CAN (250 kbit/s), compliant with SAE J1939. It is the data bus that connects all the Powertrain electronic systems (Engine management, Automatic transmission, Braking systems, etc.) All functions present in the vehicle electronic architecture Abbreviations Printed Base - 12/2010

32 2-4 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY 2009 Other functions 3. Other functions The Expansion Module makes available additional functions: Run-Lock Safety / Alarms Additional Lights 3.1 Compatibility between PTO and additional functions It is not possible to use all functions of the Expansion Module (PTO and additional functions) simultaneously. Each line of the following table indicates the maximum permitted configuration, bearing in mind that the sum of the electrical currents associated with the functions used should NOT exceed 10 A. However, it must be remembered that: - additional lights 1 are incompatible with the use of PTO3 - additional lights 2 are incompatible with the use of PTO2 No. PTO1 PTO2 PTO3 Rear lights Table 3 Additional lights 1 Additional lights 2 Scene lights Run-Lock 1 X X 2 X X X X 3 X X X X 4 X X X X X X 5 X X X X X X 6 X X X X X X 7 X X X X X X 8 X X X X X 9 X X X X X X 10 X X X X 11 X X X X 12 X X X X 13 X X X X 14 X X X X 15 X X X 16 X X X 17 X X X X 18 X X X X 19 X X X X 20 X X X X 21 X X X X Dipped beams flash Other functions Base - 12/2010 Printed

33 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS Run-Lock The Run Lock allows the engine to keep running even when the key has been removed. For the Run-Lock control to be considered valid, the vehicle must be in the following situation: Table 4 Type of gearbox MANUAL AUTOMATIC Vehicle at standstill (vehicle speed = 0) Vehicle at standstill (vehicle speed = 0 Conditions required for activation of the Run-Lock Gearbox in neutral with clutch not depressed Gearbox in neutral Parking brake on Parking brake on Connections The following figure shows the connections to be made in order to use the Run-Lock function. Switch is low active. The Expansion Module control unit pins are available for the Fitter through the two BLACK connectors. Refer to Section 1 Expansion Module - PTO, paragraph 6.1 Fitter sockets for Expansion Module to see them illustrated. The Fitter must see to: installing the switch its connection to pin 11 of the EM Fitters BLACK 20-pin connector the connection between pin 20 of the EM Fitters BLACK 20-pin connector and pin 5 of the Fitters BLUE 12-pin connector For the ground connection, the Fitter can choose to use: pin 17 of the Fitters BLUE connector the grounding points available on the vehicle as indicated in the Bodybuilders Manual Other functions Printed Base - 12/2010

34 2-6 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY 2009 Figure 1 Fitters BLUE 12-way connector Run-Lock relay Run-Lock switch EM Fitters BLACK 20-pin connector WAY BLACK EM CONNECTOR PIN Table 5 BLACK connector Pin Description 11 Run-Lock switch 20 Run-Lock relay Signal Low active input Maximum deliverable current 10 ma High active output Maximum deliverable current 1 A 12-WAY BLUE CONNECTOR PIN Table 6 BLUE connector pin Description 5 Automatic key Signal Max input 500 ma Simulates initial key rotation by providing a positive signal (key position ON) Other functions Base - 12/2010 Printed

35 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS Run-Lock engagement procedure with manual gearbox The correct procedure for engaging the Run-Lock is: a) engine running b) park the vehicle c) check the gearbox is in/engage neutral (clutch not depressed) d) engage the parking brake e) operate the Run-Lock switch f) remove the key. During operation of Run-Lock mode, the engine will be shut down if one of the following disengagement conditions is detected: clutch depressed parking brake released vehicle speed > 0 km/h Run-Lock disengagement procedure with manual gearbox The correct procedure for disengaging the Run-Lock is: a) turn the key to position 2 b) return the Run-Lock switch to OFF position Run-Lock engagement procedure with automatic gearbox The correct procedure for engaging the Run-Lock is: a) engine running b) park the vehicle c) check the gearbox is in/engage neutral d) engage the parking brake e) operate the Run-Lock switch f) remove the key. During operation of Run-Lock mode, the engine will be shut down if one of the following disengagement conditions is detected: gearbox not in neutral parking brake released vehicle speed > 0 km/h Other functions Printed Base - 12/2010

36 2-8 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY Run-Lock disengagement procedure with automatic gearbox The correct procedure for engaging the Run-Lock is: a) turn the key to position 2 b) return the Run-Lock switch to OFF position. 3.3 Safety/Alarm function The Safety/Alarm function can be applied in all cases in which the vehicle is under attack. In this situation the engine is switched off or limited to a certain number of revs; the activation of the flashing dipped headlights is possible. Safety mode is turned on by operating the Alarm State switch. The Expansion Module will apply a different strategy according to whether the vehicle is parked (stationary) or in motion. The details are as follows: a) with vehicle at a standstill the engine will be turned off and immobilised and maybe started up only and exclusively if the alarm state switch is turned OFF both dipped headlights will flash (a flashing period equal to 1 second is set by default). b) with vehicle in motion the speed will be limited to a default level of 30 km/h once the vehicle has been stopped, stationary vehicle management will begin to operate both dipped headlights will flash (a flashing period equal to 1 second is set by default) Connections The following figure shows the connections to be made in order to use the Alarm function. Switch is high active. The Expansion Module control unit pins are available for the Fitter through the two BLACK connectors. Refer to Section 1 Expansion Module - PTO, paragraph 6.1 Fitter sockets for Expansion Module to see them illustrated. The Fitter must see to: installing the switch its connection to pin 4 of the EM control unit Fitters BLACK 12-pin connector and pin 6 of the Fitters BLUE 20-pin connector the connection between pin 7 of the EM Fitters BLACK 12-pin connector and pin 2 of the Fitters BLUE 20-pin connector If low beam flashing is required, the Fitter must see to: installing the two relays for the dipped headlights connecting the relays on the same line that runs from the dipped headlight relay on the normal production vehicle (relay T01 is present on the fuse box and under-dashboard relay) toward the headlights IVECO Customer Service should disable the diagnosis of relay T01. For the ground connection the Fitter can choose to use: pin 17 of the Fitters BLUE connector; the grounding points available on the vehicle as indicated in the Bodybuilders Manual. Other functions Base - 12/2010 Printed

37 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS 2-9 Figure 2 Alarm switch Fitters BLUE 20-pin connector Engine shut-down command EM Fitters BLACK 12-pin connector Right dipped headlight relay Left dipped headlight relay WAY BLACK EM CONNECTOR PIN Connector pin BLACK Description Table 7 1 Right dipped beam relay 2 Left dipped beam relay Signal High active output Maximum current 1 A High active output Maximum current 1 A 4 Alarm activation control switch High active input 7 Engine shut-down command. High active output Maximum deliverable current 1 A 20-WAY BLUE CONNECTOR PIN Table 8 Connector pin BLUE Description 2 Engine shut-down 6 Battery positive Signal Input Maximum current 10 ma 15 A max output positive protected by fuse present on dashboard node F32 Other functions Printed Base - 12/2010

38 2-10 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY Flashing of dipped/main beam headlights When the Alarm function is activated, the dipped headlights or the main beam headlights can also flash at the same time. Bear in mind that, irrespective of the type of lights chosen, the flashing is interrupted if the dipped headlights are activated via the steering column switch unit. A flashing period can also be configured: flashing time is normally enabled and is equal to 1 second; the minimum configurable period corresponding to maximum frequency is 0.5 seconds. If the additional lights 1 and/or the additional lights 2 and/or the Alarm function are configured and if for each of these functions there has been a request for the flashing of the dipped headlights, the system takes the flashing time as the shortest period or the maximum frequency. The flashing period may only be modified by IVECO Customer Service Speed limit The speed limit for the Alarm function is set at 30 km/h as standard, but it can be changed. Bear in mind that the limit cannot be increased beyond the level set by the Speed Limiter. If the additional lights 1 and/or additional lights 2 and/or the Alarm function and/or the background lights are configured, and if for each of them there has been a requestfor a speed limit, the system will always use the minimum limit. The speed limit may only be modified by IVECO Customer Service. Other functions Base - 12/2010 Printed

39 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS Additional Lights The Additional Light function offers the user the option of installing various additional lights managed directly by the Expansion Module control unit: additional lights 1 additional lights 2 scene lights tail lights Connections The following figure shows the connections to be made in order to use the additional light function. All the switches are high active. The Expansion Module control unit pins are available for the Fitter through two BLACK connectors. Refer to Section 1 Expansion Module - PTO, paragraph 6.1 Fitter sockets for Expansion Module to see them illustrated. The Fitter must see to: installing the switches installing the white light relays connection of the switches to the pins of the EM Fitters BLACK connectors connection of the relay to the pins of the EM Fitters BLACK connectors Installing the lights If low beam flashing is required, the Fitter must see to: installing the two relays for the dipped headlights connecting the relays on the same line that runs from the dipped headlight relay on the normal production vehicle (relay T01 is present on the fuse box and under-dashboard relay) toward the headlights IVECO Customer Service should disable the diagnosis of relay T01. For the ground connection the Fitter can choose to use: pin 17 of the Fitters BLUE connector the grounding points available on the vehicle as indicated in the Bodybuilders Manual Other functions Printed Base - 12/2010

40 2-12 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY 2009 Figure 3 Right brake light 21 W Right direction indicator 21 W Left brake light 21 W Left direction indicator 21 W Additional lights 2 21 W EM Fitters BLACK 20-pin connector Additional lights 1 36 W Spot lights switch Additional Lights 1 switch Additional Lights 2 switch Right low beam relay Left low beam relay EM Fitters BLACK 12-pin connector Side lights 10 W Scene lights relay Other functions Base - 12/2010 Printed

41 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS WAY BLACK EM CONNECTOR PIN Table 9 BLACK connector Pin Description 1 21 W right brake light command 2 21 W right direction indicator command 3 21 W left brake light command 4 21 W left direction indicator command 5 21 W Additional light command 6 36 W Additional light 1 command 12 White light switch 13 Additional light switch 1 14 Additional light switch 2 Signal High active output Maximum current 1.5 A High active output Maximum current 1.5 A High active output Maximum current 1.5 A High active output Maximum current 1.5 A High active output Maximum current 1.5 A High active output Maximum current 3 A Low active input Maximum current 10 ma Low active input Maximum current 10 ma Low active input Maximum current 10 ma 12-WAY BLACK EM CONNECTOR PIN Table 10 BLACK connector Pin Description 1 Right low beam relay 2 Left low beam relay 8 10 W side light command 9 White light relay command Signal High active output Maximum current 1 A High active output Maximum current 1 A High active output Maximum current 1 A High active output Maximum current 1 A Other functions Printed Base - 12/2010

42 2-14 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY Additional lights 1 For example, the additional lights 1 can be the blue ambulance and Police lights. The maximum power consumption for Additional lights 1 is 3 A, while the maximum power is 36 W. Additional lights 1 are incompatible with the use of PTO3. The additional lights 1 can be linked to different functions, all configurable by Fitter request: flashing of additional lights 1 flashing of dipped headlights speed limit when additional lights 1 are ON speed limit when additional lights 1 are OFF. Additional lights 1 are incompatible with the use of PTO Flashing of additional lights 1 It is possible to configure a period of flashing for additional lights 1, taking into account that: - flashing is normally disabled, meaning that the lights remain fixed when switched on - the minimum configurable period corresponding to maximum frequency is 0.5 seconds. The flashing period may only be modified by IVECO Customer Service Flashing of dipped/main beam headlights When the additional lights 1 are activated, the dipped headlights or the main beam headlights may also flash at the same time. Bear in mind that, irrespective of the type of lights chosen, the flashing is interrupted if the dipped headlights are activated via the steering column switch unit. A flashing period can also be configured: - flashing is normally disabled - the minimum configurable period corresponding to maximum frequency is 0.5 seconds. If the additional lights 1 and/or the additional lights 2 and/or the Alarm function are configured and if for each of these functions there has been a request for the flashing of the dipped headlights, the system takes the flashing time as the shortest period or the maximum frequency. The flashing period may only be modified by IVECO Customer Service. Other functions Base - 12/2010 Printed

43 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS Speed limit It is possible to configure a speed limit when the lights are ON and/or when the lights are OFF. This option is normally disabled. If the additional lights 1 and/or additional lights 2 and/or the Alarm function and/or the background lights are configured, and if for each of them there has been a requestfor a speed limit, the system will always use the minimum limit. The speed limits may only be modified by IVECO Customer Service. Additional lights 1 are incompatible with the use of PTO Additional lights 2 For example, additional lights 2 may take the form of blue ambulance and Police lights. Additional lights 2 are incompatible with the use of PTO2. The maximum power consumption for additional lights 2 is 1.5 A, while the maximum power is 21 W. The additional lights 1 can be linked to different functions, all configurable by Fitter request: flashing of additional lights 2 flashing of dipped headlights speed limit when additional lights 2 are ON speed limit when additional lights 2 are OFF Additional lights 2 are incompatible with the use of PTO2. Other functions Printed Base - 12/2010

44 2-16 EXPANSION MODULE - ADDITIONAL FUNCTIONS DAILY MY Flashing of additional lights 2 It is possible to configure a period of flashing for additional lights 2, taking into account that: - flashing is normally disabled, meaning that the lights remain fixed when switched on - the minimum configurable period corresponding to maximum frequency is 0.5 seconds. The flashing period may only be modified by IVECO Customer Service Flashing of dipped/main beam headlights When the additional lights 2 are activated, the dipped headlights or the main beam headlights may also flash at the same time. Bear in mind that, irrespective of the type of lights chosen, the flashing is interrupted if the dipped headlights are activated via the steering column switch unit. A flashing period can also be configured: - flashing is normally disabled - the minimum configurable period corresponding to maximum frequency is 0.5 seconds. If the additional lights 1 and/or the additional lights 2 and/or the Alarm function are configured and if for each of these functions there has been a request for the flashing of the dipped headlights, the system takes the flashing time as the shortest period or the maximum frequency. The flashing period may only be modified by IVECO Customer Service Speed limit It is possible to configure a speed limit when the lights are ON and/or when the lights are OFF. This option is normally disabled. If the additional lights 1 and/or additional lights 2 and/or the Alarm function and/or the background lights are configured, and if for each of them there has been a requestfor a speed limit, the system will always use the minimum limit. The speed limits may only be modified by IVECO Customer Service. Additional lights 2 are incompatible with the use of PTO2. Other functions Base - 12/2010 Printed

45 DAILY MY 2009 EXPANSION MODULE - ADDITIONAL FUNCTIONS Scene Lights Maximum power consumption for scene lights is 1 A. Scene lights may be associated with various functions: speed limit when scene lights are ON speed limit when scene lights are OFF Speed limit It is possible to configure a speed limit when the lights are ON and/or when the lights are OFF. This option is normally disabled. If the additional lights 1 and/or additional lights 2 and/or the Alarm function and/or the background lights are configured, and if for each of them there has been a requestfor a speed limit, the system will always use the minimum limit. The speed limit may only be modified by IVECO Customer Service Tail lights Tail lights consist of: - right-hand direction indicator - left-hand direction indicator - right brake light - left brake light - side lights As indicated in the Figure 1 in the paragraph Connections, tail lights may be installed provided that the maximum power of each individual light is as follows: - turn signals: 21 W - brake lights: 21 W - side lights: 5 W The lights do not work with the key OFF and maximum power consumption is 7 A. Other functions Printed Base - 12/2010